WO2022239829A1 - 回転子及び回転電機並びに回転電機の製造方法 - Google Patents

回転子及び回転電機並びに回転電機の製造方法 Download PDF

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Publication number
WO2022239829A1
WO2022239829A1 PCT/JP2022/020044 JP2022020044W WO2022239829A1 WO 2022239829 A1 WO2022239829 A1 WO 2022239829A1 JP 2022020044 W JP2022020044 W JP 2022020044W WO 2022239829 A1 WO2022239829 A1 WO 2022239829A1
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WO
WIPO (PCT)
Prior art keywords
iron core
core
rotor
magnet
resin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2022/020044
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English (en)
French (fr)
Japanese (ja)
Inventor
太一 徳久
遼 並河
勇士 八木
洋樹 麻生
隆徳 渡邉
晶子 建部
和也 原田
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mitsubishi Electric Corp
Original Assignee
Mitsubishi Electric Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mitsubishi Electric Corp filed Critical Mitsubishi Electric Corp
Priority to CN202280029959.0A priority Critical patent/CN117223197A/zh
Priority to JP2023521240A priority patent/JP7481586B2/ja
Priority to DE112022002596.4T priority patent/DE112022002596T5/de
Priority to US18/547,890 priority patent/US12573898B2/en
Publication of WO2022239829A1 publication Critical patent/WO2022239829A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2746—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets arranged with the same polarity, e.g. consequent pole type
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/028—Fastening stator or rotor bodies to casings, supports, shafts or hubs
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
    • H02K15/035—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets on the rotor
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/12—Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/12—Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines
    • H02K15/121—Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines of cores

Definitions

  • This application relates to a rotor, a rotating electrical machine, and a method of manufacturing a rotating electrical machine.
  • a rotating electric machine with an IPM (Interior Permanent Magnet) structure which consists of a stator consisting of an armature wound around an annular iron core and a rotor having a plurality of magnets arranged in the iron core at predetermined intervals in the circumferential direction. It is The IPM structure is excellent in that rare earth magnets with strong residual magnetic flux density and coercive force can be used with good yield. Since it is necessary to provide a bridging iron core (bridge) between them, part of the magnetic flux of the magnet leaks to the adjacent magnet via the bridge, so there is a problem that the magnetic flux cannot be effectively used.
  • IPM Interior Permanent Magnet
  • the bridge is eliminated, the core is separated inside and outside in the radial direction of the magnet, the gap between the magnets in the circumferential direction is filled with resin, and the concave portion provided in the core on the inner diameter side is used.
  • Rotors and motors have been proposed in which leakage of magnetic flux is reduced by fixing a resin portion (see, for example, Patent Document 1).
  • the iron core of the rotor is generally manufactured by lamination pressing of steel plates with good transmittance and has a cylindrical shape. .
  • the iron core of the inner diameter of the magnet is an integral structure of steel plate, there is a problem that the material yield in press working is low.
  • the divided iron core and magnet are simply molded as they are, the parts will move during molding due to the clearance that is ensured so that each part can be easily put into the mold, and the rotor will be outside after molding is completed.
  • the precision of the diameter was poor, and the vibration or noise characteristics of the rotary electric machine deteriorated.
  • the clearance mentioned above becomes resistance of a magnetic circuit, there also existed a problem that it was difficult to raise the efficiency of a rotary electric machine.
  • the present application discloses a technology for solving the above-described problems.
  • Another object of the present invention is to provide a method for manufacturing a rotating electric machine.
  • the rotor disclosed in the present application includes a main shaft serving as a rotating shaft, a first resin portion formed by filling resin so as to surround the main shaft, and an outer peripheral portion of the first resin portion.
  • a first iron core arranged in a radial direction, a magnet attached to the radially outer side of the first iron core, and a second iron core arranged in close contact with the outer diameter side end surface of the magnet,
  • a plurality of structures in which the magnets are sandwiched between the first iron core and the second iron core are arranged in a circumferential direction with respect to the main shaft, and are arranged between and adjacent to the circumferential end surfaces of the adjacent second iron cores.
  • a second resin portion is formed between the circumferential end surfaces of the magnets that meet, and the first iron core is provided between the adjacent first iron cores in the circumferential direction of the adjacent first iron cores. It is characterized in that the end faces have split faces that are in surface contact with each other, and the second core does not come into contact with the adjacent second core.
  • a rotating electric machine disclosed in the present application is characterized by including a stator arranged to face the rotor in a radial direction. Further, in the method for manufacturing a rotating electric machine disclosed in the present application, by pressing the first iron core and the second iron core, which are arranged in the circumferential direction in close contact with the inner diameter of the rotor, from the inner diameter side, A step of filling resin while pressing the first iron core and the second iron core into a mold that is in contact with the outer periphery of the second iron core to mold the first resin portion and the second resin portion. It is characterized by having
  • the rotor, the rotating electrical machine, and the manufacturing method of the rotating electrical machine disclosed in the present application the rotor, the rotating electrical machine, and the highly efficient rotor that can reduce the leakage magnetic flux have a good iron core yield and a high outer diameter accuracy.
