WO2023058736A1 - 磁性楔、回転電機及び磁性楔の製造方法 - Google Patents

磁性楔、回転電機及び磁性楔の製造方法 Download PDF

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Publication number
WO2023058736A1
WO2023058736A1 PCT/JP2022/037524 JP2022037524W WO2023058736A1 WO 2023058736 A1 WO2023058736 A1 WO 2023058736A1 JP 2022037524 W JP2022037524 W JP 2022037524W WO 2023058736 A1 WO2023058736 A1 WO 2023058736A1
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WIPO (PCT)
Prior art keywords
magnetic
magnetic wedge
wedge
electric machine
soft magnetic
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Ceased
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PCT/JP2022/037524
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English (en)
French (fr)
Japanese (ja)
Inventor
野口伸
西村和則
菊地慶子
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Proterial Ltd
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Proterial Ltd
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Application filed by Proterial Ltd filed Critical Proterial Ltd
Priority to JP2023518711A priority Critical patent/JP7405305B2/ja
Priority to EP22878603.4A priority patent/EP4415225A4/en
Priority to CN202280060279.5A priority patent/CN117957745A/zh
Priority to US18/689,400 priority patent/US20240413690A1/en
Publication of WO2023058736A1 publication Critical patent/WO2023058736A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/02—Details of the magnetic circuit characterised by the magnetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/003—Apparatus, e.g. furnaces
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0264—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements the maximum content of each alloying element not exceeding 5%
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
    • H01F1/26—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • 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
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/16—Stator cores with slots for windings
    • 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
    • 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
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/48—Fastening of windings on the stator or rotor structure in slots
    • H02K3/487—Slot-closing devices
    • H02K3/493—Slot-closing devices magnetic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B22F3/03—Press-moulding apparatus therefor
    • B22F2003/033—Press-moulding apparatus therefor with multiple punches working in the same direction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0824—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid with a specific atomising fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2301/00—Metallic composition of the powder or its coating
    • B22F2301/35—Iron

Definitions

  • the present invention relates to a magnetic wedge used in a magnetic circuit of a rotating electrical machine, a rotating electrical machine, and a method for manufacturing such a magnetic wedge.
  • a stator and a rotor are arranged coaxially, and a plurality of teeth with coils wound around the rotor are arranged at regular intervals in the circumferential direction.
  • a magnetic wedge may be arranged at the tip of the teeth on the rotor side so as to connect the tips of adjacent teeth. In this case, the magnetic wedge is used without winding a coil around the magnetic wedge itself, unlike a coil component or the like.
  • a composite material made of ferromagnetic powder such as iron powder and thermosetting resin is known.
  • This magnetic wedge is manufactured by kneading a ferromagnetic powder and a thermosetting resin to form a paste, which is then compression molded in the thickness direction of the magnetic wedge and thermally cured to form a sheet-like base material. It is manufactured and machined into the required dimensions and shape as a magnetic wedge.
  • Such a conventional magnetic wedge is usually a long and narrow rectangular parallelepiped (strip shape) or machined to have a trapezoidal or convex cross section perpendicular to the length direction, and is provided at the tip of the tooth.
  • the magnetic wedge is inserted into a groove or the like in the longitudinal direction of the magnetic wedge and is fitted and fixed.
  • an object of the present invention is to provide a magnetic wedge that allows smoother insertion of the magnetic wedge into the tips of the teeth, and a method for manufacturing the magnetic wedge.
  • the present invention provides a magnetic wedge to be installed in a slot opening of a stator of a rotating electric machine, wherein the dimension of the magnetic wedge in the circumferential direction of the rotating electric machine is defined as a width.
  • the projected shape of the magnetic wedge is a rectangle, parallelogram or right-angled trapezoid, and the corners of the rectangle, parallelogram or right-angled trapezoid are rounded.
  • the magnetic wedge preferably includes a plurality of soft magnetic particles and an electrically insulating substance between the soft magnetic particles.
  • the soft magnetic particles are Fe-based soft magnetic particles
  • the Fe-based soft magnetic particles contain an element M that is more easily oxidized than Fe
  • the electrically insulating substance is an oxidizing material containing the element M. It is preferable that the Fe-based soft magnetic particles are bound by the oxide phase.
  • the element M is preferably at least one selected from the group consisting of Al, Si, Cr, Zr and Hf.
  • the Fe-based soft magnetic particles are preferably Fe--Al--Cr alloy particles.
  • the width has a different shape in the thickness direction of the magnetic wedge.
  • a rotary electric machine has a plurality of teeth and a plurality of slots formed by the plurality of teeth, and any one of the magnetic wedges is fitted between the tips of the adjacent teeth. It is characterized by being a rotating electric machine having a child and a rotor arranged at a position sharing an axis.
