WO2005017318A2

WO2005017318A2 - A rotary machine and a method of manufacturing the same

Info

Publication number: WO2005017318A2
Application number: PCT/US2004/026747
Authority: WO
Inventors: Yukio Kinoshita
Original assignee: INOKI KANJI
Current assignee: INOKI KANJI
Priority date: 2003-08-14
Filing date: 2004-08-16
Publication date: 2005-02-24
Anticipated expiration: 2006-02-14
Also published as: WO2005017318A3

Abstract

A rotating machine has a stator (Figure 3) and a permanent rotor (Figure 6). The stator has magnetic poles (6 and 8) and bobbin winding (10) located between the magnetic poles (6 and 8). The magnetic poles are connected by circular plates (21 and 22). The rotor (Figure 6) has permanent magnets (271, 272 and 274) embedded in a rotor core (206) made of non-magnetic member in order to reduce weight.

Description

SPECIFICATION

TITLE OF THE INVENTION:

A ROTARY MACHINE AND A METHOD OF MANUFACTURING THE SAME

FIELD OF THE INVENTION

[0001 ] The present invention relates to a rotary machine in which multiple DC and AC magnets having bobbin type windings and magnetic pole iron cores are incorporated and a method of manufacturing the same, wherein the manufacturing method intends to expand its application into a wide range of applications including from compact devices to large equipment.

BACKGROUND TECHNOLOGY

[0002] Generally, a stator in a conventional power generator or electronic device has windings wound in a distributed manner to induce electromagnetic coupling therein. These windings are built into slots provided on stacked electromagnetic steel plates for the inserting windings.

[0003] The post winding-embedment process involves connection of the edges of the windings, shaping and fixing the end of the coil, and the like, and these steps are complex, inefficient, and time-consuming. The process diminishes efficiency, output, and reliability for the following reasons: scratches or similar damage that will break off the insulation thereof during operation; entanglement or interference between the windings within narrow slots; a reduction in the slot space factor below about 50% which is the level normally required for easy wire assembly; an increase in manufacturing cost due to the excessive extension of the end of the coil; an increase in resistance loss in the end of the coil; an increase in magnetic flux loss; and similar disadvantages. [0004] In addition, the process is difficult to automate and requires a large capital investment in facilities if it is to be automated. Further, a low voltage-type device or a middle- or large-sized device requires windings of a larger diameter, which further aggravates manageability, resulting in greatly increasing costs of manufacturing.

[0005] To change the number of poles in the conventional configuration, the number of turns are adjusted. Normally, the number of poles is limited to eight (8) unless the outer diameter of the iron core is increased.

[0006] In a magnet type electronic motor or power generator, output, actuation torque, and efficiency enhancement are modified mainly by adjusting the number of turns and the intensities of stationary magnets in a rotor. Generally, iron cores have an integral body of laminated layers and there is no split type iron core that is available on the market.

[0007] In an electronic device having the conventional iron core winding structure used in an ultra-high temperature environment, the temperature is controlled so as only to rise up to 250 °C, which is the sum of the surrounding temperature and the temperature risen by coils.

[0008] A conventional rotary machine having a purely iron core winding configuration has a very low efficiency, particularly at low speed and low output. Generally, the efficiency of a magnet-type rotating device under the same conditions is only 20-30%.

[0009] The Japanese Patent Publication No. 2000-324768 tried to address the above problems. This prior patent document discloses a magnetic pole configuration in which a generator or motor is constructed for example with bobbin type magnets, and the rotor is constructed for example with magnets, electromagnets, or a combination of both types wherein the poles on the stator facing the gap from the rotor are given a rectangular shape to deviate linearly or skew along the circumference. Hence, at least one of either the rotor or stator takes advantage of the skewing or similar effect in this pole configuration.

DISCLOSURE OF THE INVENTION

[0010] The present invention intends to solve at least one of the following problems of simplifying the configuration of the rotary machine and achievement of multiple functionalities therein in terms of the windings and the iron core configuration of a stator or rotor in an AC power generator, motor or the like, and the constitution or similar construction thereof. The present invention further solves the problems of simplifying the configuration, constitution, and material of iron cores and the winding configuration to achieve multiple functionalities therein. The present invention intends to solve another technical problem, which is to provide a rotary machine with the above simplifications that can accommodate production on a small scale or large scale with the capability to produce various models. Another object of the present invention is to commercialize a broad range of rotary machine from large size to small size.

[0011] Simplification of the winding configuration for a stator or rotor involves simplifying the configuration-, constitution, material and winding configuration of the iron cores. For example, there is a concentrated winding configuration such as bobbin type that forms a magnetic field about the magnetic pole iron core components. In this configuration, a magnetic field loses little current and attention can be focused on the workability of the iron cores. Additionally, the material used for the iron cores is a sintered material or a laminated configuration made from electromagnetic steel plates. The present invention is a method of assembly or manufacturing of a rotating electronic device haying the configuration described above that concretely surely realizes the objectives.