  • a method for manufacturing a rotating electric machine can be obtained.
  • FIG. 1 is a plan view showing a rotating electric machine according to Embodiment 1;
  • FIG. 2 is a side view showing the rotor of the rotary electric machine according to Embodiment 1;
  • FIG. 3 is a cross-sectional view taken along line AA of FIG. 2;
  • 3 is a cross-sectional view taken along line BB of FIG. 2;
  • FIG. 4 is a plan view showing a state before molding a resin portion of the rotor according to Embodiment 1;
  • FIG. 6 is a cross-sectional view taken along line CC of FIG. 5;
  • FIG. 4 is a plan view showing a layout in which the iron core of the rotor according to Embodiment 1 is arranged on the roll material in press working;
  • FIG. 11 is a perspective view showing a rotor according to Embodiment 2;
  • FIG. 8 is a cross-sectional view showing a rotor according to Embodiment 2;
  • FIG. 11 is a perspective view showing a rotor according to Embodiment 3;
  • FIG. 11 is a cross-sectional view showing a rotor according to Embodiment 4;
  • FIG. 11 is a plan view showing a rotor according to Embodiment 5;
  • FIG. 11 is a plan view showing a modification of the rotor according to Embodiment 5;
  • FIG. 12 is a plan view showing a rotor according to Embodiment 6;
  • FIG. 12 is a plan view showing a layout in which the iron core of the rotor according to Embodiment 6 is arranged on a roll material in press working;
  • FIG. 20 is a plan view showing a modification of the rotor according to Embodiment 6;
  • 14C is a plan view showing a layout in which the iron core of the rotor shown in FIG. 14B is arranged on the roll material in press working.
  • FIG. FIG. 20 is a plan view showing a state before molding a resin portion of a rotor according to Embodiment 7;
  • FIG. 20 is a plan view showing a modified example of the state before molding the resin portion of the rotor according to Embodiment 7;
  • FIG. 20 is a cross-sectional view showing a state before molding a resin portion of a rotor according to Embodiment 8;
  • FIG. 20 is a cross-sectional view showing a modified example of the state before molding the resin portion of the rotor according to the eighth embodiment;
  • FIG. 11 is a plan view of rotors according to Embodiments 7 and 8 as viewed from the lower mold side;
  • FIG. 11 is a plan view of a rotor according to Embodiment 5 as viewed from the lower mold side;
  • FIG. 11 is a plan view of a modification of the rotor according to Embodiment 5, viewed from the lower mold side;
  • FIG. 12 is a plan view of a second modification of the rotor according to Embodiment 5, viewed from the lower mold side;
  • FIG. 23 is an enlarged view of FIGS. 20 to 22 and is a view showing leakage magnetic flux from the magnet of the rotor to the core on the inner diameter side;
  • FIG. 12B is an enlarged view of FIG. 12A or 12B, and is a view showing leakage magnetic flux from the magnet of the rotor to the inner core.
  • Embodiment 1 will be described below with reference to the drawings.
  • the same reference numerals denote the same or corresponding parts.
  • the terms axis (direction), diameter (direction), inner diameter (side, direction), outer diameter (side, direction), and circumference (direction) refer to the rotation axis of the rotor. Rotational axis (direction), radial (direction), relative radially toward the center (side, direction), relative radially outwards (side, direction), circumference of the rotational axis in a centered cylindrical coordinate system (direction) shall be indicated.
  • FIG. 1 is a plan view of a rotating electrical machine 1 according to Embodiment 1 as viewed from an axial end face.
  • the rotary electric machine 1 is wound around the teeth 4 projecting in the radial direction from a yoke connected in a circle at the outermost diameter by the number of slots corresponding to the number of slots, and the teeth 4 sandwiching an insulating layer (not shown).
  • the rotor 100 includes a stator 2 having a stator winding 5 made of copper wire and a rotor 100 in which a magnet 200 is embedded in an iron core integrated with a main shaft 600 .
  • FIG. 2 is a side view showing the rotor of the rotating electric machine according to Embodiment 1.
  • FIG. 3 is a cross-sectional view taken along the line AA of FIG. 2
  • FIG. 4 is a cross-sectional view taken along the line BB of FIG.
  • a main shaft 600 that coincides with the rotation axis of the rotating electric machine 1 passes through the center of the rotor 100, and a structure in which the magnets 200 are radially sandwiched between the inner diameter side iron core 300 and the outer diameter side iron core 400 is the rotation center axis. A plurality of them are arranged at predetermined intervals in the circumferential direction with respect to a certain main shaft 600 . Further, in the rotor 100, resin is filled between the main shaft 600 and the inner core 300 and between the outer core 400 and the magnets 200 in the circumferential direction to form an inner diameter filling portion 500b and a gap filling portion 500a.