  • a method for manufacturing a magnetic wedge of the present invention is a method for manufacturing a magnetic wedge to be installed in a slot opening of a stator of a rotating electric machine, and the width of the magnetic wedge in the circumferential direction of the rotating electric machine is soft magnetic.
  • a mold having a part and a punch that can be inserted into the opening of the mold is used.
  • a plurality of soft magnetic particles and an electrically insulating substance be included between the soft magnetic particles.
  • the raw material powder is a mixed powder of a powder of Fe-based soft magnetic particles containing an element M that is more easily oxidized than Fe, and a binder, and after the press molding step, A heat treatment step of heat-treating the compact to form surface oxide phases of the Fe-based soft magnetic particles that bind the Fe-based soft magnetic particles between the Fe-based soft magnetic particles. is preferred.
  • the element M is preferably at least one selected from the group consisting of Al, Si, Cr, Zr and Hf.
  • the Fe-based soft magnetic particles are preferably Fe--Al--Cr alloy particles.
  • the punch has a punch surface that is asymmetric with respect to a center line in the short side direction of the rectangle.
  • FIG. 1A and 1B are a perspective view and a cross-sectional view showing the shape of a magnetic wedge that is a first embodiment of the present invention
  • FIG. 3 is a schematic diagram showing the attachment form of the magnetic wedges of the first embodiment in the radial gap type rotary electric machine
  • FIG. 3 is a schematic diagram showing a magnetic wedge forming method according to the first embodiment of the present invention.
  • FIG. 4A is a perspective view and a cross-sectional view showing the shape of a magnetic wedge that is a second embodiment of the present invention; It is a cross-sectional schematic diagram of tooth front-end
  • FIG. 5 is a schematic diagram showing a magnetic wedge forming method according to a second embodiment of the present invention.
  • FIG. 4 is a cross-sectional view showing the shape of a lower punch used for molding in the examples of the present invention; It is an appearance photograph of the example of the present invention.
  • FIG. 4 is a schematic diagram of a partial model; It is an appearance photograph of an example and a comparative example. 4 is a graph comparing the pushing force between the example and the comparative example. 4 is a DC magnetization curve (BH curve) of an example of the present invention; 1 is a model diagram of a rotating electric machine used for electromagnetic field analysis;
  • FIG. FIG. 5 is a cross-sectional view showing the shape of a magnetic wedge that is a third embodiment of the present invention; FIG.
  • BH curve DC magnetization curve
  • FIG. 12 is a cross-sectional view showing another example of the third embodiment of the present invention
  • FIG. 11 is a cross-sectional view showing an attachment mode when inserting a plurality of magnetic wedges of the third embodiment in tandem
  • FIG. 11 is a schematic diagram of a rotating electric machine showing an example of a fourth embodiment of the present invention
  • An embodiment of the present invention relates to a magnetic wedge installed in a slot opening of a stator of a rotating electric machine, wherein the width is the dimension of the magnetic wedge in the circumferential direction of the rotating electric machine, and a plane perpendicular to the width direction
  • the projected shape of the magnetic wedge projected onto is a rectangle, a parallelogram or a right-angled trapezoid, and the corners of the rectangle, the parallelogram or the right-angled trapezoid are rounded.
  • a magnetic wedge characterized by: In other words, in the magnetic wedge according to the embodiment of the present invention, the corners of the cross section perpendicular to the width direction of the magnetic wedge are rounded, so that the corners are shaved and the iron powder and the like scatter. do not have.
  • the tips of the teeth refer to the tips of the teeth, and are not particularly limited to the ends.
  • the projection shape of the magnetic wedge described above may be a shape in which at least a pair of opposite sides are parallel.
  • a stator for a rotating electrical machine has a plurality of teeth and a plurality of slots formed between adjacent teeth.
  • a magnetic wedge having any of the projection shapes described above is fitted between the portions).
  • FIG. 1 shows a perspective view of a magnetic wedge 10 in this embodiment.
  • the magnetic wedge 10 is a magnetic wedge for a rotating electric machine, and has a substantially rectangular parallelepiped shape with some curved surfaces at the corners.
  • the curved surface of the corner is hereinafter referred to as radius (R) 24 .
  • FIG. 1 also shows the cross-sectional shape of the magnetic wedge 10 .
  • the cross section (xz cross section) perpendicular to the length direction (y direction) of the magnetic wedge has a rectangular shape.
  • the shape of a cross section (yz cross section) perpendicular to the width direction (x direction) is a rectangle with rounded corners 24 at the corners.
  • the projected shape of the magnetic wedge projected onto a plane (yz cross section) perpendicular to the width direction (x direction) is a rectangle, and the corners of the rectangle are rounded. . That is, the projected shape of the magnetic wedge can be recognized as a rectangle as a whole, even if it has a radius.