[0012] An example of the invention is a rotary machine comprising a stator constructed with multiple DC or AC electromagnets that have bobbin type windings and magnetic pole iron cores. The stator comprises: magnetic pole iron cores, which are electromagnetically coupled through the windings; a magnetic path-forming iron core or secondary yoke component; a magnetic pole iron core pressing plate; winding bodies; and a partition plate for partitioning each phase. The magnetic pole iron cores to be electromagnetically coupled are laminated to give a parenthesis ("]" ) shape. The pole components of the magnetic pole iron cores facing the rotor have a parallelogram shape. At a minimum, a magnetic path-forming iron core A or secondary yoke component A is provided on the first facing plane of a first parenthesis shape of the magnetic path component or yoke component for forming a magnetic path for the magnetic pole iron core, and a magnetic path-forming iron core B or secondary yoke component B provided on the rear plane of a second parenthesis shape ("]" ) , that provides a magnetic path-pole configuration. [0013] Another example of the invention provides an improvement in the above described rotary machine wherein the magnetic path-forming iron cores A and B (secondary yoke component B) are secured on the outer circumference of the parenthesis ("]" )-shaped magnetic path component or yoke component of the magnetic pole iron core, which are common components to each phase-block; and , a magnetic path-forming iron core C is formed on the outer circumference of the parenthesis ("]" )-shaped magnetic path, thereby reducing the length of the magnetic path-pole configuration in the axial and circumferential directions.

[0014] Another example of the invention provides an improvement in the above described rotary machine which further comprises a cylindrical ring for adjusting the intensity of the magnetic field generated provided on the inner circumference in contact with the parenthesis ("]" )-shaped magnetic path component or yoke component; wherein the cylindrical ring is made of a sintered iron material or a laminated member of electromagnetic steel plates whose axial length is greater than that of the parenthesis-shaped pole of the magnetic path component or yoke component so as to generate a smooth magnetic field, thus to eliminate cogging and improve the properties thereof.

[0015] Still another example of the invention provides an improvement in the above described rotary machine which further comprises a cylindrical ring for adjusting the intensity of a magnetic field generated about the inner circumference of the parenthesis ("]" )-shaped magnetic path component or yoke component of the iron core via a cylindrical non-magnetic member; wherein the cylindrical ring is made of a sintered iron material or a laminated member of electromagnetic steel plates whose axial length is longer than that of the parenthesis ("]" )-shaped pole of the magnetic path component or yoke component so as to generate a smooth magnetic field, thus to eliminate cogging and improve the properties thereof.

[0016] Still another example of the invention provides an improvement in the above described rotary machine which further comprises a cylindrical ring for adjusting the intensity of a magnetic field generated about a part or the entire vertical length of the outer circumference of the rotor; wherein the cylindrical ring is made of a sintered iron material or a laminated member of electromagnetic steel plates so as to generate a smooth magnetic field, thus to eliminate cogging improve the properties thereof.

[0017] Still another example of the invention provides an improvement in the above described rotary machine which further comprises a cylindrical ring for adjusting the intensity of a magnetic field generated about a part or the entire vertical length of the outer circumference of the rotor via a non-magnetic member; wherein the cylindrical ring being made of a sintered iron material or a laminated member of electromagnetic steel plates so as to generate a smooth magnetic field, thus to eliminate cogging and improve the properties thereof.

[0018] Still another example of the invention combines two of the above described improvements , thus to eliminate cogging and improve the properties thereof.

[0019] Another example of the invention involves a rotary machine which further comprises a pin on a part of the parenthesis ("]" )-shaped magnetic path component or yoke component of the magnetic pole iron core to be electromagnetically coupled and multiple groove holes for confining the magnetic pole iron core into the support frame utilizing the pin, thereby providing a magnetic path-pole configuration.

[0020] Still another example of the invention involves a rotary machine wherein the magnetic pole iron cores to be electromagnetically coupled are laminated to give a parenthesis shape; the pole component of the magnetic pole iron cores facing the rotor are shaped in a parallelogram; the rotating electronic device further comprises a support frame for holding the shape of the pole component or pole piece component securely before assembling the magnetic pole iron cores, thereby providing a magnetic path-pole configuration.

[0021] Still another example of the invention involves a rotary machine which further comprises a lead line groove on the magnetic path-forming iron core or secondary yoke component and the partition plate, thereby taking the lead line from the winding bodies to be electromagnetically coupled to the outside.

[0022] Still another example of the invention involves a rotary machine which further comprises a lead guide so as to insert the lead line from the winding bodies to be electromagnetically coupled to the magnetic pole iron cores of each phase.

[0023] Still another example of the invention involves a rotary machine using magnets wherein the iron used to construct the iron core component for holding permanent magnets on the rotor is replaced with a non-magnetic member, thereby preventing magnetic flux loss between magnets and making the invention applicable to devices of a large capacity.

