WO2021010009A1

WO2021010009A1 - Motor

Info

Publication number: WO2021010009A1
Application number: PCT/JP2020/019445
Authority: WO
Inventors: 孝浩深澤; 光大塚; 新鍬田; 鉄平森川; 祐史林; 真治河田
Original assignee: 株式会社デンソー
Priority date: 2019-07-17
Filing date: 2020-05-15
Publication date: 2021-01-21
Also published as: JP2021019370A

Abstract

A fan motor (10), provided with a rotor (22) having a magnet (32) that has a plurality of magnetic poles, the magnet (32) being formed using a magnetic material in which the holding force Hc is 400 [kA/m] or above and the residual magnetic flux density Br is 1.0 [T] or above. The fan motor (10) is provided with a stator (20) configured so as to include a conductor (27), the stator (20) having a coil body (26) in which a part of the conductor (27) is configured as a plurality of conductor sections (29A) arranged in the circumferential direction and disposed so as to face the magnet (32). A conductor-to-conductor member is not provided between the conductor sections (29A) with respect to the circumferential direction. In the conductor sections, the radial thickness dimension thereof is smaller than the circumferential width dimension corresponding to one phase in one magnetic pole. The alignment angle, etc., of the magnet (32) is set so that the induced voltage waveform produced in the coil body (26) follows a sine wave.

Description

motor

Cross-reference of related applications

This application is based on Japanese Application No. 2019-131856 filed on July 17, 2019, and the contents of the description are incorporated herein by reference.

This disclosure relates to motors.

Patent Document 1 below discloses a fan motor that constitutes a part of an air conditioner for a vehicle. The fan motors described in this document include a stator having a plurality of coils formed by winding a conductive winding. In the stator described in this document, the space inside the coil is an air-core coil filled with air, synthetic resin, or the like. As a result, the weight of the fan motor is reduced while maintaining the drive output.

Japanese Patent No. 5611348

It is desirable for a motor mounted in a vehicle such as a fan motor to be quiet by reducing vibration and to suppress an increase in physique. However, the configuration described in Patent Document 1 described above is this. There is room for improvement in terms of points.

In consideration of the above facts, the purpose of this disclosure is to obtain a motor that can reduce the noise by reducing vibration and suppress the increase in physique.

In the motor of the first aspect of the present disclosure, the resistance value between the rotor provided with magnets having a plurality of magnetic poles and the bundled strands formed by bundling the conductive strands is the wire. A coil body composed of a wire that is an aggregate of strands that is larger than the resistance value of itself, and is a plurality of wire portions in which a part of the wire is arranged in the circumferential direction and is arranged so as to face the magnet. A member between the conductors is provided between the respective conductors in the circumferential direction, and as the member between the conductors, the width dimension of the member between the conductors in the circumferential direction at one magnetic pole is Wt, and the saturation magnetic flux of the member between the conductors. When the density is Bs and the width dimension of one magnetic pole of the magnet in the circumferential direction is Wm, a stator having a structure of using a magnetic material having a relationship of Wt × Bs ≦ Wm × Br is provided. The magnet has a holding force Hc of 400 [kA / m] or more and a residual magnetic flux density Br of 1.0 [T] or more so as to cause magnetic saturation when a member between the wires is present between the wires. The lead wire portion is formed by using the magnetic material of the above, and the thickness dimension in the radial direction thereof is smaller than the width dimension in the circumferential direction for one phase in one magnetic pole, and the induced voltage generated in the coil body. The orientation angle of the magnet, the distance between the plurality of magnets adjacent to each other in the circumferential direction, the shape of the recess formed in the magnet, and the coil body of the magnet so that the waveform becomes a waveform along the sinusoidal wave. At least one of the thickness dimension in the direction, the distance between the magnet and the coil body, and the width dimension in the circumferential direction of each of the conducting wire portions is set.

By configuring in this way, it is possible to reduce vibration and reduce the size of the physique.