  • the long side direction of the rectangle corresponds to the length of the magnetic wedge, and the short side direction of the rectangle corresponds to the thickness of the magnetic wedge.
  • the length direction of the magnetic wedge (the y direction in FIG. 1, the long side direction of the above-mentioned rectangle) is the axial direction of the rotating electric machine, and the magnetic wedge
  • the thickness direction (the z direction in FIG. 1, the short side direction of the above-described rectangle) corresponds to the radial direction of the rotating electric machine, and the width direction of the magnetic wedge (the x direction in FIG. 1) corresponds to the circumferential direction of the rotating electric machine. do.
  • the length direction of the magnetic wedge (the y direction in FIG. 1, the long side direction of the above-mentioned rectangle) is the axial direction of the rotating electric machine
  • the magnetic wedge The thickness direction corresponds to the radial direction of the rotating electric machine
  • the width direction of the magnetic wedge (the x direction in FIG. 1) corresponds to the circumferential direction of the rotating electric machine. do.
  • the length direction of the magnetic wedge (the y direction in FIG.
  • the long side direction of the above-mentioned rectangle is the radial direction of the rotating electric machine
  • the magnetic The thickness direction of the wedge corresponds to the axial direction of the rotating shaft
  • the width direction of the magnetic wedge (the x direction in FIG. 1) is the circumferential direction of the rotating electric machine.
  • the approximate dimensions of the magnetic wedge 10 are, for example, 10 mm to 300 mm in the length direction (y direction) of the magnetic wedge, 2 mm to 20 mm in the width direction (x direction) of the magnetic wedge, and 2 mm to 20 mm in the thickness direction (z direction) of the magnetic wedge. It is about 1 to 5 mm.
  • the length of the magnetic wedge in this case is approximately 100 mm or less.
  • FIG. 2 is a schematic diagram showing a form when the magnetic wedge 10 is attached to a radial gap type rotating electric machine.
  • the magnetic wedge 10 is inserted into the groove provided at the tip of the tooth 34 in the axial direction of the rotary electric machine.
  • the risk of the wedge 10 being caught on the inner surface of the groove of the tooth 34 is reduced, and the wedge 10 can be smoothly inserted, fitted and fixed.
  • FIG. 2 shows the case of a radial gap type rotating electric machine, in the case of an axial gap type rotating electric machine, the rotation of the radial gap type is possible except that the insertion direction of the magnetic wedge 10 is the radial direction of the rotating electric machine. Since it is the same as an electric machine and is also inserted from the portion where the radius 24 is formed, it can be smoothly inserted and fitted and fixed.
  • the magnetic wedge 10 can be a green compact made of soft magnetic particles (hereinafter also referred to as soft magnetic powder), such as iron powder or Fe-based soft magnetic alloy powder, or both.
  • soft magnetic powder such as iron powder or Fe-based soft magnetic alloy powder
  • FIG. 3 shows a schematic diagram of a molding die (die 20) and an upper punch 21 and a lower punch 22 used when manufacturing the magnetic wedge 10 shown in FIG. 1 by powder press molding.
  • the die 20 is provided with a cavity having a rounded rectangular opening 23 having the same yz cross-sectional shape as the magnetic wedge 10 .
  • the shape of the cavity provided in the die 20 is tapered so that the upper part is wider and the lower part is narrower.
  • the taper makes it possible to easily remove the molded body from the die 20 after molding. It is possible to solve problems such as scratches on the mold and shortening of the life due to wear of the mold.
  • the upper punch 21 and the lower punch 22 have a rounded rectangular cross-sectional shape perpendicular to the molding direction, which is also the same as the cross-sectional shape of the magnetic wedge 10 . That is, the upper punch 21 and the lower punch 22 are substantially rectangular with rounded corners and substantially the same shape as the opening 23 of the die 20 . However, since the upper punch 21 and the lower punch 22 can be inserted into the opening 23 of the die 20, their dimensions are smaller than the opening by several micrometers.
  • a magnetic wedge manufacturing method is a method for manufacturing a magnetic wedge to be installed in a slot opening of a stator of a rotating electric machine, wherein the dimension of the magnetic wedge in the circumferential direction of the rotating electric machine is the width. Then, a press molding step is performed to obtain a molded body by press molding the raw material powder containing the soft magnetic particles in the width direction, and in the press molding step, a rectangle, parallelogram or A mold with a right-angled trapezoidal opening and a punch that can be inserted into the opening of the mold are used.
  • a die and a punch can be used to obtain the molded body of the magnetic wedge 10 .