[0024] Still another example of the invention involves an improvement in a rotary machine using magnets wherein the iron constructing the iron core component for holding permanent magnets on the rotor is replaced with a member made of non-magnetic material which is lighter than iron, thereby preventing magnetic flux loss between magnets, making the invention applicable to devices of a large capacity, and attaining a light weight rotor.

[0025] Still another example of the invention involves an improvement in a rotary machine wherein the iron core component for holding permanent magnets on the rotor is replaced with a conductive non-magnetic member, thereby preventing magnetic flux loss between magnets, making the invention applicable to devices of a large capacity, and achieving a self starting during an induced start-up.

[0026] Still another example of the invention involves a rotary machine as described above wherein the magnetic path component or yoke component of the magnetic pole iron core to be electromagnetically coupled and magnetic path-forming iron core C are constructed with laminated layers of Si steel plates and non-magnetic members having insulating properties, thereby providing a magnetic path-pole configuration that allows adjustment of intensities of the magnetic fields, prevents eddy currents despite a high-frequency magnetic field being generated, and attains a high spinning speed with high performance and high efficiency.

[0027] As another example, the invention provides a method of manufacturing a rotary machine, comprising the steps of putting multiple DC or AC electromagnets constructed with windings wound around bobbins and magnetic pole iron cores together to give a stator. The stator comprises magnetic pole iron cores, which are electromagnetically coupled through the windings; magnetic path-forming iron cores or secondary yoke components; magnetic pole iron core pressing plates; winding bodies; and partition plates for partitioning each phase.

[0028] The first pole block having magnetic pole iron cores to be electromagnetically coupled is laminated to give a parenthesis shape, and the pole component (pole piece component) of the magnetic pole iron cores that faces the rotor is shaped in a parallelogram.

[0029] A magnetic path-forming iron core B or secondary yoke component B, which is the block common to each phase, and iron magnetic path-forming iron core A or secondary yoke component A, which are provided to each second pole block independently, are together assembled in such a manner that said secondary yoke component B is held by the rear plane of the parenthesis-shaped magnetic path component (yoke component) of the pole irons on a partition plate that utilizes a magnetic pole iron core pressing plate.

[0030] After the winding bodies are inserted inside the parenthesis shape, as the block having the second pole, the magnetic path-forming iron core A or secondary yoke component A is assembled such that each first and second block faces the other, forming a square layout in a similar manner.

[0031] The constitution in which each phase is given a building block provides the magnetic path-pole configuration. As a result, the magnetic force that is electromagnetically coupled is reliably enhanced. The productivity in the machinability and assembly, and the like, is also enhanced.

[0032] As discussed previously, another example of the invention involves the rotary machine described above in which the first pole block has magnetic pole iron cores to be electromagnetically coupled that are laminated in a parenthesis ("]" ) shape, and the pole component (pole piece component) of the magnetic pole iron cores facing the rotor are shaped in a parallelogram.

[0033] Apin is provided, for example, on a part of the rear plane of the parenthesis-shaped magnetic path component (yoke component) of the magnetic pole iron core, and multiple groove holes are provided on the support frame, which is the block common to each phase such that the pin-guided magnetic pole iron cores are fitted therein. Then, a partition plate for isolating the blocks having the opposite polarity is assembled utilizing the magnetic pole iron core pressing plate.

[0034] After winding bodies are inserted inside the parenthesis-shaped magnetic pole iron core, the block having the second pole, which is the facing plane of the parenthesis-shaped magnetic path component (yoke component) is assembled on the magnetic pole iron core in such a manner that each of the magnetic path-forming iron cores A (secondary yoke components A) face each other so as to form a closed square shaped layout.

[0035] To completely eliminate cogging while enhancing the magnetic fields generated in the gap between the stator and rotor, specifically defined by the parenthesis shape of magnetic path component (yoke component) on the magnetic pole iron core in the rotating device described above, a cylindrical ring made of iron is provided on the inner plane of the stator or on the outer plane of the rotor wherein this ring is made of a sintered iron material, Si steel plate or the like. The performance and reliability are enhanced while increasing productivity in the machinability and assembly. The cylindrical ring may be provided with a skewed groove or a groove capable of spreading the magnetic fields of each phase smoothly if required.

[0036] Additionally, to prevent shorting between poles, a cylindrical ring made of iron may be provided on the inner plane of the stator or on the outer plane of the rotor via a non-magnetic member, instead of being provided directly on the ring.

[0037] Stators may be assembled in a square shape and may be arranged on the outer circumferential portion of the parenthesis shape of the magnetic path component (yoke component) of the magnetic iron cores such that the stator in each of the blocks faces the other, thereby providing the shortest magnetic path.