The above objectives and other objectives, features and advantages of the present disclosure will be clarified by the following detailed description with reference to the accompanying drawings. The drawing is
FIG. 1 is a perspective view showing a fan motor. FIG. 2 is a cross-sectional view showing a fan motor cut along line 2-2 shown in FIG. FIG. 3 is an exploded perspective view showing the fan motor in an exploded manner. FIG. 4 is a perspective view showing the stator. FIG. 5 is a perspective view showing the stator core. FIG. 6 is a perspective view showing the lead wire after the first step. FIG. 7 is a perspective view showing the lead wire after the second step. FIG. 8 is a perspective view showing a U-phase lead wire after the third step. FIG. 9 is a perspective view showing a V-phase lead wire after the third step. FIG. 10 is a perspective view showing a W phase lead wire after the third step. FIG. 11 is a perspective view showing another form of the stator. FIG. 12A is a bottom view showing a rotor with magnets arranged in a very anisotropic arrangement. FIG. 12B is a bottom view showing a rotor with a plurality of magnets arranged in a very anisotropic arrangement. FIG. 13 is a schematic diagram for explaining the orientation of the magnetic flux lines in the magnet. FIG. 14 is a schematic diagram for explaining the orientation of the magnetic flux lines in the magnet, and shows an example in which the orientation angle is set to 90 ° or less. FIG. 15 is a schematic view showing an example in which a gap is formed between the magnets and the gap is adjusted. FIG. 16 is a schematic view showing an example in which a recess is provided between the magnets. FIG. 17 is a schematic view showing an example in which the thickness of the magnet is adjusted. FIG. 18 is a schematic view showing an example in which the distance between the magnet and the coil body is adjusted. FIG. 19 is a schematic view showing an example in which the width of the lead wire portion is adjusted. FIG. 20 is a bottom view showing a rotor equipped with magnets arranged in a Halbach array. FIG. 21 is a schematic diagram for explaining the orientation of the magnetic flux lines in the magnet of the rotor shown in FIG. 20.

The motor according to the embodiment will be described with reference to FIGS. 1 to 19.

As shown in FIGS. 1 to 3, the fan motor 10 as the motor of the present embodiment is used to rotate a fan that constitutes a part of a vehicle air conditioner. The fan motor 10 supports a motor body 13 that rotates the rotating shaft 12, a control circuit (not shown) that controls the rotation of the rotating shaft 12 by controlling energization of the motor body 13, and the motor body 13 and the control circuit. The center piece 16 is provided. The arrow Z direction, the arrow R direction, and the arrow C direction, which are appropriately shown in the drawing, indicate the rotation axis direction, the rotation radial direction, and the rotation circumference direction of the rotation shaft 12, respectively. Hereinafter, when the axial direction, the radial direction, and the circumferential direction are simply indicated, the rotational axis direction, the rotational radial direction, and the rotational circumferential direction of the rotating shaft 12 are indicated unless otherwise specified.

The motor body 13 is composed of a rotating shaft 12, a rotor 22, and a stator 20 as main elements.

The rotating shaft 12 is formed of a columnar steel material. As shown in FIG. 2, the rotating shaft 12 is rotatably supported by a pair of bearings 23 fixed to the center piece 16.

The rotor 22 is configured by fixing a magnet 32 to a rotor housing 34 formed in a bottomed cylindrical shape with the other side open in the axial direction. The rotor housing 34 includes a disc-shaped bottom wall 34A and a peripheral wall 34B that bends and extends from the radially outer end of the bottom wall 34A to the other side in the axial direction. At the center of the bottom wall 34A, an insertion portion 34C into which the rotation shaft 12 is inserted is provided. By press-fitting the rotary shaft 12 into the insertion portion 34C, the rotor housing 34 and the rotary shaft 12 are integrally rotatably coupled to each other.

As shown in FIG. 4, the stator 20 includes a stator core 24 formed in an annular shape and an annular coil body 26 fixed to a radially outer portion 24A of the stator core 24.