  • the outer diameter side iron core 400 is in contact with the magnet 200 at the magnet side inner diameter end face 400a, and serves as a magnetic path between the stator 2 and the magnet 200 with a minute air layer (air gap) sandwiched in the outer diameter direction.
  • a circumferential end surface which is a side surface of the outer diameter side iron core 400, has a tapered portion having an angle such that the arc length of the outermost diameter end surface 400c of the outer diameter side iron core 400 is narrower than the length of the magnet side inner diameter end surface 400a. 400b is provided.
  • the inner diameter side core 300 is in contact with the magnet 200 at the magnet side outer diameter end face 300b, and serves as a magnetic path between the magnets 200 adjacent in the circumferential direction.
  • the radial thickness 300 d of the inner core 300 is the minimum length that can ensure a magnetic path that does not saturate the magnetic flux emitted by the magnet 200 .
  • the inner diameter side cores 300 are arranged in the circumferential direction with the adjacent inner diameter side cores 300 sandwiching the dividing surface 300a.
  • the size of the gap between the split surfaces 300a varies within the range of variation in the circumferential dimension between both circumferential end surfaces (split surfaces 300a) of the inner diameter side iron cores 300, with the tight contact between the inner diameter side iron cores 300 being minimized.
  • the magnet abutment surface 300c may be provided as, for example, a circumferential projection as necessary.
  • gap filling portions 500a are filled in the circumferential gaps between the outer diameter side iron core 400 and the magnet 200, and as shown in FIG. formed by (connecting) Further, the inner diameter filling portion 500b fixes and holds the main shaft 600 and the outer diameter direction end surface of the outer diameter side iron core 400 so that the required coaxiality is satisfied.
  • the gap filling portion 500a reduces the short-circuited magnetic flux in the circumferential direction of the magnet 200, and positions the magnet 200 and the outer diameter side iron core 400 in the circumferential direction.
  • the end plate portions 500c and 500d can restrict the movement of the magnet 200, the outer diameter side iron core 400, and the gap filling portion 500a in the axial and radial directions.
  • the radially inward movement of the magnet 200, the outer diameter side core 400, and the inner diameter side core 300 can be restricted by the inner diameter filling portion 500b, and fixing and positioning with the main shaft 600 are possible.
  • the gap filling portion 500a is a structural member corresponding to the bridge of the conventional IPM structure, but resin does not transmit the magnetic flux in the circumferential direction because its relative magnetic permeability is equivalent to that of air.
  • FIG. 5 is a plan view showing the state before molding the resin portion of the rotor according to Embodiment 1, and more specifically shows the state where the iron core and the magnets are put into the molding die.
  • FIG. 6 is an example of a cross-sectional view of the plan view of FIG. 5 cut along line CC and viewed in the direction of the arrows.
  • a molding die 700 for integrally resin-molding rotor 100 of rotating electric machine 1 according to Embodiment 1 includes magnets 200, outer diameter side iron core 400, inner diameter side iron core 300, and main shaft 600, which are rotor members before molding. and an upper mold 700e for closing the molding die 700.
  • a bottom surface 700g of the lower die 700a is provided with a positioning pin 700b for determining the circumferential position of the outer diameter side iron core 400 and a positioning pin 700c for determining the circumferential position of the magnet 200 as well.
  • a positioning pin 700d is arranged on the inner diameter side of the inner diameter side iron core 300 to position the radial end face of the inner diameter side iron core 300 .
  • the positioning pins 700b, 700c, and 700d do not need to be cylindrical as long as the inner core 300, the outer core 400, and the magnet 200 can be positioned.
  • a shape along the outer diameter of the radial side iron core 400 or the magnet 200, or a polygonal prism shape may be used. Quantities may also be added or deleted as appropriate in cases other than those shown in FIG.
  • the axial height of each of the positioning pins 700b, 700c, and 700d may also be set freely within the range of contact with the outer end faces of the inner core 300, outer core 400, and magnet 200.
  • FIG. If the functions of the positioning pins 700b and 700c are fulfilled, protrusions or the like for fixing the outer diameter side iron core 400 to the lower die inner diameter end surface 700aa of the lower die 700a may be substituted.
  • FIG. 6 is a cross-sectional view of the CC line in FIG. 5 viewed from the arrow direction. It should be noted that FIG. 6 shows the positioning pin 700d transparently so that the structure can be easily understood. If the rotor member is placed on the bottom surface 700g of the lower die 700a as it is when the rotor member is put into the lower die 700a, the end plate portion 500d cannot be molded. The axial bottom surface of the end plate portion 500d is lifted by the axial thickness of the end plate portion 500d and supported. As long as the gap filling portion 500a, the inner diameter filling portion 500b, and the end plate portion 500d are not separated, the spacer 700f may be pin-shaped or polygonal. Further, the spacer 700f may be made of the same material as the resin used to mold the spacer 700f, and may be formed so as to become a part of the end plate portion 500d after molding.