[0038] The configuration described above eases alignment and assembly and prevents loosening of the assembly, and provides a building block for each phase which functions as the magnetic path-pole configuration. As a result, the magnetic force which electromagnetically couples the magnetic pole iron cores and the magnetic path forming iron cores (secondary yoke components) is enhanced, thereby enhancing the performance and reliability thereof. Additionally, productivity in terms of machinability and manageability in assembly or the like is increased.

[0039] In some of the above examples of the invention, a cylindrical ring may be provided on the inner plane of the stator or on the outer plane of the rotor wherein the ring is made of a sintered iron material, Si steel plate or the like, to completely eliminate cogging while enhancing the magnetic fields generated in the gap between the stator and rotor, specifically defined by the parenthesis shape of magnetic path component (yoke component) of the magnetic pole iron cores in the rotating device described above. The performance and reliability are enhanced while increasing productivity in the machinability and assembly. The cylindrical ring may be provided with a skewed groove or a groove capable of spreading of the magnetic fields from each phase smoothly if required.

[0040] Additionally, to prevent shorting between poles, a cylindrical ring made of iron may be provided on the inner plane of the stator or on the outer plane of the rotor via a non-magnetic member, instead of being provided directly on the ring.

[0041] One of the above examples of the invention involves the rotary machine described above that has a pole piece configuration as the first pole block in which the magnetic pole iron cores to be electromagnetically coupled are laminated to give a parenthesis shape and the pole component (pole piece component) of the magnetic pole iron cores facing the rotor is provided to give an approximate parallelogram shape.

[0042] Apin is provided, for example, on a part of the rear plane of the parenthesis-shaped magnetic path component (yoke component) of the magnetic pole iron core and; multiple groove holes are provided on the magnetic path-forming iron core B (secondary yoke component B), which is the common block to each phase such that the pin-guided magnetic pole iron cores are fitted thereto. Then, the magnetic path-forming iron core A (secondary yoke component A), which is provided to the second pole block independently is assembled on the partition plate utilizing the magnetic pole iron core pressing plate.

[0043] After winding bodies are inserted into the parenthesis ("]" )-shaped magnetic pole iron core, the block having the second pole, which is the facing plane of the parenthesis-shaped magnetic path component (yoke component), is assembled on the magnetic pole iron core in such a manner that each of the magnetic path-forming iron cores A (secondary yoke components A) faces the other so as to form a closed square shaped layout.

[0044] The above configuration provides the building blocks of each of the phases with a magnetic path-pole configuration that ensures accuracy, performance, and reliability in the electromagnetic coupling of the magnetic pole iron cores and magnetic path forming iron cores (secondary yoke components). The productivity thereof in terms of machinability, assembling and the like can thus be enhanced.

[0045] One of the above examples of the invention involves the rotary machine described above in which the first pole block having magnetic pole iron cores to be electromagnetically coupled is laminated to give a parenthesis shape, and the pole component (pole piece component) of the magnetic pole iron cores facing the rotor have a parallelogram shape.

[0046] A magnetic path forming iron core B or secondary yoke component B, which is the block common to each phase, is assembled in such a manner that the secondary yoke component B is held by the rear plane of the parenthesis-shaped magnetic path component (yoke component) of the pole irons. Then, the magnetic path-forming iron core A or secondary yoke component A, which is provided to each second pole block independently, is built together on a partition plate utilizing the magnetic pole iron core pressing plate.

[0047] After the winding bodies are inserted inside the parenthesis shape as the block having the second pole, the magnetic path- forming iron core A or secondary yoke component A is assembled such that each first and second block faces the other forming a square layout in a similar manner.

[0048] The constitution in which each phase is given a building block provides the magnetic path-pole configuration. As a result, the magnetic forces that are electromagnetically coupled through magnetic cores are reliably enhanced and productivity in machinability and assembly and the like is enhanced.

[0049] The above described examples of the invention provide the following effects. In a stator constructed with multiple DC or AC magnets having bobbin type windings and magnetic pole iron cores, the stator is constructed with module blocks of a simple configuration, which ensures formation of the magnetic path-pole configuration and enhances intensity of the magnetic force. Accordingly, the performance is stabilized, reliability thereof is improved, and productivity is increased, taking advantage of the building block configuration which is easy to assemble.

[0050] The simple configuration of the building blocks eases assembly operation, which is an advantageous characteristic in that automation can be accomplished with only a small scale investment in facilities.

[0051] Since windings take advantage of the concentrated winding and a magnetic pole iron core is provided to each phase independently in the form of a building block, it is easy to adjust the output, capacity, and actuation torque, and it is easy to enhance efficiency.

[0052] Moreover, the use of a sintered material or of the laminated configuration for the pole components and magnetic path components also help to improve performance and productivity in the rotary machine. Furthermore, the use of an independent pole component can permit small scale production of iron cores of various types. It also permits production of split-cores that can be applied to production of iron cores of both small and large capacities. The use of an independent pole component further allows the number of poles to be changed freely.