As shown in FIG. 5, the stator core 24 is formed by laminating steel plates formed in a predetermined shape or the like. An engaging groove 24B that engages with the engaging convex portion 16A (see FIG. 3) formed in the center piece 16 is formed along the axial direction on the inner peripheral portion of the stator core 24 on the inner side in the radial direction. By engaging the engaging convex portion 16A formed on the center piece 16 with the engaging groove 24B, the stator core 24 (stator 20) is positioned in the circumferential direction with respect to the center piece 16. Further, the radial outer surface 24C in the radial outer portion 24A of the stator core 24 is formed as an example on a curved surface having no unevenness. Further, the surface 24D on one side in the axial direction and the surface 24E on the other side in the axial direction in the radial outer portion 24A of the stator core 24 are formed in a planar shape extending in the radial direction and the circumferential direction.

As shown in FIG. 4, the coil body 26 is formed by bending and bending a plurality of lead wires 27 into a shape that covers the radially outer portion 24A of the stator core 24. The conducting wire 27 constituting the coil body 26 is an aggregate of strands formed by bundling conductive strands. Further, the resistance value between the bundled strands is larger than the resistance value of the strands themselves. As a result, the vortex current loss is reduced.

Here, the detailed configuration of the coil body 26 will be described together with the explanation of the manufacturing method of the coil body 26.

First, as shown in FIG. 6, by winding the lead wire 27 in the circumferential direction, most of the lead wire 27 is formed in an annular shape and laminated in the axial direction. The portion of the lead wire 27 that is formed in an annular shape and is laminated in the axial direction is referred to as an annular laminated portion 27A.

Next, as shown in FIG. 7, the annular laminated portion 27A is alternately bent along the circumferential direction to one side in the axial direction (arrow Z1 direction) and the other side in the axial direction (arrow Z2 direction).

Next, as shown in FIG. 7, the alternately bent annular laminated portions 27A are arranged on the outer peripheral side of the stator core 24, and as shown in FIG. 8, the shafts of the alternately bent annular laminated portions 27A are arranged. By bending the portion on one side in the direction and the portion on the other side in the axial direction inward in the radial direction, the coil portion 28U of the U phase is formed, and the coil portion 28U of the U phase is the portion outside the radial direction of the stator core 24. It is arranged along 24A (see FIG. 4).

Similar to the step of forming the U-phase coil portion 28U, as shown in FIG. 9, the portion of the annular laminated portion 27A bent alternately on one side in the axial direction and the portion on the other side in the axial direction are radially inward. By bending, the V-phase coil portion 28V is formed, and the V-phase coil portion 28V is arranged together with the U-phase coil portion 28U along the radial outer portion 24A (see FIG. 4) of the stator core 24. Will be done.

Similar to the step of forming the U-phase coil portion 28U and the V-phase coil portion 28V, as shown in FIG. 10, the alternately bent annular laminated portion 27A has one axial portion and the other axial portion. The W-phase coil portion 28W is formed by bending this portion inward in the radial direction, and the W-phase coil portion 28W together with the U-phase coil portion 28U and the V-phase coil portion 28V has the diameter of the stator core 24. It is arranged along the directional outer portion 24A. As a result, as shown in FIG. 4, the coil body 26 is formed by the U-phase coil portion 28U, the V-phase coil portion 28V, and the W-phase coil portion 28W. An insulator or the like is interposed between the coil body 26 and the stator core 24 to ensure the insulating property between the two and to improve the heat transfer between the two.

Further, in the U-phase coil portion 28U, the V-phase coil portion 28V, and the W-phase coil portion 28W, they are arranged along the radial outer surface 24C (see FIG. 5) in the radial outer portion 24A of the stator core 24. The portion is called the lead wire portion 29A. The lead wire portion 29A is configured by arranging a part of the lead wire 27 extending in the axial direction in the circumferential direction. Further, the thickness dimension of the lead wire portion 29A in the radial direction is smaller than the width dimension in the circumferential direction of one phase in one magnetic pole. The U-phase lead wire portion 29A, the V-phase lead wire portion 29A, and the W-phase lead wire portion 29A are arranged in this order along the circumferential direction.