  • a gate for injecting resin is provided at an arbitrary position in the molding die 700 to fill the resin portion 500 with the resin. Since the outer core 400, the magnet 200, and the inner core 300 are positioned by the spacer 700f, the pressure during resin molding acts to press each member against the inner diameter end face 700aa of the lower die, and the outer core 400, magnet 200, and inner core 300 are in close contact with each other, and the circularity of the inner diameter end surface 700aa of the lower die is transferred, so that the outer diameter of the rotor 100 also has good circularity.
  • a space is provided in the bottom surface 700g of the lower mold 700a, and the base 700h of the positioning pin 700d is arranged.
  • the base portion 700h can be smoothly slid in the mold radial direction by an appropriate guide mechanism, and the repulsive force of a spring 700i connected to the lower mold 700a presses the inner diameter end face of the inner diameter side iron core 300, and the magnet 200 and each iron core are pushed. It can be pressed against the inner diameter end face 700aa of the lower die.
  • the positioning pin 700d passes through an opening 700j provided in the bottom surface 700g of the lower mold 700a and can be exposed inside the mold. Since the portion where the positioning pin 700d is not exposed is sealed by the upper surface of the base portion 700h, the resin does not flow into the space of the bottom surface 700g of the lower mold 700a.
  • the inner diameter core 300 and the outer diameter core 400 are moved along the outer diameter direction by the elastic restoring force of the inner diameter core 300 and the outer diameter core 400 .
  • a method of adsorbing to the inner diameter end surface 700aa of the mold is also conceivable.
  • other power sources such as pneumatic pressure, hydraulic pressure, and expansion/contraction due to temperature change may be used.
  • the power of the slide mechanism of the base 700h is not limited to the spring either.
  • the iron core and the magnet 200 are brought into close contact with each other and pressed against the lower die inner diameter end surface 700aa, which is the inner circumference of the die, to minimize the magnetic resistance between the magnet 200 and the iron core, thereby improving the outer diameter accuracy of the rotor 100. can be secured.
  • FIG. 7 is a plan view showing the layout when punching the inner diameter side iron core 300 and the outer diameter side iron core 400 from the iron core roll material 800 in the step of pressing the iron core of the rotor according to Embodiment 1.
  • a good material yield can be obtained by arranging the combination of the inner diameter side iron core 300 and the outer diameter side iron core 400 as one unit continuously on the core roll material 800 as shown in FIG.
  • the forward feeding direction of the core roll material 800 in press working may be the up-down direction or the left-right direction on the paper surface of FIG.
  • the rotor 100 and the rotating electric machine 1 since the parts corresponding to the bridges in the conventional IPM structure are filled with resin, not only can leakage magnetic flux in the circumferential direction be reduced, but also the dimensional accuracy of the magnets 200 can be improved. , the gap between the magnet 200 and the core due to the dimensional accuracy of the core can be reduced, and the magnetic flux of the magnet can be effectively utilized. Furthermore, the air gap 3, which is the radial gap between the stator 2 and the rotor 100, is also formed by positioning the outer diameter side iron core 400 and the main shaft 600 with the molding die 700, so that the dimensions can be stabilized. It is possible to reduce the air gap 3 and improve the roundness.
  • the inner core 300 and the outer core 400 need only be press-formed to the size required for the magnetic circuit, the use of materials is reduced compared to a conventional rotor in which circular pressed products are laminated. amount can be significantly reduced.
  • the yield of the iron core roll material 800 which is the material of the iron core
  • the iron core of the rotor 100 according to Embodiment 1 has a shape close to a square. It is possible to lay out on the plane of the material 800 without gaps, thereby improving the material yield.
  • the iron core required for the stator 2 is not pressed all at once, a large press machine or a mold is not required, and investment can be suppressed.
  • the resin with which the rotor 100 is filled is a thermosetting resin, but the material is not particularly limited as long as the material has a lower magnetic permeability than that of the iron core.
  • the material may be a cement or glassy material.
  • the cylindrical rotor 100 having eight poles was illustrated as an example.
  • a so-called petal-shaped rotor in which the curvature of the outer diameter of diameter-side core 400 is larger than the curvature of the outermost diameter of the rotor may be used.
  • the rotor 100 of the rotary electric machine 1 of Embodiment 1 includes the main shaft 600 serving as the rotation shaft and the first resin portion formed by filling the resin so as to surround the main shaft 600.