[0053] In addition to having a low voltage, the diameter of the windings used in the middle- or large-sized device is relatively small, which provides better manageability and achieves a reduction in manufacturing cost.

[0054] Further, the number of poles can be adjusted easily and the winding structure is simple and easy to rewind. More than eight (8) poles can be obtained without increasing the outer diameter of iron cores significantly.

[0055] Some of the above examples of the invention provide a rotary machine comprising a stator constructed with multiple DC or AC electromagnets having bobbin type windings and magnetic pole iron cores. The stator comprises: magnetic pole iron cores, which are electromagnetically coupled through the windings; a magnetic path-forming iron core (secondary yoke component); magnetic pole iron core pressing plates; winding bodies; and a partition plate for partitioning each phase. ^• The first pole block having the magnetic pole iron cores to be electromagnetically coupled is laminated to give a parenthesis shape and the pole component (pole piece component) of the magnetic pole iron cores facing the rotor is shaped in a parallelogram.

[0056] The magnetic path-forming iron cores (secondary yokes) and the partition plates are provided with a lead line groove to accommodate the lead line derived from windings for the use in electromagnetic coupling of each phases, and the rotor is built into a casing of the rotating electronic device.

[0057] The above configuration requires only a short wire for the windings that electromagnetically couple the magnetic pole iron cores and a small space. The end of the coil thereof does not limit the reduction of the wire length during production of the rotating electronic device. Accordingly, the rotating electronic device exhibits good performance, increased productivity through a reduction in size, and enhancement in machinability and manageability during assembly, and the like.

[0058] In one of the above examples of the invention, a lead guide is provided to a building block such that the lead line for electromagnetic coupling of each phase is inserted thereto. The presence of a lead guide ensures the above effects and further enhances mechanical stress protection, insulation, high temperature resistance and productivity in the assembly operation or similar improvements.

[0059] In other words, the post-embedment process steps after embedding of the windings in this invention do not include connection of the edges of the windings; shaping and fixing of the end-coils, and the like, which are complicated, inefficient, and time consuming. Therefore, the present invention is free from deteriorating reliability due to insulation breakage arising from scratches generated during handling, entanglement and interference between the windings in narrow slots, losing the slot space factor required for easy wire assembly, increasing manufacturing cost due to extension of the end of the coil, deterioration in resistance loss at the end of the coil, aggravation of magnetic flux loss, and deterioration in efficiency or output. [0060] The rotary machine having the configuration of the present invention can be used under ultra-high temperatures and can operate at 250 °C or higher, which is the sum of the surrounding temperature and the temperature rise in the coil.

[0061] One of the above examples of the invention involves a rotary machine utilizing magnets wherein the iron core component holding the permanent magnets of the rotor is replaced with a non-magnetic member which is lighter than iron, thereby preventing magnetic flux loss between magnets and allowing the invention to be used for devices having a large capacity.

[0062] Another one of the above examples of the invention involves a rotary machine utilizing magnets wherein the iron core component holding permanent magnets of the rotor is replaced with a non-magnetic member which is lighter than iron, thereby preventing magnetic flux loss between magnets and allowing the invention to be used for devices of a large capacity, and reducing the weight of the rotors, shafts, and the amount of wear on the bearings.

[0063] One of the above examples of the invention involves replacement of the iron core component holding permanent magnets of the rotor with a non-magnetic member which is lighter than iron, thereby preventing magnetic flux loss between magnets and reducing the weight of the rotors and providing a self-start capability during an induced start.

[0064] Still another one of the above examples of the invention involves the rotary machine wherein the magnetic path component (yoke component) of the magnetic pole iron cores to be electromagnetically coupled and the magnetic path-forming iron core C are constructed with laminated layers of Si steel plates and non-magnetic members having an insulating property. This configuration allows adjustment of intensities of the magnetic fields, and prevents eddy currents despite a high-frequency magnetic field being generated. It also achieves a high spinning speed with high performance and high efficiency.

BRIEF DESCRIPTION OF THE DRAWINGS

[0065] The foregoing and other objects, advantages, effects and aspects of the invention will be better understood from the following detailed description of the invention with reference to the drawings in which:

[0066] Figure 1 is a rotating electronic device of an embodiment of the present invention.

[0067] Figure 2 is a block diagram of a stator of an embodiment of the present invention.

[0068] Figure 3 is another block diagram of a stator of an embodiment of the present invention.

[0069] Figure 4 is a diagram illustrating a rotor assembly of an embodiment of the present invention.

[0070] Figure 5 is a diagram illustrating a gap-magnetic field tuning ring assembly of an embodiment of the present invention.

[0071] Figure 6 is a cross sectional view of a rotating device utilizing non-magnetic bodies in place of iron cores of a rotor of an embodiment of the present invention.

[0072] Figure 7 is a diagram illustrating a gap-magnetic field tuning ring assembly in which magnetic poles and magnetic shorting ring are made of Si steel plates and non-magnetic member plates.

