WO2023276514A1 - Rotor, son procédé de fabrication et moteur électrique - Google Patents

Rotor, son procédé de fabrication et moteur électrique Download PDF

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Publication number
WO2023276514A1
WO2023276514A1 PCT/JP2022/021825 JP2022021825W WO2023276514A1 WO 2023276514 A1 WO2023276514 A1 WO 2023276514A1 JP 2022021825 W JP2022021825 W JP 2022021825W WO 2023276514 A1 WO2023276514 A1 WO 2023276514A1
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WO
WIPO (PCT)
Prior art keywords
rotor
magnet
permanent magnets
magnetically conductive
electric motor
Prior art date
Application number
PCT/JP2022/021825
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English (en)
Japanese (ja)
Inventor
修悟 福田
Original Assignee
パナソニックＩｐマネジメント株式会社
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 パナソニックＩｐマネジメント株式会社 filed Critical パナソニックＩｐマネジメント株式会社
Priority to JP2023531717A priority Critical patent/JPWO2023276514A1/ja
Publication of WO2023276514A1 publication Critical patent/WO2023276514A1/fr

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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
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets

Definitions

  • the present disclosure relates to rotors and electric motors used in various devices including household electrical devices and industrial devices.
  • Electric motors are used in various electrical equipment such as household equipment and industrial equipment.
  • An IPM (Interior Permanent Magnet) motor is known as an electric motor.
  • the rotor of the IPM motor includes, for example, a rotor core, permanent magnets arranged in each of a plurality of magnet arrangement holes provided in the rotor core, and magnets extending through the rotor core.
  • a rotating shaft fixed to the In the IPM motor magnetic flux generated by the permanent magnet of the rotor is passed through the stator to generate torque for rotating the rotor.
  • a predetermined space is sometimes provided between the rotor core and the permanent magnets in order to improve the insertability of the permanent magnets into the magnet placement holes.
  • the permanent magnet when a permanent magnet is inserted into the magnet placement hole, the permanent magnet is magnetically attracted to either the left or right inner surface of the magnet placement hole (left or right in the circumferential direction when viewed from the axial direction).
  • the attraction points of the permanent magnets vary in the circumferential direction, variations in the amount of magnetic flux density of the magnetic poles of the permanent magnets increase, resulting in a problem of increased cogging torque.
  • the present disclosure aims to solve the above problems, and aims to provide a rotor capable of reducing cogging torque, a method for manufacturing the same, and an electric motor.
  • a rotor includes a rotor core having a plurality of magnet placement holes, a plurality of permanent magnets respectively arranged in the plurality of magnet placement holes, and fixed to the rotor core and a rotating shaft.
  • Each of the plurality of permanent magnets is covered with magnetically conductive resin on at least two side faces facing in the direction of rotation.
  • Each of the plurality of permanent magnets is fixed to a corresponding one of the plurality of magnet placement holes by the magnetically conductive resin layer.
  • a method for manufacturing a rotor according to a second aspect of the present disclosure includes forming the magnetism-permeable resin layer on at least two side surfaces of the permanent magnets of the rotor facing in the rotation direction, and then magnetizing the permanent magnets. After that, the permanent magnet having the magnetically conductive resin layer formed on the two side surfaces is inserted into the magnet arrangement hole.
  • An electric motor includes the rotor, and a stator arranged to face the rotor and generating a magnetic force acting on the rotor.
  • FIG. 1 is a perspective view of an electric motor according to an embodiment of the present disclosure
  • FIG. A perspective view of a rotor of the same electric motor.
  • each figure is a schematic diagram and is not necessarily strictly illustrated.
  • symbol is attached
  • FIG. 1 is a perspective view of an electric motor 1 according to an embodiment.
  • the electric motor 1 includes a rotor 2 and a stator 3.
  • Electric motor 1 in the present embodiment is an inner rotor type motor in which rotor 2 is arranged inside stator 3 . That is, the stator 3 is configured to surround the rotor 2 .
  • the rotor 2 (rotor) is rotated by the magnetic force generated in the stator 3.
  • the rotor 2 has a rotating shaft 10 and rotates about an axis C of the rotating shaft 10 as a rotation center.
  • the rotor 2 generates a magnetic force that acts on the stator 3.
  • the rotor 2 has a structure in which a plurality of N poles and S poles, which are main magnetic fluxes, are repeatedly present in the circumferential direction.
  • the direction of the main magnetic flux generated by the rotor 2 is perpendicular to the direction of the axis C of the rotating shaft 10 (rotating shaft direction). That is, the direction of the main magnetic flux generated by the rotor 2 is the radial direction.
  • the rotor 2 is arranged with the stator 3 through an air gap. Specifically, a minute air gap exists between the surface of the rotor 2 and the surface of the stator 3 .