  • a plurality of such structures are arranged in the circumferential direction with respect to the main shaft 600, and the gaps, which are the second resin portions, are arranged between the circumferential end faces of the adjacent second iron cores and between the circumferential end faces of the adjacent magnets 200.
  • the filling portion 500a is formed, and the first iron core has a dividing surface 300a between the adjacent first iron cores, where the circumferential end surfaces of the adjacent first iron cores are in surface contact, The second core does not contact adjacent second cores.
  • the inner diameter filling portion 500b as the first resin portion and the gap filling portion 500a as the second resin portion are arranged at the end plate portions 500c and 500d as the third resin portion on both axial end surfaces of the structure described above. are connected by Further, the circumferential end face of outer diameter side core 400, which is the second core, has a tapered shape in which the circumferential width becomes narrower toward the radially outer side.
  • the rotary electric machine 1 of Embodiment 1 includes a stator 2 arranged to face the rotor 100 described above in the radial direction.
  • the inner diameter side iron cores 300 that are the first iron cores and the outer cores that are the second iron cores are closely attached to the inner diameter of the rotor 100 and are arranged in the circumferential direction.
  • the resin is filled while pressing the first core and the second core into the molding die 700 that is in contact with the outer periphery of the second core. 1 and a step of molding the second resin portion, which is the gap filling portion 500a.
  • the rotor 100 is a highly efficient rotor capable of reducing leakage magnetic flux, and has a good iron core yield and a high outer diameter accuracy. And, the rotating electric machine 1 and the manufacturing method of the rotating electric machine can be obtained.
  • FIG. 8 is a perspective view showing a rotor according to Embodiment 2.
  • FIG. 9 is a sectional view showing a rotor according to Embodiment 2.
  • the rotor 100 according to the second embodiment will be described below, focusing on the parts different from the first embodiment.
  • Features of the main shaft 600, the magnet 200, the iron core, and the molding die 700, which are not mentioned below, are the same as those of the first embodiment, and the description thereof is omitted here.
  • the gap filling portion 500a is provided as a structural member in place of the bridge portion of the iron core.
  • the gap filling portion 500a is connected to the inner diameter filling portion 500b through the end plate portions 500c and 500d, and the tapered portion 400b can resist the rotational centrifugal force acting on the iron core and the magnet 200.
  • FIG. when applied to the rotary electric machine 1 that rotates at high speed, depending on the magnitude of the centrifugal force, the strength or rigidity of the gap filling portion 500a alone may be insufficient, and the rotor 100 may be deformed and parts may scatter.
  • Embodiment 2 provides a stronger structure against the centrifugal force of rotor 100 .
  • FIG. 8 shows a state of the rotor 100 before resin molding according to the second embodiment.
  • Inner core 300 in the second embodiment has reinforcing holes 301a extending in the inner diameter of the rotor, which are not used in the magnetic circuit, in comparison with inner core 300 in the first embodiment. ing.
  • outer diameter side core 400 also has reinforcing hole 401a of a size that has little effect on the magnetic circuit.
  • the reinforcing holes 301a and 401a do not have to be round holes as long as the influence on the magnetic circuit can be tolerated. may
  • reinforcing hole 301a or reinforcing hole 401a is filled with resin and connected to end plate portions 500c and 500d.
  • the resin filled in the reinforcing holes 301a and 401a can receive rotational centrifugal force starting from the end plate portions 500c and 500d.
  • At least one of the inner diameter side iron core 300 as the first iron core and the outer diameter side iron core 400 as the second iron core is provided with reinforcements, which are holes penetrating in the axial direction. Holes 301a and 401a are formed, respectively, and a fourth resin portion is formed by filling the reinforcing holes 301a and 401a with resin. Also, the fourth resin portion is connected to the end plate portions 500c and 500d, which are the third resin portion.
  • the resin which is the fourth resin portion, has a support shape and is fitted with the inner diameter side iron core 300, which is the first iron core, and the outer diameter side iron core 400, which is the second iron core. Therefore, torque transmission strength can be improved by receiving force in the bending direction when torque is generated.
  • FIG. 10 is a perspective view showing a rotor according to Embodiment 3.
  • FIG. Rotor 100 and rotary electric machine 1 according to Embodiment 3 will be described below with reference to FIG. 10 .
  • the dividing surface 300a between the inner diameter side iron cores 300 is provided in the middle of the magnets 200 in the circumferential direction.
  • the size of the dividing surface 300a is such that the close contact between the iron cores is minimized. passage), there is a problem that the magnetic flux density decreases due to the gap.
  • the configuration of the rotor 100 according to Embodiment 3 basically follows the structure of the rotor 100 shown in Embodiments 1 and 2, and divides the inner core 300 in the circumferential direction.
  • the surface 300a is arranged around the center of the magnet 200 in the circumferential direction.
