WO2018105452A1 - Electric motor component, electric motor, device - Google Patents

Abstract

An electric motor component including at least a stator and a rotor, said rotor including: a first rotor section disposed at a part excluding both ends of a cylindrical body of the rotor; and second rotor sections respectively disposed at both ends of the cylindrical body of the rotor. The first rotor section includes: multiple d-axis flux passages for generating a magnetic torque component of a rotational torque generated by a rotating magnetic field from the stator; and multiple q-axis flux passages for generating a reluctance torque component of the rotational torque, and a first bonded magnet part is included at least in a portion of each of the multiple d-axis flux passages. The second rotor sections include multiple second bonded magnet parts integrated with the first bonded magnet parts.

Description

Motor elements, motors, equipment

The present invention relates to an electric motor element and an electric motor and an apparatus including the electric motor element.

In recent years, as a configuration that contributes to improving the performance of electric motor elements, application of permanent magnet embedded (IPM) rotors in which permanent magnets are embedded in the rotor is prosperous.

As the permanent magnet, a ferrite magnet, a rare earth sintered magnet, a bonded magnet, and the like are appropriately employed.

For example, Patent Document 1 describes an electric motor in which a sintered magnet such as a ferrite magnet or a rare earth sintered magnet is embedded in a rotor. Patent Document 2 and the like describe an electric motor in which a bond magnet is embedded in a rotor.

When using sintered magnets, magnet embedding holes with dimensions corresponding to the tolerance of the outer dimensions of the sintered magnets are arranged in the rotor core. For this reason, the magnet arrangement hole provided in the rotor core has a larger dimensional tolerance than the rotor core. Therefore, the magnet arrangement hole has a slightly larger shape than the sintered magnet. For this reason, a space | gap arises between a rotor core and a sintered magnet, and the surface magnetic flux density of a rotor falls with the magnetic resistance of a space | gap. Moreover, since a sintered magnet is hard and brittle, it is not suitable for complication of the external shape of the sintered magnet for utilizing reluctance torque.

In the configuration in which the sintered magnet is replaced with the bonded magnet, no gap is generated between the bonded magnet and the rotor core. For this reason, the influence by the magnetic resistance of a space | gap is avoidable. However, the magnetic properties of bonded magnets are inferior to those of rare earth sintered magnets. Therefore, it has not yet been possible to replace the sintered rare earth magnet with a bonded magnet by avoiding the influence of the magnetic resistance of the air gap.

In Patent Document 3 and the like, in a permanent magnet embedded type rotor in which a permanent magnet is embedded in a rotor, small pieces of permanent magnets are arranged on both end faces of the cylinder of the rotor. A technical idea is described in which a back yoke is arranged on the bearing side to improve the characteristics of the motor element. However, this is a configuration in which small pieces of permanent magnets having different shapes are assembled inside the rotor. Therefore, the difficulty of the manufacturing technique is high and the number of manufacturing steps increases. Therefore, the problem from a management viewpoint, such as a productivity fall, is invited.

In recent years, the development of new bonded magnets that contribute to improving the performance of electric motor elements has been active. In particular, the high performance of this new bonded magnet is desired to be applied to a permanent magnet embedded rotor in which a bonded magnet (permanent magnet) is embedded in the rotor. On the other hand, the bonded magnet has a characteristic that its external shape can be complicated.

FIG. 16 is a perspective view showing a configuration of a permanent magnet embedded rotor 190 according to the prior art. FIG. 17 is a cross-sectional view showing a cross section along a plane parallel to the rotation axis of a permanent magnet embedded rotor 190 according to the prior art.

The rotor 190 made of the core sheet 180 stacked in the direction of the rotation axis is provided with a plurality of bond magnet arrangement hole portions 220 for arranging the bond magnet portions 210. The bonded magnet arrangement hole 220 is filled with a bonded magnet melt that mixes and melts the resin material and the magnet powder, and is solidified to arrange the bonded magnet unit 210.