  • a method of forming the magnetic wedge 10 using the die 20 and the upper and lower punches 21 and 22 is as follows. First, only the lower punch 22 is inserted into the die 20, and raw material powder containing soft magnetic powder is filled into the cavity. After that, the upper punch 21 is inserted into the opening and pressurized with a predetermined pressure. At this time, the pressing direction (molding direction) is the width direction of the magnetic wedge 10 . The pressurized raw material powder is compacted to form the compact 11 . The molded body 11 thus obtained has a shape having a radius 24 .
  • the magnetic wedge 10 can be obtained by solidifying the compact 11 by heat treatment or the like.
  • pressure can be applied in the yz plane, which has a relatively small area, and the load can be significantly reduced compared to the case of molding in the thickness direction.
  • the rounded shape of the end portion can be easily formed by appropriately shaping the opening of the die as described above.
  • the compacting pressure can be appropriately adjusted according to the material and properties of the raw material powder. In some cases, the density becomes low even after heat treatment, causing problems such as insufficient strength and failure to obtain desired magnetic properties. Therefore, the molding pressure is preferably 0.1 GPa or higher, preferably 0.2 GPa or higher, and more preferably 0.3 GPa or higher. On the other hand, if the molding pressure is too high, the load on the mold becomes large, and wear and cracking are likely to occur, shortening the life of the mold. From such a viewpoint, the molding pressure is preferably 3 GPa or less, more preferably 2 GPa or less, and even more preferably 1 GPa or less.
  • At least the portions of the die 20 and the upper and lower punches 21 and 22 that are in contact with the compact 11 are made of cemented carbide.
  • the rounded shape can be formed at the end of the magnetic wedge 10 without machining, and the magnetic wedge 10 can be easily fitted and attached to the rotating electric machine. can be manufactured at low cost. Furthermore, since the shape of the opening of the die is a rectangle with rounded corners, the stress concentration on the corners caused by the molding pressure is alleviated by the rounded shape, which is effective in extending the life of the mold.
  • the radius of the radius is preferably 0.1 mm or more, more preferably 0.2 mm or more, and even more preferably 0.3 mm or more, in order to receive the above effects more reliably.
  • the radius of the radius is preferably 50% or less, more preferably 40% or less, and even more preferably 30% or less of the thickness of the magnetic wedge 10.
  • the radius of the radius is preferably 50% or less of the thickness of the magnetic wedge 10, more preferably 40% or less, and even more preferably 30% or less.
  • the magnetic wedge 10 can be a composite material (composite material) made of soft magnetic particles and an electrically insulating substance.
  • the composite material has an electrically insulating substance present between a plurality of soft magnetic particles to bind the soft magnetic particles together and electrically isolate the particles, thereby reducing the electrical resistance of the magnetic wedge 10. By increasing it, eddy current loss occurring in the magnetic wedge 10 can be suppressed.
  • the average particle diameter of the soft magnetic particles (median diameter d50 in the cumulative particle size distribution) is preferably 200 ⁇ m or less, more preferably 100 ⁇ m or less, and even more preferably 50 ⁇ m or less, because if it is too large, the electrical resistance will decrease and the eddy current loss will increase. .
  • the average particle size of the ferromagnetic particles is preferably 2 ⁇ m or more, more preferably 5 ⁇ m or more, and even more preferably 10 ⁇ m or more.
  • Both organic and inorganic substances can be used as electrically insulating substances.
  • epoxy resin, phenolic resin, polyimide, polyphenylene sulfide, polyamide, polyamide-imide, silicon resin, colloidal silica, and low-melting-point glass can be used. is.
  • transfer molding, injection molding, hot pressing, etc. can also be used.
  • the raw material powder is a mixed powder of a powder of Fe-based soft magnetic particles containing an element M that is more easily oxidized than Fe, and a binder, and the press molding After the step, heat treatment is performed on the molded body to form a surface oxide phase of the Fe-based soft magnetic particles that binds the Fe-based soft magnetic particles between the particles of the Fe-based soft magnetic particles. have a process.
  • the magnetic wedge 10 is a compacted body of a plurality of Fe-based soft magnetic particles 1 containing an element M that is more easily oxidized than Fe.
  • the element M that is more easily oxidized than Fe means an element whose standard Gibbs energy of oxide formation is lower than that of Fe 2 O 3 .
  • element M at least one selected from the group consisting of Al, Si, Cr, Zr and Hf can be used.
  • the soft magnetic particles are an Fe-based alloy containing an element M that is more easily oxidized than Fe, and an oxide phase of the element M is generated between the soft magnetic particles to bind the particles together.
  • the soft magnetic particles are press-molded by the above-described method, and then heat-treated in an atmosphere in which oxygen is present, whereby an oxide phase of the element M can be grown at the grain boundaries.
  • the ratio of the electrically insulating material in the grain boundaries can be minimized, and the density is increased, so that the strength and the magnetic permeability are increased, which is more preferable.