  • the shape of the dividing surface 300a here may have gaps within a range that allows the influence on the magnetic circuit, and does not need to be a single plane in the axial direction.
  • the magnetic flux emitted from the magnet 200 in the inner diameter direction is separated starting from the center in the magnet circumferential direction and forms a magnetic circuit with two adjacent magnets 200, so almost all the magnetic flux crosses the dividing surface 300a in the structure according to Embodiment 3. do not do.
  • dividing surface 300a of inner diameter side iron core 300 which is the first iron core, is positioned at the center of magnet 200 in the circumferential direction. Therefore, according to the rotor 100 and the rotating electric machine 1 of the third embodiment, in addition to the magnetic flux leakage reduction shown in the first embodiment, it is possible to suppress the decrease of the magnetic flux density at the inner diameter of the magnet.
  • FIG. 11 is a sectional view showing a rotor according to Embodiment 4.
  • FIG. The configuration of the rotor 100 of the fourth embodiment is designed to strongly resist the rotational centrifugal force of the rotor 100, as in the second embodiment.
  • Outer diameter side iron core 400 follows the basic shape of outer diameter side iron core 400 of Embodiment 1, and has projecting portion 402a on the circumferential end surface having tapered portion 400b.
  • the protrusion 402a may have a polygonal shape or a curved surface other than the rectangular shape shown in FIG.
  • protrusions 402a are axially connected to the end plate portions 500c and 500d, they can resist the centrifugal force of the rotor 100, and can be rotated at a higher speed by being used alone or in combination with the configuration of the second embodiment. It can be applied to the electric machine 1 .
  • Embodiment 5 is a plan view showing a rotor according to Embodiment 5.
  • FIG. Rotor 100 and rotary electric machine 1 according to Embodiment 5 will be described below with reference to FIG. 12A.
  • inner core 300 and outer core 400 are divided in the same number as the number of magnetic poles of rotor 100, and the number of magnets 200 is the same as the number of magnetic poles.
  • a structure is provided in which the number of parts can be reduced and the processing cost of the magnet 200 can be reduced.
  • the rotor 100 has a concentric pole structure in which half of the total magnetic poles are replaced with iron cores and the thickness of the magnets 200 is increased.
  • magnets 200 having the same polarity as half the number of magnetic poles of the rotor 100 are arranged in the circumferential direction.
  • the total number of inner cores 300 is half the number of magnetic poles, and the magnet 200 has a split surface 300a around the central portion in the circumferential direction. Also, regarding the dividing surface 300a, it is not necessary to be a single plane as in the third embodiment.
  • the inner core 300 has a protrusion 306a that protrudes radially so as to fit between the two magnets 200 that are adjacent in the circumferential direction.
  • the magnetic pole is formed as an arc having the same radius as the outermost diameter end surface 400 c of the outer diameter side iron core 400 . Therefore, the gap filling portion 500a is formed by filling the gap between the inner core 300, the magnet 200, and the outer core 400 with resin.
  • the inner diameter core 300 may be provided with a flux barrier 303b for correcting the flow of magnetic flux placed at the magnetic pole portion forming a magnetic circuit with the stator 2.
  • FIG. 12B is a plan view showing a modification of the rotor according to Embodiment 5.
  • FIG. 1 the dividing surface 300a of the inner core 300 is desirably located at the center of each polarity, which is a surface on which the lines of magnetic force are unlikely to intersect. 300a may be centered on protrusion 306a.
  • the magnets 200 are arranged half the number of magnetic poles, and have the same polarity on the radially outer side. , half the number of magnetic poles are arranged.
  • the inner core 300 which is the first core, has a projecting portion 306a projecting from the inner diameter side between the circumferential end faces of the magnets 200, and the outermost diameter end face 305a of the projecting portion of the first core. forms a magnetic pole as an arc having the same radius as the outermost diameter end face 400c of the second iron core, and the circumferential end face of the projecting portion 306a is separated from the circumferential end face of the magnet 200.
  • the number of parts can be reduced to half while maintaining the advantages of the first embodiment, and the machining cost including the reduction in the number of magnets 200 can be suppressed. and ease of automation difficulty.
  • Embodiment 6. 13 is a plan view showing a rotor according to Embodiment 6.
  • FIG. FIG. 14A is a plan view showing a layout in which the iron core of rotor 100 according to Embodiment 6 is arranged on a roll material in press working.
  • Rotor 100 and rotary electric machine 1 according to Embodiment 6 will be described below with reference to FIGS. 13 and 14A.
  • Most of the structure of rotor 100 in the sixth embodiment follows that of rotor 100 in the fifth embodiment. is an arc having the same curvature as the outermost diameter end surface 400c which is the outermost peripheral surface of the outer diameter side iron core 400.
  • FIG. 14A is a plan view showing a modification of the rotor according to Embodiment 6, and FIG. 14C is a plan view showing a layout in which the iron core of the rotor shown in FIG. 14B is arranged on a roll material in press working. As shown in FIGS.