In the permanent magnet embedded type rotor 190, when a coil wound around the stator is energized, a magnetic flux is generated by an electric current. The magnetic force generated by the interaction between the magnetic flux generated by the current and the magnetic flux generated from the magnet becomes the torque for rotating the rotor. The rotor is driven by this torque.

At this time, leakage magnetic flux generated from the bonded magnet unit 210 at both end faces in the axial direction of the permanent magnet embedded type rotor 190 and not using the core of the rotor 190 as a magnetic flux path is generated at both ends in the axial direction of the rotor 190. From the surface, the atmosphere is used as a magnetic flux path. This leakage magnetic flux forms a short-circuit magnetic path 200 that returns to the adjacent bonded magnet unit 210. Thereby, the surface magnetic flux of the rotor 190 decreases, and the effective magnetic flux amount contributing to the torque decreases.

JP-A-8-331783 Japanese Patent Laid-Open No. 11-262205 JP 2006-280199 A

An object of the present invention is to improve the characteristics of a motor element in a configuration in which a bond magnet is embedded in the rotor, and to provide a rotor and a motor element having a novel configuration.

In order to achieve the above-mentioned object, the inventors of the present application conducted trial and error and intensively studied. Details are described below.

The electric motor element of the present invention is an electric motor element including at least a stator and a rotor, and the rotor includes a first rotor portion disposed in a portion excluding both ends of the cylindrical body of the rotor, and a rotating portion. And a second rotor portion disposed at each of both ends of the cylindrical body of the child. The first rotor section generates a plurality of d-axis magnetic flux paths for generating magnet torque out of the rotational torque components generated by the rotating magnetic field from the stator, and reluctance torque among the rotational torque components. A plurality of q-axis magnetic flux passages, and at least a part of each of the plurality of d-axis magnetic flux passages includes a first bond magnet portion. The second rotor portion includes a plurality of second bond magnet portions that are integral with the first bond magnet portion. Each of the second bonded magnet portions extends from the bonded magnet connecting portion to the outer peripheral portion of the rotor, the bonded magnet connecting portion where the second bonded magnet portion and the first bonded magnet portion are in contact, and And a bonded magnet extending portion in contact with the first rotor core portion of the first rotor portion excluding the first bonded magnet portion. The magnetic poles of the magnetic pole faces facing the outer peripheral face of the rotor in the first bonded magnet section have different magnetic poles in the adjacent magnetic pole faces. The magnetic pole of the surface in contact with the first rotor core portion in the bonded magnet extending portion constituting the surface continuous with the magnetic pole surface of the first bond magnet portion is the same as that of the first bond magnet portion constituting the continuous surface. It has the same magnetic pole as the magnetic pole face.

According to the present invention, it is possible to increase the amount of effective magnetic flux contributing to the torque generation of the motor element by increasing the interlinkage magnetic flux of the stator by suppressing the leakage magnetic flux from both axial ends of the rotor core. it can. Therefore, it can contribute to the improvement of the characteristics of the electric equipment. Therefore, it has a great industrial value.