REFERENCE SYMBOLS IN THE DRAWINGS

1 : rotary machine

2, 202: stators

21: stator block A

22: stator block B

3, 203: rotors

40: rotor iron core

5, 205: casings

6, 206: magnetic pole iron cores

61 : pole component (pole piece component)

62: magnetic path component (yoke component) 76: stacked iron core yoke component

77: divided stacked iron core yoke component

78: wound iron core yoke component

63: pin

7, 80: magnetic path-forming iron cores (secondary yoke components)

71 : magnetic path-forming iron core (secondary yoke component A)

72: magnetic path-forming iron core (secondary yoke component B)

73, 73': groove holes

74, 740 notches

90, 91 : insulating non-magnetic members

8: support frame

9: magnetic pole iron core pressing plate

10, 204: winding bodies

101: lead line

102: lead guide

11: partition plate

111: notch

12: screw A

13: screw B

30: gap

31 : non-magnetic member (gap portion)

33, 220, 221 : non-magnetic members (rotor iron core component)

4, 212: shafts

271, 272, 274: magnets

DETAILED DESCRIPTION OF EMBODIMENTS

[0073] More specifically, as illustrated in Figure 1, the rotating electronic device 1 comprises: a stator 2, which is constructed with multiple DC or AC electromagnets and bobbin type windings ; a rotor 3 which is a combination of multiple magnets; a rotating shaft 4; and a casing 5 and the like, which is the basic configuration

[0074] Figures 2 and 3 illustrate embodiments of the present invention. The stator 2, in which multiple DC or AC electromagnets constructed with the bobbin type windings are put together, comprises: a magnetic pole iron core 6 which is electromagnetically coupled via windings; a magnetic path-forming iron core (secondary yoke component) 7; a supporting frame 8; a magnetic pole iron core pressing plate 6; winding bodies 10; and a partitioning plate 11. The magnetic pole iron core 6 and magnetic path-forming iron core (secondary yoke component) 7 are constructed of a sintered iron type material or stacked layers of electromagnetic steel plates or the like.

[0075] The magnetic pole iron core 6 is constructed with a pole component (pole piece component) 61 and magnetic path component (yoke component) 62 in a "parenthesis ("]" ) shape." The magnetic pole iron core 6 is further constructed with a magnetic path-forming iron core A (secondary yoke component A) 71 and a magnetic path-forming iron core B (secondary yoke component B) 72 which are positioned on the rear plane of the parenthesis shape.

[0076] The order of the assembly of the above configuration begins with the step of building the first poles (4 poles in the example of Figure 2), which are constructed by placing a magnetic path-forming iron core B (secondary yoke component B) 72 on partition plate 11 in such a manner that the secondary yoke component B is positioned on the rear plane of the "parenthesis shape" of the pole component (yoke component) 62 of the magnetic pole iron core 6.

[0077] Next, the magnetic iron cores 6 to be electromagnetically coupled are laminated to give a parenthesis shape, and pole components (pole piece components) 61 having three same poles and magnetic path component 62 are arranged in such a manner that pole components (pole piece components) 61 of magnetic iron cores 6 give an approximate parallelogram shape. Supporting frame 8 may be used to hold the shape of magnetic pole iron core 6 if required. The use of supporting frame 8 helps an operator assemble magnetic pole iron core 6 easily and prevents iron core 6 from deformation after assembly.

[0078] In the vicinity of magnetic pole iron core 6, magnetic path-forming iron cores A (secondary yoke components A) 71, which are provided to each of the second pole blocks independently, are assembled simultaneously with core pressing plate 8 via screw Al 2 to give block 21. [0079] It is noteworthy that in this case, if the magnetic path components (yoke components) 62 of magnetic pole iron core 6 are provided with a pin 63, for example, as illustrated in Figure 3, the magnetic pole iron cores 6 can be aligned and assembled more easily and the resulting assembly will not loosen.

[0080] Next, after winding bodies 10 are inserted inside the parenthesis-shaped magnetic pole iron core 6, the second pole block B22 having the opposite polarity is assembled in the same manner as first pole block A 21 as shown in Figures 3 and 4.

[0081 ] Furthermore, the facing plane of the parenthesis-shaped magnetic path component (yoke component) 62 of the magnetic pole iron core 6 in first pole block A21 and the magnetic path-forming iron core A (secondary yoke component A) 71 in the second pole block B22 are arranged to face each other, thereby forming an integral body of a closed magnetic path having a closed square shape.

[0082] Moreover, as illustrated in Figure 4, in order to generate a rotating magnetic field that corresponds to 1200 the 3-phase sine wave in the case of three phases, for example, AC electromagnets constructed with bobbin type winding bodies 10 and magnetic pole iron cores 6 are assembled using screws B13 to build a stator 2 such that each pole has three pieces of poles or pole piece components 61; an integral body of blocks A and B prepared for each phase has 2 pole pairs, and the integral body of blocks A and B is displaced by 30° for each of the three phases.