  • the element M may be selected not only by one type but also by combining two or more types such as Al and Cr or Si and Cr.
  • the Fe-based soft magnetic particles may be Fe--Al--Cr alloy particles.
  • the Fe--Al--Cr alloy is an alloy in which Cr and Al (in no particular order) are the elements with the highest content next to Fe, and other elements are contained in smaller amounts than Fe, Cr, and Al. It's okay to be there.
  • the composition of the Fe--Al--Cr alloy is not particularly limited, for example, the Al content is preferably 2.0% by mass or more, more preferably 5.0% by mass or more.
  • the Al content is preferably 10.0% by mass or less, more preferably 6.0% by mass or less.
  • the Cr content is preferably 1.0% by mass or more, more preferably 2.5% by mass or more.
  • the Cr content is preferably 9.0% by mass or less, more preferably 4.5% by mass or less.
  • the total content thereof is preferably 1.0% by mass or more and 20% by mass or less, as in the case of selecting one element.
  • the Fe-based soft magnetic particles may be particles surface-treated by a chemical method, heat treatment, or the like.
  • the Fe-based soft magnetic particles can be composed of a plurality of types of Fe-based soft magnetic particles having different compositions.
  • FIG. 4 shows a perspective view of a magnetic wedge 10 that is a second embodiment of the present invention.
  • the magnetic wedge 10 has a substantially rectangular parallelepiped shape as in the above-described first embodiment, and has a radius 24 at its end.
  • FIG. 4 also shows the shape of a cross section (xz cross section) perpendicular to the length direction (y direction) of the magnetic wedge 10 .
  • the cross-sectional shape is trapezoidal as a general shape.
  • the shape of the cross section (yz cross section) perpendicular to the width direction (x direction) is a rounded rectangle with rounded corners 24, as in the first embodiment.
  • the magnetic wedge 10 of the second embodiment When attaching the magnetic wedge 10 of the second embodiment to the rotating electric machine, it is preferable to attach it in the direction in which the upper side of the trapezoid in the xy section faces the rotor, as shown in FIG. At this time, it is preferable that the shape of the grooves at the tips of the teeth into which the magnetic wedges 10 are fitted should also match the cross-sectional shape of the magnetic wedges 10 .
  • the magnetic wedge 10 can be brought closer to the rotor, and the loss reduction effect of the rotating electric machine by the magnetic wedge can be increased.
  • the punch surfaces of the upper punch 21 and the lower punch 22 have the same shape as the side surface of the magnetic wedge 10, and the magnetic wedge 10
  • the compact 11 is produced by pressure-molding in the width direction of , which is solidified by heat treatment or the like.
  • the shape of the magnetic wedge 10 of the second embodiment in the xz cross section is not limited to the substantially trapezoidal shape shown in FIG. Any shape is acceptable as long as the width of the magnetic wedge differs in the thickness direction, and various shapes such as a convex shape can be adopted.
  • the punching surfaces of the upper punch 21 and the lower punch 22 are also arranged in the thickness direction of the magnetic wedge, that is, the width of the cavity (rectangular shape) of the opening 23. It is configured in a shape that is asymmetric with respect to the center line in the side direction.
  • the shape of the side surface 25 of the magnetic wedge 10 (and the shape of the upper punch 21 and the lower punch 22) is made up of straight lines and curved lines that are smoothly connected. It is more preferable that the portion where the straight portion and the inclined portion are connected has a rounded shape. With such a shape, when the raw material powder in the cavity of the opening 23 is pushed by the upper punch 21 and the lower punch 22 during molding, the raw material powder flows along the shape of the punch surface from the high-pressure portion. Since it can move to a lower portion, the density uniformity inside the compact 11 can be improved.
  • the magnetic wedge 10 is repeatedly pressed against the teeth by the electromagnetic excitation force when the motor is driven, and stress is generated. can be prevented. Therefore, it is effective in improving the durability and life of the magnetic wedge.
  • a molding method (single-stage molding) of simply compressing with an upper punch 21 and a lower punch 22 as shown in FIG. 6 can be used. It is also possible to use a molding method (multi-stage molding) in which one or both of the are divided and each is independently controlled and compressed.
  • the one-step molding method is preferable because it is possible to avoid complication and enlargement of the press machine and mold to be used, and the time required for molding can be relatively short.
  • W1/W2 is preferably 60% or more, more preferably 70% or more, and even more preferably 80% or more.
  • the value of W1/W2 is preferably 95% or less, more preferably 90% or less, and even more preferably 85% or less.
  • the value of W1/W2 may have to be 60% or less.
  • FIG. 14 shows a cross-sectional view of a magnetic wedge 10 that is a third embodiment of the present invention.