Sectional drawing which shows the electric motor element of Embodiment 1. FIG. Sectional drawing which shows the cross section of the plane containing a rotating shaft in the electric motor element of Embodiment 1. FIG. FIG. 3 is a perspective view showing a rotor in the first embodiment. FIG. 3 is a perspective view showing a first rotor core part of the rotor in the first embodiment. The perspective view which shows the magnet shape which integrated the 1st bond magnet part of the rotor in Embodiment 1, and the 2nd bond magnet part, and a recessed part side is N pole. The perspective view which shows the magnet shape which integrated the 1st bond magnet part of the rotor in Embodiment 1, and the 2nd bond magnet part, and a recessed part side is a south pole. Sectional drawing which shows the cross section along a surface parallel to the rotating shaft of the rotor in Embodiment 1. FIG. Sectional drawing which shows the cross section along the surface perpendicular | vertical to the rotating shaft of a rotor in the 1st rotor core part and 1st bond magnet part in Embodiment 1. FIG. The figure which shows the simulation result of an induced voltage in the rotor of Embodiment 1, and the rotor of a prior art. Sectional drawing which shows the stator intermediate | middle assembly and stator frame which are contained in the stator structural body of the electric motor in Embodiment 2. FIG. The expanded sectional view of the principal part of the stator intermediate assembly in FIG. Sectional drawing which looked at the principal part corresponding to FIG. 9A from the upper side. The figure for demonstrating the procedure which forms the stator structural body of the electric motor in Embodiment 2. FIG. Sectional drawing of the stator structure in Embodiment 2. FIG. FIG. 6 is an enlarged cross-sectional view of a main part of a stator structure in a second embodiment. Sectional drawing of the electric motor in Embodiment 2. FIG. FIG. 5 shows a configuration of an air conditioner indoor unit as an example of an apparatus according to Embodiment 3. The figure which shows the structure of the air cleaner as another example of the apparatus in Embodiment 3. FIG. The perspective view which shows the structure of the rotor of a permanent magnet embedded type by a prior art. Sectional drawing which shows the cross section along a surface parallel to the rotating shaft of the permanent magnet embedded type rotor by a prior art.

Hereinafter, the present invention will be described with reference to the drawings. Note that the present invention is not limited to the following embodiments.

(Embodiment 1)
FIG. 1 is a cross-sectional view showing a motor element 14 according to the first embodiment. FIG. 2 is a cross-sectional view showing a cross section of a plane including the rotation axis in the electric motor element 14 of the first embodiment. The combination of the number of poles and the number of slots of the motor element 14 shown in FIG. 1 is a so-called concentrated winding configuration of 6 poles and 9 slots. The motor element 14 includes a stator 1 having a concentrated winding body in nine tooth portions, and a rotor 2 having six magnetic pole portions having magnetic saliency.

Note that the electric motor element of the present invention is not limited to this. In addition, in FIG. 1, although the winding body 6 by the concentrated winding which wound the coil | winding to the one tooth part 5 is illustrated, this invention is not restricted to this. For example, various winding modes such as distributed winding in which the winding is wound over the plurality of tooth portions 5 or wave winding can be employed.

For example, a configuration of concentrated winding of 10 poles and 9 slots, a configuration of concentrated winding of 10 poles and 12 slots, a configuration of concentrated winding of 12 poles and 9 slots, a configuration of concentrated winding of 14 poles and 12 slots, and a distributed winding of 4 poles and 24 slots Configuration, 4-pole 36-slot distributed winding configuration, 6-pole 36-slot distributed winding configuration, 8-pole 48-slot distributed winding configuration, 4-pole 12-slot wave winding configuration, 4-pole 12-slot wave winding configuration The present invention is applicable to any known combination of the number of poles and the number of slots, such as a configuration and a 6-pole 18-slot wave winding configuration.

As shown in FIG. 1, the electric motor element 14 of the present embodiment has a substantially cylindrical stator 1 and a rotor 2 that is rotatably held inside the stator 1. A shaft hole 3 is provided at the center of the rotor 2. The rotor 2 and the shaft are fixed in a state where a shaft (not shown) is inserted through the shaft hole 3. A pair of bearings that rotatably support the shaft are provided at both ends of the shaft. In FIG. 1, the shaft and the bearing are self-explanatory and are not shown.

The stator 1 includes a substantially cylindrical yoke portion 4 and a magnetic core 7 of the stator 1 having a tooth portion 5 extending inside the yoke portion 4, and an insulated wire wound around each of the tooth portions 5. And a wound body 6 provided. Between the tooth part 5 and the wound body 6, an insulator 8 that electrically insulates the two is provided. The cylindrical rotor 2 includes a first rotor core 9a and a second rotor core 9b. The arrangement holes 11 formed in a plurality (six in this example) in the circumferential direction of the rotor 2 have a first bond magnet part 140 and a second bond magnet part 150. As the material of the core wire of the insulated wire constituting the wound body 6, a material containing inevitable impurities and any of copper, copper alloy, aluminum or aluminum alloy is used.