[0083] In Figure 4, the lead line 101 from winding bodies 10 is connected to external terminals via magnetic path-forming iron cores (secondary yoke components) 7, notches 74, and notches 111 on partition plates 11 in each phase. Note that lead guide 102 for securing, protecting, and holding the lead line 101 is provided between winding bodies 10 and casing 5. The lead line 101 is protected from mechanical stress, insulation breakage, and heat.

[0084] Figure 5 illustrates the rotating electronic device described above. To completely eliminate cogging while enhancing the magnetic field generated in the gap between the stator and rotor, wherein the gap is specifically defined by the parenthesis shape of magnetic path component (yoke component) 76 on the magnetic pole iron core in the rotating device described above, a cylindrical ring 80 made of iron may be provided on the inner plane of the stator 2 or on the outer plane of the rotor 3. The ring 80 is made of a sintered iron material, Si steel plate or the like. The performance and reliability thereof are enhanced while improving productivity in machinability and assembly. The cylindrical ring may be provided with a skewed groove or a groove capable of smoothly spreading the magnetic fields of each phase if required. The connection ring provided on the outer circumference of the magnetic path component of the magnetic pole iron core is made of Si steel plate, a sintered iron material and a coil-like iron winding 78.

[0085] Additionally, to prevent shorting between poles, a cylindrical ring made of iron may be provided on the inner plane of the stator or on the outer plane of the rotor via a non-magnetic member, instead of being provided directly on the ring.

[0086] The above configuration provides a magnetic path-pole configuration in the form of building blocks for each of the phases. As a result, the magnetic force generated at the magnetic pole iron core to be electromagnetically coupled is reliably enhanced, and the performance and reliability thereof is improved while increasing productivity in terms of machinability, assembly and the like.

[0087] The configuration also finds application not only in the small-sized but also in the middle-sized to large-sized rotating devices.

[0088] Figure 6 shows a power generator in which new slots are provided on the outer circumference portion of magnets 271, which is inserted into radial slots of rotating iron cores 206 of rotor 203 of the present invention, and the magnets 274 are inserted such that magnetic fields are generated in a radial direction. In this way, repelling or attracting forces are always generated between stator poles and magnets 274 as long as the rotor spins at a synchronized speed. The output and efficiency thereof are thus increased.

[0089] Additionally, the power generator may have another configuration in which the rotor iron core 206 of rotor 203 of the present invention is constructed with a non-magnetic member 220 or conductive non-magnetic member 221, thereby providing an increased output, efficiency and induced actuation capability. [0090] Figure 7 shows the power generator of Figure 5 in which the pole piece 6 and magnetic path components (yoke components) 76 are put together with sheets 90 and 91, which are insulating non-magnetic members, to provide magnetic poles and a magnetic path component (yoke component). This configuration allows the power generator to tune [the intensity of] the magnetic fields, prevents eddy currents when high-frequency magnetic fields are generated, and achieves a high spinning speed with high performance and high efficiency.

[0091] Examples of applications of the present invention include general industrial devices, home electronic appliances, devices for automobiles or vehicles, medical devices, electronic devices using wind, water and fire, and the like. Accordingly, the present invention finds a wide range of applications.

[0092] Changes may be made in the embodiments of the invention described herein, or in parts or elements of the embodiments described herein, or in the sequence of steps of the methods described herein, without departing from the spirit and/or scope of the invention as defined in the following claims.

Claims

WHAT IS CLAIMED IS:

1. A rotary machine comprising: a stator constructed with multiple DC or AC electromagnets having bobbin type windings and magnetic pole iron cores; wherein said stator comprises: - magnetic pole iron cores, which are electromagnetically coupled through said windings; - magnetic path-forming iron cores or secondary yoke components; - magnetic pole iron core pressing plates; - winding bodies; and - partition plates for partitioning each phase; wherein said magnetic pole iron cores to be electromagnetically coupled are laminated to give a parenthesis shape; the pole components of said magnetic pole iron cores facing said rotor are in a parallelogram shape; at a minimum, a magnetic path-forming iron core A or secondary yoke component A is provided on the first facing plane of a first parenthesis shape of said magnetic path component, or yoke component for forming a magnetic path for said magnetic pole iron core, and a magnetic path-forming iron core B or secondary yoke component B is provided on the rear plane of a second parenthesis shape,, thereby providing a magnetic path-pole configuration thereof.

2. The rotary machine as defined in Claim 1, which further comprises a magnetic path-forming iron core C on the outer circumference of said parenthesis-shaped magnetic path component or yoke component of said magnetic pole iron core: wherein the magnetic path-forming iron core C are common components to said magnetic path-forming iron cores A and B or secondary yoke component B, , thereby reducing the length of said magnetic path-pole configuration thereof in the axial and circumferential directions.