  • the rotor 2 is an embedded permanent magnet rotor (IPM rotor) in which permanent magnets are embedded in an iron core. Therefore, electric motor 1 in the present embodiment is an IPM motor.
  • the stator 3 (stator) is arranged to face the rotor 2 via an air gap, and generates magnetic force acting on the rotor 2 .
  • the stator 3 is arranged so as to surround the rotor core 20 of the rotor 2 .
  • the stator 3 forms a magnetic circuit together with the rotor 2 .
  • the stator 3 is configured so that N poles and S poles are alternately generated in the circumferential direction as the main magnetic flux on the air gap surface.
  • the stator 3 has a stator core 3a (stator core) and winding coils 3b (stator coil).
  • a plurality of teeth 3a1 projecting toward the rotor core 20 of the rotor 2 are provided on the stator core 3a.
  • the plurality of teeth 3 a 1 are provided so as to protrude toward the axis C of the rotating shaft 10 .
  • the plurality of teeth 3a1 are provided at regular intervals in the circumferential direction. Therefore, the multiple teeth 3a1 radially extend in a direction perpendicular to the axis C of the rotating shaft 10 (radial direction).
  • the stator core 3a is composed of a plurality of steel plates laminated in the direction of the axis C of the rotating shaft 10, for example.
  • Each of the plurality of steel plates is, for example, an electromagnetic steel plate punched into a predetermined shape.
  • the stator core 3a is not limited to a laminate of a plurality of steel plates, and may be a bulk body made of a magnetic material.
  • the winding coil 3b is wound around each of the plurality of teeth 3a1 of the stator core 3a. Specifically, the winding coil 3b is wound around each tooth 3a1 via an insulator.
  • Each winding coil 3b is composed of unit coils of three phases, U-phase, V-phase and W-phase, which are electrically 120 degrees out of phase with each other. That is, the winding coil 3b wound around each tooth 3a1 is energized and driven by a three-phase alternating current that is energized in phase units of the U phase, the V phase, and the W phase. Thereby, the main magnetic flux of the stator 3 is generated in each tooth 3a1.
  • the winding coil 3b is made of a metal material such as copper whose surface is coated with an insulating film, and has a circular or rectangular cross section.
  • the electric motor 1 configured in this manner, when the winding coil 3b of the stator 3 is energized, a field current flows through the winding coil 3b to generate a magnetic field. Thereby, a magnetic flux is generated from the stator 3 toward the rotor 2 .
  • the rotor 2 generates a magnetic flux directed toward the stator 3 . That is, the permanent magnets of rotor 2 generate a magnetic flux that passes through stator 3 .
  • the magnetic force generated by the interaction between the magnetic flux generated by the stator 3 and the magnetic flux generated by the rotor 2 becomes torque for rotating the rotor 2 , and the rotor 2 rotates about the rotation axis 10 .
  • FIG. 2 is a perspective view of the rotor 2 according to the embodiment.
  • FIG. 3 is a plan view of main parts of the rotor 2 according to the embodiment. 2 and 3, the rotating shaft 10 is omitted.
  • the rotor 2 includes a rotating shaft 10, a rotor core 20, and a plurality of permanent magnets 30.
  • the rotating shaft 10 is a long shaft that serves as the center when the rotor 2 rotates.
  • the rotating shaft 10 is, for example, a metal rod and fixed to the center of the rotor 2 .
  • the rotating shaft 10 is fixed to the rotor core 20 .
  • rotating shaft 10 is fixed to rotor core 20 while penetrating through the center of rotor core 20 so as to protrude from both sides of rotor 2 .
  • the rotating shaft 10 is fixed to the rotor core 20 by being press-fitted into a through hole 20a formed in the center of the rotor core 20 or by shrink fitting.
  • a first portion of the rotating shaft 10 projecting to one side of the rotor 2 is supported by a first bearing, and a second portion of the rotating shaft 10 projecting to the other side of the rotor 2 is supported by a first bearing. It is supported by two bearings.
  • a load driven by the electric motor 1 is attached to the first portion or the second portion of the rotating shaft 10 .
  • the rotor core 20 (rotor core) is composed of, for example, a plurality of steel plates laminated in the direction of the axis C of the rotating shaft 10 .
  • Each of the plurality of steel plates is, for example, an electromagnetic steel plate punched into a predetermined shape, and fixed to each other by caulking or the like.
  • the rotor core 20 is not limited to a laminate of a plurality of steel plates, and may be a bulk body made of a magnetic material.
  • the rotor core 20 is a core having a plurality of magnet placement holes 21.
  • a plurality of magnet arrangement holes 21 are holes for magnet arrangement in which permanent magnets 30 are arranged.
  • a permanent magnet 30 is inserted into the magnet placement hole 21 .
  • the magnet arrangement hole 21 is a magnet insertion hole into which the permanent magnet 30 is inserted.
  • One permanent magnet 30 is inserted into each magnet placement hole 21 .
  • the rotor 2 is a ten-pole rotor having ten magnetic poles. Therefore, the rotor core 20 is provided with 10 magnet placement holes 21 and 10 permanent magnets 30 . Note that the present invention is not particularly limited to this, and can be applied to other numbers of magnetic poles.