The first bond magnet part 140 and the second bond magnet part 150 include at least magnet powder and a resin material. The type of magnetic material of the magnet powder is not particularly limited. For example, Nd—Fe—B magnet powder, Sm—Co magnet powder, Sm—Fe—N magnet powder, ferrite magnet powder, or these It selects suitably from a mixture etc.

The content of the magnet powder is preferably 93 to 97% by weight (density 5.4 Mg / m ³ to 6.5 Mg / m ³ ) with respect to the entire bonded magnet. If it is less than 93% by weight, high magnetic properties tend not to be obtained. On the other hand, when the content is more than 97% by weight, the processability is remarkably lowered and the molding tends to be difficult.

The above Nd—Fe—B magnet powder, Sm—Co magnet powder, Sm—Fe—N magnet powder, and ferrite magnet powder include scandium (Sc) belonging to Group 3 of the long-period periodic table. ), Yttrium (Y) and lanthanoid elements. Examples of lanthanoid elements include lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), and dysprosium (Dy). , Holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), lutetium (Lu), and the like, including one or more of these elements.

The resin material included in the first bond magnet part 140 and the second bond magnet part 150 is not particularly limited, and examples thereof include a thermoplastic resin, a thermosetting resin, and a mixture thereof. Examples of the thermoplastic resin include engineering plastics such as polyamide resin, polybutylene terephthalate, and polyphenylene sulfide, super engineering plastics such as liquid crystal polymers, and crystalline plastics such as polyethylene and polypropylene. Examples of the thermosetting resin include an epoxy resin, a phenol resin, and a melamine resin.

Further, the cross-sectional shape of the surface perpendicular to the axial direction of the first bonded magnet portion 140 shows a case of a substantially arc shape, but is not limited to this shape. A mode suitable for the specification, such as a substantially rectangular shape, a substantially trapezoidal shape, or a substantially V-shaped shape, is appropriately selected. Further, the substantial arc shape or the substantial V-shaped shape is a shape having a bent portion, and the arrangement of the bent portion is a configuration in which the convex portion side is located on the side of the rotation axis center of the rotor. .

Further, in the electric motor element 14 of the present embodiment, the rotor 2 has magnetic saliency. The rotor 2 having magnetic saliency has a plurality of d-axis magnetic flux paths and a plurality of q-axis magnetic flux paths. The portion shown as the imaginary line 12 in the rotor 2 shown in FIG. 1 is an example schematically showing the d-axis magnetic flux path, and the rotating magnetic field from the stator 1 makes this d-axis magnetic flux path a magnetic path. The magnet torque of the rotational torque components is generated. Moreover, the part shown as the imaginary line 13 in the rotor 2 is an example which shows a d-axis magnetic flux path typically, and the rotation magnetic field from the stator 1 rotates by making this q-axis magnetic flux path into a magnetic path. A reluctance torque among torque components is generated.

In general, the manufacturing method of the core of the motor element (both the magnetic core of the stator and the rotor core) using the electromagnetic steel sheet is obtained by using a roll-shaped electromagnetic steel sheet supplied from a metal material manufacturer, etc. The core is formed by feeding to a press machine, punching into a core sheet having a predetermined axial cross-sectional shape by a mold installed in the press machine, and stacking and integrating the core sheets.

FIG. 3 is a perspective view showing the rotor 2 in the first embodiment. FIG. 4 is a perspective view showing first rotor core portion 110a and second rotor core portion 110b of rotor 2 in the first embodiment. FIG. 5A is a perspective view showing a magnet shape in which the first bond magnet part 140 and the second bond magnet part 150 of the rotor 2 according to Embodiment 1 are integrated, and the concave side is an N pole. FIG. 5B is a perspective view showing a magnet shape in which the first bond magnet part 140 and the second bond magnet part 150 of the rotor 2 in Embodiment 1 are integrated, and the concave part is an S pole. FIG. 6A is a cross-sectional view showing a cross section along a plane parallel to the rotation axis of rotor 2 in the first embodiment. The rotor 2 includes a first rotor part 100a and second rotor parts 100b disposed at both ends of the first rotor part 100a. 6B is a cross-sectional view showing a cross section of first rotor core portion 110a and first bond magnet portion 140 according to Embodiment 1 along a plane perpendicular to the rotation axis of rotor 2. FIG.