3. The rotary machine as defined in Claim 1, further comprising a cylindrical ring for adjusting the intensity of a magnetic field generated therein provided on the inner circumference of said parenthesis-shaped magnetic path component or yoke component of said iron core in a contacting manner; said cylindrical ring being made of a sintered iron material or a laminated member of electromagnetic steel plates whose axial length is longer than that of said parenthesis-shaped pole of said magnetic path component or yoke component, so as to generate a smooth magnetic field, thereby eliminating any cogging thereof and improving the properties thereof.

4. The rotary machine as defined in Claim 1, further comprising a cylindrical ring for adjusting the intensity of a magnetic field generated therein provided on the inner circumference of said parenthesis-shaped magnetic path component or yoke component of said iron core via a cylindrical non-magnetic member; said cylindrical ring being made of a sintered iron material or a laminated member of electromagnetic steel plates whose axial length is longer than that of said parenthesis-shaped pole of said magnetic path component or yoke component, so as to generate a smooth magnetic field, thereby eliminating any cogging thereof and improving properties thereof.

5. The rotary machine as defined in Claim 1, further comprising a cylindrical ring for adjusting the intensity of a magnetic field generated therein provided on a part or the entire vertical length of the outer circumference of said rotor; said cylindrical ring being made of a sintered iron material or a laminated member of electromagnetic steel plates so as to generate a smooth magnetic field, thereby eliminating any cogging thereof and improving properties thereof.

6. The rotary machine as defined in Claim 1, further comprising: a cylindrical ring for adjusting the intensity of a magnetic field generated therein on a part or the entire vertical length of the outer circumference of said rotor via a non-magnetic member; said cylindrical ring being made of a sintered iron material or a laminated member of electromagnetic steel plates so as to generate a smooth magnetic field, thereby eliminating any cogging thereof and improving properties thereof.

7. The rotary machine comprising combination of the subject matters as defined in Claims 4 and 5 thereby eliminating any cogging thereof and improving properties thereof.

8. The rotary machine as cited in Claim 1, further comprising: a pin on a part of said parenthesis-shaped magnetic path component or yoke component of said magnetic pole iron core to be electromagnetically coupled; and multiple groove holes for confining said magnetic pole iron core into the support frame utilizing the pin, thereby providing a magnetic path-pole configuration.

9. The rotary machine as defined in any one of Claims 1, 2 and 8, wherein said magnetic pole iron cores to be electromagnetically coupled are laminated to give a parenthesis shape; pole component or pole piece component of said magnetic pole iron core facing said rotor are shaped in a parallelogram; said rotating electronic device further comprises a support frame for holding the shape of said pole component or pole piece component securely before assembling said magnetic pole iron cores, thereby providing a magnetic path-pole configuration.

10. The rotary machine as defined in Claim 9, further comprising a lead line groove on said magnetic path-forming iron core or secondary yoke component and said partition plate, thereby taking the lead line from winding bodies for electromagnetic coupling to the outside.

11. The rotary machine as defined in Claim 10, further comprising a lead guide so as to insert said lead line from said winding bodies therein for electromagnetic coupling of said magnetic pole iron cores of each phase.

12. A rotary machine utilizing permanent magnets wherein an iron for constructing an iron core component for holding the permanent magnets on a rotor is replaced with a non-magnetic member, thereby preventing magnetic flux loss between magnets and making said invention applicable to devices of a large capacity.

13. The rotary machine utilizing magnets utilizing permanent magnets wherein an iron core component for holding the permanent magnets on a rotor is replaced with a member made of non-magnetic material which is lighter than iron, thereby preventing magnetic flux loss between magnets, making said invention applicable to devices of a large capacity and attaining a light weight rotor.

14. The rotary machine as defined in any one of Claims 9 and 10, wherein said iron core component for holding permanent magnets on said rotor is replaced with a conductive non-magnetic member, thereby preventing magnetic flux loss between magnets, making said invention applicable to devices of a large capacity, and achieving a self starting property whenever said devices are induced.

15. The rotary machine as defined in Claim 2, wherein said magnetic path component or yoke component of said magnetic pole iron core to be electromagnetically coupled and magnetic path-forming iron core C are constructed with laminated layers of an Si steel plate and a non-magnetic member having insulating properties, thereby allowing adjustment of the intensity of the magnetic fields, preventing eddy currents at the occurrence of a high-frequency magnetic field, and attaining a high spinning speed with high performance and high efficiency.

16. A method of manufacturing a rotary machine, comprising the steps of putting multiple DC or AC electromagnets constructed with windings wound around bobbins and magnetic pole iron cores together to give a stator, and completing the stator comprising magnetic pole iron cores, which are electromagnetically coupled through the windings; magnetic path-forming iron cores or secondary yoke components; magnetic pole iron core pressing plates; winding bodies; and partition plates for partitioning each phase.