Further, in the U-phase coil portion 28U, the V-phase coil portion 28V, and the W-phase coil portion 28W, one side surface 24D (see FIG. 5) in the axial direction and the other axial direction in the radially outer portion 24A of the stator core 24 The portion arranged along the side surface 24E (see FIG. 5) is referred to as a coil end portion 28B.

Further, in the present embodiment, as shown in FIG. 5, the radial outer surface 24C of the radial outer portion 24A of the stator core 24 is formed on a curved surface having no unevenness, so that each of the lead wire portions 29A The structure is such that a member between the conductors such as a part of the stator core 24 is not provided between the two. Such a structure is called a "teethless structure".

It should be noted that a wire-to-wire member such as a part of the stator core 24 may be provided between the wire-leading portions 29A. In a configuration in which a member between wires is provided, the width dimension of the member between wires in one magnetic pole in the circumferential direction is Wt, the saturation magnetic flux density of the member between wires is Bs, and the width dimension in the circumferential direction of one magnetic pole of the magnet 32 described later. When is Wm, it suffices that the inter-lead wire member is formed by using a magnetic material or a non-magnetic material having a relationship of Wt × Bs ≦ Wm × Br. In addition, such a structure is also called a "teethless structure".

As shown in FIGS. 4 and 6 to 10, in the configuration described above, each of the annular laminated portion 27A is bent inward in the radial direction by bending one portion in the axial direction and the other portion in the axial direction. An example in which the

coil portions

28U, 28V, 28W are fixed to the radially outer portion 24A of the stator core 24 has been described, but the

respective coil portions

28U, 28V, 28W are fixed to the radially outer portion 24A of the stator core 24 by another method. It may be fixed to. For example, as shown in FIG. 11, the

respective coil portions

28U, 28V, and 28W are embedded in a coil support 30 formed of an insulating material (resin material or the like) to form a shape thereof. It is held, and by fixing the coil support 30 to the radially outer portion 24A of the stator core 24, the

respective coil portions

28U, 28V, 28W can be fixed to the radially outer portion 24A of the stator core 24. Good.

Next, the magnet 32 will be described.

As the magnet 32 of the present embodiment, as shown in FIG. 12A, a single magnet 32 (ring) having a polar anisotropic arrangement (polar anisotropy) in which N poles and S poles are alternately arranged in the circumferential direction. A magnet) can be used, or as shown in FIG. 12B, a plurality of magnets 32 (segment magnets) having a polar anisotropic arrangement (polar anisotropy) can be used. As shown in FIGS. 12A and 12B, the single magnet 32 or the plurality of magnets 32 are fixed to the radial inner surface of the peripheral wall 34B of the rotor housing 34 via an adhesive or the like. Further, the single magnet 32 or the plurality of magnets 32 has a holding force Hc of 400 [kA / m] or more so as to cause magnetic saturation when a member between the conducting wires is present between the respective conducting wire portions 29A. It is formed by using a magnetic material having a residual magnetic flux density Br of 1.0 [T] or more. As an example, the magnet 32 of the present embodiment is formed by using a magnetic material such as NdFe ₁₁ TiN, Nd ₂ Fe ₁₄ B, Sm ₂ Fe ₁₇ N ₃ , FeNi or the like.

Here, in the present embodiment, the magnet is provided so that the induced voltage waveform generated in the coil body 26 (see FIG. 2) when the motor body 13 is operating (when the rotor 22 is rotating) becomes a waveform along a sine wave. 32 orientation angles and the like are set. Hereinafter, a specific configuration for forming the induced voltage waveform generated in the coil body 26 into a waveform along a sine wave will be described.