The rotor 2 in the first embodiment shown in FIGS. 4, 6A, and 6B includes a first rotor core portion 110a including a first core sheet 120a stacked in the direction of the rotation axis, and the first rotor. Each of both ends of the core part 110a includes a second rotor core part 110b made of a second core sheet 120b stacked in the direction of the rotation axis.

The second core sheet 120b and the second rotor core portion 110b include a circular shaft hole 3 for arranging a shaft in the center portion, and a plurality of bay portion structures (recesses, first portions) on the outer periphery of the shaft hole 3. It has a star shape having two bonded magnet arrangement bays 130b).

The first core sheet 120a and the first rotor core portion 110a have a hole portion for arranging the shaft in the center, and a first bonded magnet arrangement hole portion 130a that is an arc-shaped hole portion in the annular portion. A plurality. FIG. 6B is a cross-sectional view showing a cross section of the first rotor core portion 110a and the first bonded magnet portion 140 along a plane perpendicular to the rotation axis of the rotor.

Note that, as shown in FIG. 6B, the cross-sectional shape of the first bonded magnet portion 140 is an arc shape. This arc shape has a first radius of curvature 141 of the first bonded magnet portion and a second radius of curvature 142 of the first bonded magnet portion. Then, comparing the first radius of curvature 141 of the first bonded magnet part and the second radius of curvature 142 of the first bonded magnet part, the first radius of curvature 141 of the first bonded magnet part Is big. The center of the virtual circle 144 with the first radius of curvature and the center of the virtual circle 145 with the second radius of curvature are located near the outer periphery of the rotor 2. The position of the center 143 of the imaginary circle of this radius of curvature is not particularly specified because there are cases where it is located within the outer diameter circle of the rotor 2 or cases where it is located outside the outer diameter circle of the rotor 2. In addition, the position of the center of the virtual circle 144 based on the first radius of curvature and the position of the center of the virtual circle 145 based on the second radius of curvature may be substantially coincident with each other or separated from each other. do not do.

Further, as shown in FIGS. 3 and 6A, in the rotor 2, the columnar diameter of the first rotor portion 100a and the columnar diameter of the second rotor portion 100b are substantially the same. A cylindrical surface having substantially no step is formed between the first rotor part 100a and the second rotor part 100b.

The first core sheet 120a is an electromagnetic steel plate called 35H300. The thickness of the electromagnetic steel sheet is 0.35 mm. The electromagnetic steel sheet contains Fe and Si as main components, and is not particularly limited as subcomponents. The components of the electrical steel sheet include inevitable impurities that are not specified.

The second core sheet 120b is an electromagnetic steel plate called 35H300, like the first core sheet 120a. The thickness of the electromagnetic steel sheet is 0.35 mm. The electromagnetic steel sheet contains Fe and Si as main components, and is not particularly limited as subcomponents. The components of the electrical steel sheet include inevitable impurities that are not specified.

The first rotor core part 110a is provided with a plurality of first bonded magnet arrangement holes 130a. In the first bonded magnet arrangement hole 130a, the first bonded magnet part 140 is arranged to constitute the first rotor part 100a. The 2nd rotor core part 110b of the both ends of the 1st rotor core part 110a is comprised with the magnetic body (laminated body of an electromagnetic steel plate). The second rotor core portion 110b is provided with a second bonded magnet arrangement bay portion 130b having a shape different from that of the first bonded magnet arrangement hole portion 130a of the first rotor core portion 110a. In the second bonded magnet arrangement bay 130b, the second bonded magnet part 150 is arranged to constitute the second rotor part 100b.