  • This figure shows the cross-sectional shape of the magnetic wedge 10 in the yz plane perpendicular to the x-axis when the x-, y-, and z-axes are the same as in FIG. That is, the cross-sectional shape is perpendicular to the width direction (x direction) of the magnetic wedge 10 .
  • the yz cross section of the magnetic wedge 10 is generally a parallelogram, and has rounded portions 24 at its corners.
  • FIG. 1 shows the cross-sectional shape of the magnetic wedge 10 in the yz plane perpendicular to the x-axis when the x-, y-, and z-axes are the same as in FIG. That is, the cross-sectional shape is perpendicular to the width direction (x direction) of the magnetic wedge 10 .
  • the yz cross section of the magnetic wedge 10 has a general shape of a right-angled trapezoid with rounded corners 24 .
  • the magnetic wedges 10 of the third embodiment when a plurality of magnetic wedges 10 are to be inserted in a single tooth tip portion in tandem, it is preferable to install the magnetic wedges 10 of the third embodiment in the manner shown in FIG. If the magnetic wedges of the third embodiment are inserted as shown in FIG. 16, the gaps at the boundaries between the magnetic wedges can be made small or dispersed, which is preferable in that problems such as disturbance of the magnetic flux can be alleviated. . Furthermore, in the portions where the magnetic wedges 10 overlap each other, the inner wall surfaces of the grooves provided in the tips of the teeth press against each other, so that the magnetic wedges 10 are fixed more firmly. Further, it is preferable to use magnetic wedges positioned on the end surfaces of the teeth 34 having a rectangular trapezoidal cross-sectional shape.
  • FIG. 16 shows a case in which four magnetic wedges 10 are arranged in tandem, this is merely an example, and the number of magnetic wedges 10 can be appropriately determined according to the thickness of the teeth 34 and the length of the magnetic wedges 10. Can be changed.
  • the configuration in which a plurality of magnetic wedges 10 having a parallelogram or right-angled trapezoidal cross-sectional shape are arranged in tandem has the effect of pressing the magnetic wedges 10 against each other at overlapping portions regardless of the presence or absence of the radius 24.
  • a rotary electric machine includes a rotary electric machine stator in which a plurality of wedges are arranged in tandem, and a rotor arranged at a position sharing an axis with the rotary electric machine stator.
  • ⁇ is preferably in the range of 15° or more and 75° or less, more preferably in the range of 30° or more and 60° or less, and further preferably in the range of 40° or more and 50° or less.
  • the magnetic wedge 10 of the third embodiment is preferably a powder compact made of soft magnetic particles and is produced by powder press molding.
  • the cross-sectional shape of the magnetic wedge 10 shown in FIG. 14 is such that the opening 23 of the die (die 20) in FIG.
  • the shape makes it possible to easily manufacture the magnetic wedge 10 of the third embodiment.
  • the shape of the xz cross section is not limited to a substantially trapezoidal shape, and various shapes such as a convex shape, such as a shape in which the width of the magnetic wedge differs in the thickness direction of the magnetic wedge, are also possible. is.
  • FIG. 17 is a schematic diagram of rotating electric machine 300 and shows a cross-sectional structure perpendicular to the rotating shaft of rotating electric machine 300 .
  • the rotating electric machine 300 is a radial gap type rotating electric machine, and has a stator for the rotating electric machine (stator 31) and a rotor (rotor 32) arranged inside the stator 31, which are coaxially arranged.
  • the stator 31 has a plurality of teeth 34 and a plurality of slots formed by the plurality of teeth 34.
  • the plurality of teeth 34 around which the coils 33 are wound are arranged at regular intervals in the circumferential direction.
  • the magnetic wedge 10 of the first embodiment is fitted to the rotor 32 side of the slot, that is, to the rotor 32 side tip of the tooth 34 so as to connect the tip of the adjacent teeth 34 .
  • the relative magnetic permeability and saturation magnetic flux density of the teeth 34 are usually designed to be higher than those of the magnetic wedge 10 .
  • the magnetic flux from the rotor 32 that has reached the magnetic wedge 10 flows into the teeth 34 via the magnetic wedge 10, and the magnetic flux that reaches the coil is suppressed, thereby reducing eddy current loss occurring in the coil.
  • the rotating electric machine is driven, most of the magnetic flux in the teeth 34 generated by the coil current flows into the rotor 32 across the gap, but part of it is attracted by the magnetic wedges and spreads in the circumferential direction. Become.
  • the magnetic flux distribution in the gap between the stator 31 and the rotor 32 becomes smooth. Loss can be reduced.