  • the core occupation ratio in the core roll material 800 can be reduced to can be enhanced.
  • FIG. 15 is a plan view showing the state before molding the resin portion of the rotor according to Embodiment 7, and more specifically shows the state where the iron core and the magnets are placed in the molding die.
  • a permanent magnet or electromagnet 700z is embedded in the cylindrical portion of the molding die 700 at a position facing the outer diameter side iron core 400 . Since the iron core is a magnetic material, the resin is filled while being attracted to the molding die 700 by the magnetic force generated by the permanent magnet or the electromagnet 700z. can be improved.
  • a permanent magnet it is necessary to design the frictional force due to the magnetic force to be weaker than the force of the ejector when the mold is released after molding.
  • the magnetic force can be controlled by setting the current.
  • FIG. 16 is a plan view showing a modified example of the state before molding the resin portion of the rotor according to Embodiment 7.
  • FIG. 16 when a permanent magnet or electromagnet 700z is arranged between adjacent outer diameter side iron cores 400, the iron cores are attracted by arranging the magnetic poles as shown in FIG.
  • the orientation direction of the magnet 200 is elongated along the circumferential direction, so the number of turns of the electromagnet can be easily ensured and a space-saving configuration can be achieved.
  • the permanent magnets or electromagnets 700z embedded in the molding die 700 do not have to be the same magnet.
  • FIG. 17 is a cross-sectional view showing the state before molding the resin portion of the rotor according to Embodiment 8, and more specifically shows the state where the iron core and magnets are placed in the molding die.
  • the outer diameter side iron core 400 is longer than the magnet 200 in the axial direction, and receives the flow pressure of the resin in the direction from the inner diameter to the outer diameter when filled with resin.
  • the gate 700y for injecting resin is arranged on the inner diameter side of the outer diameter side core 400 in order to set the flow direction of the resin that presses the outer diameter side iron core 400 against the lower mold inner diameter end surface 700aa that is the inner periphery of the molding die 700. I have Furthermore, since it is preferable to push the inner core 300 in the outer diameter direction and bring it into close contact with the magnet 200 , it is desirable to arrange the gate 700 y inside the inner core 300 .
  • FIG. 18 is a cross-sectional view showing a modification of the state before molding the resin portion of the rotor according to the eighth embodiment.
  • the portion of the outer diameter side iron core 400 that is longer than the magnet 200 in the axial direction is By forming the tapered shape, it is possible to generate a component force that presses the outer diameter side iron core 400 in the outer diameter direction, and press the outer diameter side iron core 400 against the molding die 700 .
  • Inner diameter side iron core 300 is similarly tapered on the inner peripheral side, so that inner diameter side iron core 300 can be pressed in the outer diameter direction.
  • the tapered shape can be laminated by a working punch or multiple rows of progressive press dies, but forged iron parts or dust cores may be used instead.
  • the outer diameter side core 400 which is the second core
  • the outer diameter side core 400 is longer than the magnet 200 in the axial direction.
  • the second core is pressed against the molding die 700 and molded by pressing the fluid resin against the portion longer than the magnet 200 .
  • the inner diameter side core 300 which is the first core, has a tapered shape in which the thickness in the radial direction decreases from the inner peripheral side to the outer peripheral side toward the axial end face, and the fluid resin is pressed against the tapered shape.
  • the first iron core, the magnet 200 and the second iron core are pressed against the molding die 700, and the magnet 200, the first iron core and the second iron core are formed in close contact with each other.
  • FIG. 19 is a plan view of the rotor according to Embodiments 7 and 8 as viewed from the lower mold side. As shown in FIG. 19, in the rotor 100, the outer diameter side iron core 400 and the magnets 200 are exposed at positions where they are positioned in the circumferential direction. Rotor 100 has exposed portions 800c that are not filled with resin and that are positioning traces in which gap filling portions 500a are not formed on the circumferential end face of magnet 200 .
  • the exposed portion 800c which is the positioning trace, corresponds to the position where the positioning pin 700c is provided.
  • the rotor 100 has an exposed portion 800b which is not filled with resin and which is a positioning trace where the gap filling portion 500a is not formed on the circumferential end surface of the outer diameter side iron core 400 .
  • the exposed portion 800b which is the positioning mark, corresponds to the position where the positioning pin 700b is provided.
  • Exposed portions 800c and 800b, which are positioning traces are formed on part or all of the circumferential end faces of magnet 200 and outer diameter side iron core 400, respectively.
  • FIG. 20 is a plan view of the rotor according to Embodiment 5 as viewed from the lower mold side.
  • FIG. 21 is a plan view of a modification of the rotor according to Embodiment 5, viewed from the lower die side.
  • the shape of the exposed portion 800a which is the positioning mark, is as shown in FIGS.