The second bonded magnet unit 150 has a shape extending more radially outward than the first bonded magnet unit 140. The first bonded magnet part 140 is magnetized in an in-plane direction substantially perpendicular to the axial direction. The second bonded magnet unit 150 is magnetized so as to have an axial component.

That is, the magnetic poles of the magnetic pole faces facing the outer peripheral face of the rotor 2 in each of the first bonded magnet portions 140 have different magnetic poles on the adjacent magnetic pole faces. Further, the magnetic poles of the surfaces in contact with the first rotor core portion 110a in the bonded magnet extension portion 152 of the second bonded magnet portion 150 constituting the surfaces continuous with the respective magnetic pole surfaces of the first bonded magnet portion 140. Has the same magnetic pole as the magnetic pole face of the first bonded magnet portion 140 constituting a part of the continuous face. FIG. 5A is a perspective view showing a magnet shape in which the first bonded magnet part 140 and the second bonded magnet part 150 are integrated, and the concave side is an N pole. FIG. 5B is a perspective view showing a magnet shape in which the first bonded magnet part 140 and the second bonded magnet part 150 are integrated, and the concave side is the S pole.

The number of the second core sheets 120b stacked in the second rotor core part 110b is smaller than the number of the first core sheets 120a stacked in the first rotor core part 110a.

The first bonded magnet part 140 is arranged so as to fill the first bonded magnet arrangement hole part 130a and occupies the positions of both end faces of the first rotor core part 110a. The second bonded magnet part 150 is arranged so as to fill the second bonded magnet arrangement bay part 130b, and each of the second rotor core part 110b on the side not in contact with the first rotor core part 110a. Occupies the position of the end face. The first bonded magnet unit 140 and the second bonded magnet unit 150 constitute an integrated bonded magnet.

The core formed by integrating the first rotor core portion 110a and the second rotor core portion 110b is a frame shape similar to a mold used for resin molding having a cylindrical recess along the external shape of the core. Is housed in. Filling and solidifying a bonded magnet melt in which a resin material and magnet powder are mixed and melted in the bonded magnet arrangement hole formed by the first bonded magnet arrangement hole 130a and the second bonded magnet arrangement bay 130b that communicate with each other. . In this way, the first bond magnet part 140 and the second bond magnet part 150 are arranged.

With the above-described configuration, the leakage magnetic flux from the first bonded magnet portion 140 is arranged on both end surfaces in the axial direction of the rotor so as to have an axial component in the vicinity of both end surfaces in the axial direction of the rotor 2. The second bonded magnet portion 150 that is magnetized converges to the central portion in the axial direction of the rotor 2. For this reason, the magnetic flux leakage is reduced and the magnetic flux contributing to the torque is increased.

2nd rotor core part 110b is arrange | positioned at an axial direction both ends, and is comprised with a magnetic body (laminated body of an electromagnetic steel plate). The second core sheet 120b and the second rotor core portion 110b include a circular shaft hole 3 for arranging a shaft in the center portion, and a plurality of bay portion structures (recesses, first portions) on the outer periphery of the shaft hole 3. It has a star shape having two bonded magnet arrangement bays 130b). As a result, the magnetic resistance at both axial ends of the rotor 2 is increased. Further, the effect of converging a part of the magnetic flux from the second bonded magnet portion 150 disposed at both axial end portions of the rotor to the central portion in the axial direction of the rotor 2 without damaging the leakage magnetic flux is enhanced. Yes.

磁 界 In order to confirm the effectiveness of this embodiment, magnetic field analysis is performed by the finite element method. FIG. 7 is a diagram showing a simulation result of the induced voltage in the rotor 2 of the first embodiment and the conventional rotor. Referring to FIG. 7, the induced voltage per unit magnet amount of the rotor 2 of the first embodiment is increased as compared with the conventional rotor. Thereby, it can confirm that the increase amount of an induced voltage can be improved with respect to the increase amount of the bond magnet of the axial direction both ends of the rotor 2. FIG. Therefore, it can be confirmed that the leakage magnetic flux can be effectively used.