FIG. 13 shows a schematic view in which a part of the single magnet 32 shown in FIG. 12A is linearly represented along the circumferential direction. Further, in FIG. 13, the magnetic flux lines and the directions of the magnetic fluxes in the magnet 32 are schematically shown by arrows W. As shown in this figure, in a single magnet 32, the circumference of the magnetic flux line at the radial inner end of the magnetic pole center L (the magnetic pole center of the N pole in FIG. 13) when the magnet 32 is viewed from the axial direction. The orientation angle with respect to the direction is θ °. Then, in order to make the induced voltage waveform generated in the coil body 26 become a waveform along the sine wave when the motor body 13 is operated, the magnetic flux center is as shown by the broken magnetic flux line (arrow W) shown in FIG. It has been found by analysis and experiments that the orientation angle of the magnetic flux line in L with respect to the circumferential direction should be set to less than 90 °. The magnetic flux line (arrow W) having an orientation angle of 90 ° is indicated by a solid arrow.

FIG. 15 shows a schematic diagram showing a part of the plurality of magnets 32 shown in FIG. 12B. As shown in this figure, in the plurality of magnets 32, the magnets 32 adjacent to each other in the circumferential direction are separated from each other at the magnetic pole center L (a gap is formed between the magnets 32 adjacent to each other in the circumferential direction). Then, in order to make the induced voltage waveform generated in the coil body 26 along the sine wave when the motor body 13 operates, it is sufficient to adjust the interval C3 of the magnets 32 adjacent to each other in the circumferential direction. I know by

FIG. 16 shows a schematic diagram showing a part of the single magnet 32 shown in FIG. 12A. In this magnet 32, a recess 54 is formed inside the portion of the magnet 32 including the magnetic pole center L in the radial direction. The recess 54 is formed in a U shape whose edge portion is open in the radial direction when viewed from the axial direction. Further, the recess 54 is formed without interruption from one end of the magnet 32 in the axial direction to the other end. Since the recess 54 is formed in the magnet 32, the thickness dimension T1 in the radial direction of the portion where the recess 54 is formed is compared with the thickness dimension T2 of the portion where the recess 54 is not formed. It has a small size. Further, in this example, the thickness dimension T1 in the radial direction of the magnet 32 is the smallest at the magnetic pole center L. Then, it is analyzed that in order for the induced voltage waveform generated in the coil body 26 when the motor body 13 is operated to be a waveform along the sine wave, the shape and size of the recess 54 and the thickness of the magnet 32 should be adjusted. And experiments have shown. As shown in FIG. 17, the recesses 54 may be formed on both sides of the magnet 32 on one side and the other side in the axial direction.

Further, as shown in FIG. 18, by adjusting the radial distance R1 between the magnet 32 and the coil body 26, the induced voltage waveform generated in the coil body 26 when the motor body 13 is operated becomes a sinusoidal wave. It is known from analysis and experiment that the waveform can be made to follow.

Further, as shown in FIG. 19, by adjusting the width dimension C4 of the lead wire portion 29A of the coil body 26 in the circumferential direction, the induced voltage waveform generated in the coil body 26 when the motor body 13 is operated becomes a sine wave. It is known from analysis and experiment that the waveform can be made to follow.

As described above, in order for the induced voltage waveform generated in the coil body 26 to be a waveform along the sinusoidal wave, the orientation angle of the magnet 32, the spacing between the plurality of magnets 32 adjacent to each other in the circumferential direction, and the magnet 32 If at least one of the thickness dimension T1 of the magnet 32, the distance R1 between the magnet 32 and the coil body 26, and the width dimension C4 of each lead wire portion 29A in the circumferential direction is adjusted, such as the shape of the formed recess 54. Good. As a result, it is possible to effectively suppress the generation of noise due to the generation of vibration when the motor body 13 is operated. That is, it is possible to reduce the noise by reducing the vibration.

Further, as described above, in the motor body 13 of the fan motor 10 of the present embodiment, magnetic saturation does not occur even if the current value of the current flowing through each lead wire portion 29A is increased. In addition to this, the magnet 32 is formed by using a magnetic material having a holding force Hc of 400 [kA / m] or more and a residual magnetic flux density Br of 1.0 [T] or more, and the magnet 32 is extremely different. It is an array. As a result, a desired output can be obtained while suppressing an increase in the size of the motor body 13.