  • the rotor 100 has exposed portions 800a, which are positioning traces in which part or all of the circumferential end surfaces of the magnets 200 are not filled with resin and gap filling portions 500a are not formed. have.
  • the exposed portion 800a which is a positioning trace, corresponds to the position where the positioning pins 700c and 700b are provided.
  • FIG. 22 is a plan view of a second modification of the rotor according to Embodiment 5, viewed from the lower mold side.
  • FIG. 23 is an enlarged view of FIGS. 20 to 22, showing leakage magnetic flux from the magnet of the rotor to the core on the inner diameter side.
  • FIG. 24 is an enlarged view of FIG. 12A or 12B, showing leakage magnetic flux from the magnet of the rotor to the core on the inner diameter side. Since the outer core 400 and the magnets 200 are positioned in the circumferential direction by the positioning shape of the molding die 700, as shown in FIGS. , the leakage magnetic flux from the magnet 200 to the inner core 300 as indicated by the dashed arrows in FIG. 23 can be reduced, and the efficiency of the rotor 100 can be increased.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)
PCT/JP2022/020044 2021-05-14 2022-05-12 回転子及び回転電機並びに回転電機の製造方法 Ceased WO2022239829A1 (ja)

Priority Applications (4)

Application Number Priority Date Filing Date Title
CN202280029959.0A CN117223197A (zh) 2021-05-14 2022-05-12 转子、旋转电机以及旋转电机的制造方法
JP2023521240A JP7481586B2 (ja) 2021-05-14 2022-05-12 回転子及び回転電機並びに回転電機の製造方法
DE112022002596.4T DE112022002596T5 (de) 2021-05-14 2022-05-12 Rotor, elektrische Rotationsmaschine und Verfahren zum Herstellen der elektrischen Rotationsmaschine
US18/547,890 US12573898B2 (en) 2021-05-14 2022-05-12 Rotor, rotary electric machine, and method of manufacturing the rotary electric machine

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JP2021082085 2021-05-14

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JP2002171702A (ja) * 2000-12-05 2002-06-14 Isuzu Motors Ltd 回転機のロータ
JP2005168128A (ja) * 2003-12-01 2005-06-23 Honda Motor Co Ltd 回転電機用ロータ
JP2007060860A (ja) * 2005-08-26 2007-03-08 Honda Motor Co Ltd 永久磁石式回転子
JP2013074660A (ja) * 2011-09-27 2013-04-22 Panasonic Corp ブラシレスモータ
JP2015104244A (ja) * 2013-11-26 2015-06-04 ファナック株式会社 樹脂を充填するための樹脂孔を有するロータ、およびロータの製造方法
WO2020090007A1 (ja) * 2018-10-30 2020-05-07 三菱電機株式会社 コンシクエントポール型回転子、電動機、送風機、及び冷凍空調装置、並びにコンシクエントポール型回転子の製造方法

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JP4154957B2 (ja) 2002-08-27 2008-09-24 松下電器産業株式会社 マグネット内装型ロータおよびそれを用いたブラシレスモータ
JP4969064B2 (ja) 2005-06-14 2012-07-04 日立アプライアンス株式会社 電動機の回転子及び電動機
JP2007181304A (ja) 2005-12-28 2007-07-12 Hitachi Appliances Inc 電動機及び回転子の製造方法
JPWO2018180692A1 (ja) 2017-03-30 2020-02-06 日本電産株式会社 ロータ、及びモータ
WO2019016893A1 (ja) * 2017-07-19 2019-01-24 三菱電機株式会社 回転電機

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Publication number Priority date Publication date Assignee Title
JP2002171702A (ja) * 2000-12-05 2002-06-14 Isuzu Motors Ltd 回転機のロータ
JP2005168128A (ja) * 2003-12-01 2005-06-23 Honda Motor Co Ltd 回転電機用ロータ
JP2007060860A (ja) * 2005-08-26 2007-03-08 Honda Motor Co Ltd 永久磁石式回転子
JP2013074660A (ja) * 2011-09-27 2013-04-22 Panasonic Corp ブラシレスモータ
JP2015104244A (ja) * 2013-11-26 2015-06-04 ファナック株式会社 樹脂を充填するための樹脂孔を有するロータ、およびロータの製造方法
WO2020090007A1 (ja) * 2018-10-30 2020-05-07 三菱電機株式会社 コンシクエントポール型回転子、電動機、送風機、及び冷凍空調装置、並びにコンシクエントポール型回転子の製造方法

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US20240136873A1 (en) 2024-04-25
US12573898B2 (en) 2026-03-10
US20240235293A9 (en) 2024-07-11
JPWO2022239829A1 (https=) 2022-11-17
DE112022002596T5 (de) 2024-02-29
CN117223197A (zh) 2023-12-12

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