  • An alloy powder of Fe-5%Al-4%Cr (% by mass) was produced by a high-pressure water atomization method. Specific manufacturing conditions are as follows. The tapping temperature was 1,650° C. (melting point: 1,500° C.), the molten metal nozzle diameter was 3 mm, the tapping speed was 10 kg/min, the water pressure was 90 MPa, and the amount of water was 130 L/min. Note that the raw materials were melted and tapped in an Ar atmosphere. The average particle diameter (median diameter) of the produced powder was 12 ⁇ m, the specific surface area of the powder was 0.4 m 2 /g, the true density of the powder was 7.3 g/cm 3 , and the oxygen content of the powder was 0.3%.
  • PVA Polyvinyl alcohol
  • ion-exchanged water were added to this raw material powder to prepare slurry, which was then spray-dried with a spray dryer to obtain granulated powder. Assuming that the raw material powder is 100 parts by weight, the amount of PVA added is 0.75 parts by weight. 0.4 parts by weight of zinc stearate was added to the granulated powder and mixed.
  • This mixed powder was filled in a mold and press-molded at room temperature.
  • a mold having the same shape as that shown in FIG. 3 was used.
  • the material of the mold is cemented carbide.
  • the opening of the mold was a rectangle with rounded corners of 18 mm ⁇ 1.5 mm, and the radius of the corners was 0.3 mm.
  • the punch used had a punch surface with the same shape as the side surface of the magnetic wedge.
  • FIG. 7 shows the cross-sectional shape of the punch used. This figure is a cross-sectional view similar to that shown in FIG. 6, showing the shape of the tip of the upper punch.
  • a 1.5 mm
  • b 0.5 mm
  • c 0.65 mm
  • d 0.35 mm
  • e 0.65 mm
  • f R0.3
  • g 45°.
  • the shape of the tip of the upper punch has straight portions at both ends in the thickness direction of the upper punch and inclined portions connecting them. It has an arc shape.
  • the lower punch used had a shape obtained by vertically inverting the upper punch.
  • the material of the punch is cemented carbide for both the upper punch and the lower punch.
  • the mold was also lowered at about half the lowering speed of the upper punch, so that the density variation in the compact would not become too large.
  • the load at the bottom dead center during molding was 2 tons.
  • the molding pressure obtained by dividing this value by the area of the opening of the mold was 0.7 GPa.
  • Heat treatment The compact produced as described above was subjected to heat treatment at 750° C. for 1 hour in air. The heating rate at this time was 250° C./h.
  • W1 and W2 shown in FIG. 4 were measured using the length measurement function of an optical microscope (VHX-6000 manufactured by Keyence; W1/W2 was calculated by taking their ratio. As a result, W1/W2 of Example 5 was in the range of 74.4% to 75.2%.
  • the electrical resistivity of the magnetic wedge was 5 ⁇ 10 4 ⁇ m.
  • Three-point bending strength at room temperature was measured using a universal testing machine (Instron Model 5969). The measurement conditions are a load cell capacity of 500 N, a fulcrum diameter of 4 mm, an indenter diameter of 4 mm, a distance between fulcrums of 8 mm, and a test speed of 0.12 mm/min. From the load P(N) at break, the cross-sectional shape of the magnetic wedge was approximated by a trapezoid, and the three-point bending strength ⁇ was calculated using the following formula.
  • ⁇ 3LP(2W1+W2)/((W1 2 +W2 2 +4W1W2)h 2 )
  • L is the distance between fulcrums
  • W1 and W2 are the widths of the magnetic wedges (see FIG. 4)
  • h is the thickness of the magnetic wedges.
  • the three-point bending strength of the magnetic wedges (three samples) measured as described above was 140 to 160 MPa, which was confirmed to be above the strength normally required for magnetic wedges (about 100 MPa).
  • FIG. 10 A schematic diagram of the partial model 40 is shown in FIG.
  • the partial model uses a block made by bonding and laminating 50 mm ⁇ 30 mm non-oriented electrical steel sheets (35H300 made by Nippon Steel Corporation) to a thickness of 50 mm. It was produced by electrical discharge machining. As shown in FIG. 9, five recesses imitating slots were produced, but all had the same shape and dimensions.
  • a spring 41 is installed in a slot-like recess, and the magnetic wedge 10 can be fixed by pressing it against the groove (A part in FIG. 9) at the tip of the tooth via a bake plate 42 and, if necessary, a spacer (not shown). I made it As the magnetic wedge 10, the magnetic wedge described above was used.
  • the pressing force of the magnetic wedge 10 by the spring 41 can be appropriately adjusted by using springs with different spring constants or by inserting an appropriate spacer.
  • nine compression coil springs (D5509 manufactured by KS Sangyo Co., Ltd.; outer diameter 3.7 mm, free length 16 mm) having a spring constant of 1.588 N/mm were installed in parallel, and 3.5 mm was placed between the springs and the baking plate.