  • the magnet placement hole 21 is a through hole that penetrates the rotor core 20 along the direction of the axis C of the rotating shaft 10 . Therefore, the cross-sectional shape of the magnet arrangement hole 21 is the same in the direction of the axis C of the rotating shaft 10 in any cross section taken along a plane orthogonal to the rotating shaft 10 . In other words, all the steel plates forming the rotor core 20 are formed with the magnet placement holes 21 having the same shape. Note that the magnet arrangement hole 21 may not be a through hole as long as the permanent magnet 30 can be arranged.
  • the plurality of magnet arrangement holes 21 are radially provided around the rotating shaft 10. As shown in FIGS. Also, the plurality of magnet placement holes 21 are provided at regular intervals along the circumferential direction of the rotor core 20 (the rotation direction of the rotating shaft 10). Each of the plurality of magnet arrangement holes 21 extends in the radial direction of the rotor core 20 (the direction orthogonal to the direction of the axis C of the rotating shaft 10) in plan view. That is, the magnet placement holes 21 are elongated in the radial direction of the rotor core 20, and the length in the radial direction is longer than the length in the rotational direction (circumferential direction). The magnet arrangement hole 21 may be elongated in the rotational direction (circumferential direction) of the rotor core 20, and the length in the rotational direction (circumferential direction) may be longer than the radial length.
  • a plurality of elongated magnet placement holes 21 are formed in the shape of spokes around the rotating shaft 10 . That is, the rotor 2 is a spoke-type IPM rotor, and the electric motor 1 is a spoke-type IPM motor.
  • the plan view shape of each magnet placement hole 21 is substantially rectangular with the radial direction of the rotor core 20 as its longitudinal direction.
  • the plan view shape of each of the plurality of magnet placement holes 21 is the same as each other.
  • a permanent magnet 30 is inserted into each of the magnet arrangement holes 21 of the rotor 2 along the direction of the axis C of the rotating shaft 10 , and the permanent magnets 30 are inserted into each of the plurality of magnet arrangement holes 21 . placed.
  • the permanent magnet 30 is inserted from above the axis C of the rotating shaft 10 (above the paper surface), but the permanent magnet 30 may be inserted from below (above the paper surface).
  • the permanent magnet 30 is, for example, a sintered magnet.
  • the plurality of permanent magnets 30 are arranged such that the magnetic pole direction is in the circumferential direction of the rotor core 20 (the rotation direction of the rotating shaft 10). That is, the permanent magnet 30 is magnetized so that the direction of the magnetic poles is the circumferential direction of the rotor core 20 .
  • the two adjacent permanent magnets 30 have opposite magnetic pole directions of the S pole and the N pole.
  • the plan view shape of the permanent magnet 30 is substantially the same as the plan view shape of the magnet arrangement hole 21, and the size is slightly smaller.
  • the permanent magnets 30 are fitted in the magnet placement holes 21 .
  • the planar view shape of the permanent magnet 30 is an elongated substantially rectangular shape.
  • the permanent magnet 30 is a plate-like rectangular parallelepiped having a thickness in a direction perpendicular to the radial direction of the rotor core 20 . Note that the permanent magnet 30 may be divided into a plurality of pieces.
  • each magnet placement hole 21 there is a gap (space, clearance) of a certain size between the outer surface of the permanent magnet 30 and the inner surface of the magnet placement hole 21 .
  • An adhesive may be provided in this gap for adhesively fixing the permanent magnet 30 to the magnet arrangement hole 21 .
  • the adhesive may not be provided in this gap.
  • the permanent magnet 30 is composed of, for example, a Nd--Fe--B based sintered magnet or ferrite sintered magnet. Alternatively, it may be a bonded magnet formed of magnet powder such as Nd--Fe--B magnet powder or ferrite magnet powder, a resin material and a small amount of additives.
  • the permanent magnet 30 is surrounded by a magnetically conductive resin layer 31 made of resin and a magnetically conductive material.
  • the magnetically conductive material is composed of, for example, a ferromagnetic material such as iron or nickel.
  • the resin is, for example, a thermoplastic resin having a melting point of 130° C. or higher, such as polyethylene, polypropylene, or polyamide.
  • the magnetically conductive material is, for example, powdery and dispersed in resin. As shown in FIG. 2, when the permanent magnets 30 are inserted into each of the magnet arrangement holes 21, the permanent magnets 30 are in a state where at least two side surfaces facing in the direction of rotation are covered with the magnetically conductive resin layer 31. .
  • each magnet placement hole 21 is provided with two inner surfaces 21a and 21b facing each other in the circumferential direction (rotating direction of the rotating shaft 10) in plan view.
  • the permanent magnet 30 is arranged so as not to be in direct contact with the two inner surfaces 21a and 21b.
  • the permanent magnet 30 is fixed in the magnet arrangement hole 21 by the magnetically conductive resin layer 31 .