In the present embodiment, an example using the magnets 32 having a very anisotropic arrangement has been described, but the present disclosure is not limited to this. For example, as shown in FIGS. 20 and 21, a rotor may be configured using magnets 58 in a Halbach array. The magnet 58 is formed by joining three types of

magnet portions

60A, 60B, and 60C having different directions of magnetic flux in an annular shape. More specifically, the magnet 58 includes a magnet portion 60A magnetized so that the magnetic flux is directed outward in the radial direction, a magnet portion 60B magnetized so that the magnetic flux is directed inward in the radial direction, and a magnet portion 60A and a magnet. The magnet portion 60C, which is arranged between the portion 60B and magnetized so that the magnetic flux goes to one side in the circumferential direction, is configured by being coupled to each other in the circumferential direction.

Although one embodiment of the present disclosure has been described above, the present disclosure is not limited to the above, and various modifications other than the above can be carried out within a range not deviating from the gist thereof. Of course.

Further, although the present disclosure has been described in accordance with the embodiment, it is understood that the present disclosure is not limited to the embodiment mobile phone or structure. The present disclosure also includes various modifications and modifications within an equal range. In addition, various combinations and forms, as well as other combinations and forms that include only one element, more, or less, are also within the scope of the present disclosure.

Claims

A rotor (22) with a magnet (32) having a plurality of magnetic poles, and
It is formed by bundling conductive strands, and is configured to include a conductor (27), which is an aggregate of strands in which the resistance value between the bundled strands is larger than the resistance value of the strands themselves. A coil body (26) having a plurality of conducting wire portions (29A) arranged in a circumferential direction and facing the magnet is provided, and the conducting wires are provided between the respective conducting wire portions in the circumferential direction. An inter-conductor member is provided, and as the inter-conductor inter-conductor member, the width dimension of the inter-conductor member in one magnetic pole in the circumferential direction is Wt, the saturation magnetic flux density of the inter-conductor member is Bs, and the circumferential direction of one magnetic pole of the magnet. When the width dimension is Wm, the stator (20) is configured to use a magnetic material having a relationship of Wt × Bs ≦ Wm × Br.
With
The magnet has a holding force Hc of 400 [kA / m] or more and a residual magnetic flux density Br of 1.0 [T] so as to cause magnetic saturation when a member between the wires is present between the wires. Formed using the above magnetic materials,
The thickness dimension of the lead wire portion in the radial direction is smaller than the width dimension in the circumferential direction of one phase in one magnetic pole.
The orientation angle of the magnet, the distance between the plurality of magnets adjacent to each other in the circumferential direction, the shape of the recess formed in the magnet, and the magnet so that the induced voltage waveform generated in the coil body becomes a waveform along the sinusoidal wave. A motor (10) in which at least one of the thickness dimension in the direction facing the coil body, the distance between the magnet and the coil body, and the width dimension in the circumferential direction of each of the lead wire portions is set. ..
The motor according to claim 1, wherein the orientation angle of the magnetic flux line (W) at the center of the magnetic pole (L) with respect to the circumferential direction is set to less than 90 ° when the magnet is viewed from the axial direction.
The motor according to claim 1 or 2, wherein magnets adjacent to each other in the circumferential direction are separated at the center of the magnetic pole.
The motor according to claim 1 or 2, wherein the recess (54) is formed in a portion including the magnetic pole center of the magnet.
Claims 1 to 4 in which the thickness dimension (T1) of the portion of the magnet including the magnetic pole center in the direction facing the coil body is smaller than the thickness dimension (T2) of the other portion. The motor according to any one of the above.
The stator is configured to include a stator core (24).
The motor according to any one of claims 1 to 5, wherein the coil body in which the shape of the conducting wire portion is maintained is attached to the stator core.