  • An 8 mm thick spacer (not shown) was inserted. Therefore, the amount of compression of the springs when the magnetic wedge 10 was inserted was 3.8 mm, and the magnetic wedge 10 was pressed with a total force of 53 N by the nine springs.
  • the pushing force when inserting the magnetic wedge 10 into the above partial model 40 was measured as follows. First, two magnetic wedges with a length of 18 mm are inserted in advance, and the third magnetic wedge is inserted by 1 mm from the upper end of the partial model. In this state, using a universal testing machine (Instron Model 6959), insert the third magnetic wedge at a pushing speed of 0.1 mm/s. measured in As the third magnetic wedge, a magnetic wedge with a rounded end (left side in FIG. 10) and a magnetic wedge with a rounded portion removed by breaking the magnetic wedge are compared (right side in FIG. 10). bottom. When inserting the comparative example, it was inserted into the partial model 40 from the fracture surface side. FIG. 11 shows the measurement results of the pushing force. As shown in the figure, the magnetic wedge has a lower pushing force than the comparative example, and it was confirmed that by rounding the ends of the magnetic wedge, it is easier to attach to the motor.
  • DC magnetization curve A DC magnetization curve (BH curve) of the magnetic wedge was measured using a DC self-recording magnetometer (TRF-5AH manufactured by Toei Kogyo Co., Ltd.). A sample for measurement was prepared by cutting off 4 mm from each end of the above magnetic wedge in the length direction with a slicer so as to have a length of 10 mm, and then adhering them in the thickness direction. This was sandwiched between the magnetic poles of an electromagnet, and the BH curve in the longitudinal direction was measured with a maximum applied magnetic field of 360 kA/m.
  • FIG. 12 shows the measurement results at room temperature.
  • the magnetic flux density value at an applied magnetic field of 160 kA/m was 1.52T.
  • the relative magnetic permeability obtained by dividing this magnetic flux density value (1.52 T) by the applied magnetic field value (160 kA/m) and further by the vacuum magnetic permeability (4 ⁇ 10 ⁇ 7 H/m) is 7. .6.
  • FIG. 13 shows a model diagram of a rotating electric machine (motor) used in this simulation.
  • This figure shows a section perpendicular to the motor shaft.
  • the shape and installation position of the magnetic wedge 10 are shown on the right side of FIG.
  • the width of the magnetic wedge (length in the circumferential direction of the rotating electric machine)
  • the dimension corresponding to W1 in FIG. 4 was 3.0 mm
  • W2 was 4.3 mm.
  • the thickness (length in the radial direction of the rotating electrical machine) is 1.5 mm
  • the taper angle of the side surface 25 of the magnetic wedge 10 is 45° with respect to the radial direction of the rotating electrical machine.
  • Electromagnetic field analysis was performed by setting the BH curve in FIG.
  • the end portion of the magnetic wedge 10 can be rounded without machining, and the magnetic wedge 10 can be easily fitted and attached to a rotating electric machine at a low cost. It can be manufactured, and it becomes possible to improve the efficiency of the rotary electric machine.
  • Magnetic wedge 11 Molded body (magnetic wedge) 20: Die 21: Upper punch 22: Lower punch 23: Opening 24: R (R) 25: Side of magnetic wedge 31: Stator 32: Rotor 33: Coil 34: Teeth 35: Secondary conductor 40: Partial model 41: Spring 42: Bake plate 300: Rotating electric machine

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  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
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  • Organic Chemistry (AREA)
  • Dispersion Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Electromagnetism (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Powder Metallurgy (AREA)
PCT/JP2022/037524 2021-10-08 2022-10-06 磁性楔、回転電機及び磁性楔の製造方法 Ceased WO2023058736A1 (ja)

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JP2023518711A JP7405305B2 (ja) 2021-10-08 2022-10-06 磁性楔、回転電機及び磁性楔の製造方法
EP22878603.4A EP4415225A4 (en) 2021-10-08 2022-10-06 MAGNETIC WEDGE, DYNAMOELECTRIC MACHINE AND METHOD FOR MANUFACTURING THE MAGNETIC WEDGE
CN202280060279.5A CN117957745A (zh) 2021-10-08 2022-10-06 磁性楔、旋转电机及磁性楔的制造方法
US18/689,400 US20240413690A1 (en) 2021-10-08 2022-10-06 Magnetic wedge, dynamo-electric machine, and method for manufacturing magnetic wedge

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JPH0327745A (ja) 1989-05-19 1991-02-06 General Electric Co <Ge> 金属充填型ガラ織布からなるスロット封鎖用くさびを含む回転電気機械、並びにその回転電気機械を製造する方法
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JPH0327745A (ja) 1989-05-19 1991-02-06 General Electric Co <Ge> 金属充填型ガラ織布からなるスロット封鎖用くさびを含む回転電気機械、並びにその回転電気機械を製造する方法
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