  • the total thickness of the permanent magnets 30 and the magnetism-permeable resin layer 31 is approximately equal to the width of the magnet placement hole 21 or slightly wider than the width of the magnet placement hole 21 . Even if the width of the magnet placement hole 21 is wider than the width of the magnet placement hole 21, the outer magnetism-permeable resin layer 31 has resin and is therefore flexible. A stress acts on the resin layer 31 . As a result, the magnetism-permeable resin layer 31 is pushed in by the inner surfaces 21a and 21b, and after insertion, stress is also applied from the permanent magnet 30 side toward the inner surfaces 21a and 21b of the magnet arrangement hole 21. are reliably held in the magnet placement hole 21 .
  • the magnetic flux density of the permanent magnet 30 is the innermost (outer in the radial direction) than the magnetic flux density of the outermost (outer in the radial direction) portion of the permanent magnet 30 including at least two side surfaces facing in the rotation direction.
  • the magnetic flux density ratio of the portion is 0.7 or more.
  • the periphery of the permanent magnet 30 is coated with a magnetically conductive resin layer 31 made of resin and a magnetically conductive material. After that, the magnetically conductive resin layer 31 is cured.
  • the magnetically conductive resin layers 31 are formed on both surfaces of the permanent magnet 30 at least in the circumferential direction (rotational direction).
  • the permanent magnet 30 is magnetized.
  • the permanent magnet 30 covered with the magnetically conductive resin layer 31 is inserted into the magnet placement hole 21 .
  • the magnetism-permeable resin layer 31 is press-fitted so as to be in contact with the inner surfaces 21 a and 21 b of the magnet arrangement hole 21 . Since the magnetism-permeable resin layer 31 contains resin, it is possible to prevent the inner surfaces 21a and 21b from being damaged.
  • the permanent magnets 30 inserted into the magnet placement holes 21 are securely fixed in the magnet placement holes 21 by the magnetically conductive resin layer 31 .
  • each permanent magnet 30 can be prevented from moving from the arrangement position in the circumferential direction.
  • thermoplastic magnetically conductive resin when brought into contact with the magnetized permanent magnet, the permanent magnet is demagnetized by the heat generated when the resin hardens.
  • the magnetically conductive resin layer 31 is coated and cured on the permanent magnet 30 before magnetization, thermal demagnetization can be avoided.
  • FIG. 5A shows a plan view of the vicinity of the magnet placement hole 21 in the electric motor 1 according to the first modification of the embodiment of the present disclosure.
  • the configuration of the electric motor 1 is the same as that of the electric motor 1 shown in FIG.
  • the permanent magnet 30 is in contact with only one surface of the magnet arrangement hole 21 in the radial direction, and three side surfaces of the permanent magnet 30 including the surface facing the inner surface 21 a and the inner surface 21 b are covered with the magnetically conductive resin layer 31 . shows the configured configuration. Also with this configuration, the permanent magnets 30 inserted into the respective magnet arrangement holes 21 are reliably fixed in the magnet arrangement holes 21 by the magnetically conductive resin layer 31 .
  • FIG. 5B shows a plan view of the vicinity of the magnet placement hole 21 in the electric motor 1 according to the second modification of the embodiment of the present disclosure.
  • the configuration of the electric motor 1 is the same as that of the electric motor 1 shown in FIG.
  • a second modification shows a configuration in which the permanent magnet 30 is not in contact with the magnet placement hole 21 and the four side surfaces of the permanent magnet 30 are covered with the magnetically conductive resin layer 31 . Also with this configuration, the permanent magnets 30 inserted into the respective magnet arrangement holes 21 are reliably fixed in the magnet arrangement holes 21 by the magnetically conductive resin layer 31 .
  • a rotor (2) includes a rotor core (20) having a plurality of magnet placement holes (21), and a plurality of permanent magnets respectively arranged in the plurality of magnet placement holes (21). It comprises a magnet (30) and a rotating shaft (10) fixed to a rotor core (20). Each of the plurality of permanent magnets (30) is covered with a magnetically conductive resin (31) on at least two side surfaces facing in the direction of rotation. Each of the plurality of permanent magnets (30) is fixed to a corresponding one of the plurality of magnet placement holes (20) by a magnetically conductive resin layer (31).
  • a method for manufacturing a rotor (2) according to a second aspect of the present disclosure includes forming a magnetically conductive resin layer (31) on at least two side surfaces of a permanent magnet (30) facing the rotation direction of the rotor (2). After that, the permanent magnet (30) is magnetized, and then the permanent magnet (30) having the magnetically conductive resin layer (31) formed on the two sides is inserted into the magnet arrangement hole (21).
  • An electric motor (1) according to a third aspect of the present disclosure is arranged to face the rotor (2) of the first aspect and the rotor (2), and generates a magnetic force acting on the rotor (2).
  • a stator (3) that allows
  • the rotor and the electric motor according to the present disclosure can be widely used in electric motors and the like used in various devices including household electrical equipment and industrial equipment.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)

Abstract

La présente invention réduit le couple de détente d'un rotor et concerne un moteur électrique équipé de ce rotor. La présente invention comprend un noyau de rotor (20) muni d'une pluralité de trous de placement d'aimant (21), une pluralité d'aimants permanents (30) placés dans la pluralité de trous de placement d'aimant (21), respectivement, et un arbre rotatif (10) fixé au noyau de rotor (20). L'aimant permanent (30) placé à l'intérieur de chaque trou de placement d'aimant de la pluralité de trous de placement d'aimant (21) comporte deux surfaces latérales faisant face au moins au sens de rotation, et les deux surfaces latérales sont recouvertes d'une résine magnétiquement conductrice (31). L'aimant permanent (30) est fixé au trou de placement d'aimant (21) par la couche de résine magnétiquement conductrice (31).
PCT/JP2022/021825 2021-06-30 2022-05-27 Rotor, son procédé de fabrication et moteur électrique WO2023276514A1 (fr)

Priority Applications (1)

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JP2023531717A JPWO2023276514A1 (fr) 2021-06-30 2022-05-27

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2021-108267 2021-06-30
JP2021108267 2021-06-30

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WO2023276514A1 true WO2023276514A1 (fr) 2023-01-05

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2625134A (en) * 2022-12-08 2024-06-12 Jaguar Land Rover Ltd A rotor and a method of manufacture of a rotor

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2007060836A (ja) * 2005-08-25 2007-03-08 Fuji Heavy Ind Ltd 埋め込み磁石型モータのロータ及びその製造方法
JP2011239607A (ja) * 2010-05-12 2011-11-24 Toyota Motor Corp 内磁形ロータおよびその磁石固定方法
WO2013008284A1 (fr) * 2011-07-08 2013-01-17 三菱電機株式会社 Machine électrique tournante de type à aimant permanent et son procédé de fabrication

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2007060836A (ja) * 2005-08-25 2007-03-08 Fuji Heavy Ind Ltd 埋め込み磁石型モータのロータ及びその製造方法
JP2011239607A (ja) * 2010-05-12 2011-11-24 Toyota Motor Corp 内磁形ロータおよびその磁石固定方法
WO2013008284A1 (fr) * 2011-07-08 2013-01-17 三菱電機株式会社 Machine électrique tournante de type à aimant permanent et son procédé de fabrication

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2625134A (en) * 2022-12-08 2024-06-12 Jaguar Land Rover Ltd A rotor and a method of manufacture of a rotor

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