In the present embodiment, the number of poles of the rotor is 6 (the number of magnet arrangement holes is 6), but the present invention is not limited to this number and is 2n times (n is a natural number). Applicable if available.

Moreover, although the shape of the axial direction center part of the 1st bonded magnet arrangement | positioning hole part 130a has shown the case of circular arc shape substantially, it is not limited to this shape. Any magnet placement hole shape is applicable, such as a substantially rectangular shape, a substantially trapezoidal shape or a substantially V-shaped shape. Further, the substantial arc shape or the substantial V-shaped shape is a shape having a bent portion, and the arrangement of the bent portion is a configuration in which the convex portion side is located on the side of the rotation axis center of the rotor. .

As described above, the electric motor element 14 of the present embodiment is an electric motor element 14 including at least the stator 1 and the rotor 2, and the rotor 2 is a portion excluding both ends of the cylindrical body of the rotor 2. 1st rotor part 100a arrange | positioned in 2 and the 2nd rotor part 100b arrange | positioned at each of the both ends of the cylindrical body of the rotor 2 is included. The first rotor portion 100a includes a plurality of d-axis magnetic flux paths for generating magnet torque out of rotational torque components generated by the rotating magnetic field from the stator 1, and reluctance torque out of rotational torque components. A plurality of q-axis magnetic flux paths, and a first bond magnet portion 140 is included in at least a part of each of the plurality of d-axis magnetic flux paths. The second rotor part 100 b includes a plurality of second bond magnet parts 150 that are integral with the first bond magnet part 140. Each of the second bonded magnet portions 150 extends from the bonded magnet connecting portion 151 where the second bonded magnet portion 150 and the first bonded magnet portion 140 are in contact with each other to the outer peripheral portion of the rotor 2. And a bonded magnet extending portion 152 that is in contact with the first rotor core portion 110a of the first rotor portion 100a excluding the first bonded magnet portion 140. The magnetic poles of the magnetic pole surfaces facing the outer peripheral surface of the rotor 2 in the first bonded magnet unit 140 have different magnetic poles in the adjacent magnetic pole surfaces. In the bonded magnet extension portion 152 that forms a surface continuous with the magnetic pole surface of the first bonded magnet portion 140, the magnetic pole of the surface that is in contact with the first rotor core portion 110a is a first bond that forms a continuous surface. It has the same magnetic pole as the magnetic pole surface of the magnet part 140.

Thus, by suppressing the leakage magnetic flux from both axial ends of the rotor core, the interlinkage magnetic flux of the stator can be increased, and the effective magnetic flux amount contributing to the torque generation of the motor element can be increased. Therefore, it can contribute to the improvement of the characteristics of the electric equipment. Therefore, it has a great industrial value.

The first rotor part 100a includes a first rotor core part 110a in which a plurality of annular first core sheets are stacked, and a first bond magnet part 140 on the first rotor core part 110a. And a plurality of first bonded magnet arrangement holes 130a for arranging the magnets. The second rotor part 100b includes a second rotor core part 110b in which a plurality of star-shaped second core sheets are stacked, and a second bond magnet part 150 on the second rotor core part 110b. A plurality of second bonded magnet placement bays 130b to be placed may be included. The shape located on the outer periphery of each second rotor portion 100b of the second bonded magnet portion 150 may be the same shape as the outer periphery of the first rotor portion 100a. Thereby, by suppressing the leakage magnetic flux from both axial ends of the rotor core, the interlinkage magnetic flux of the stator can be increased, and the effective magnetic flux amount contributing to the torque generation of the motor element can be increased. Therefore, it can contribute to the improvement of the characteristics of the electric equipment. Therefore, it has a great industrial value.

In addition, each of the plurality of first bonded magnet arrangement holes 130 a has a substantially arc shape, a substantially rectangular shape, a substantially rectangular shape on a plane perpendicular to the rotation axis of the rotor 2. It may be trapezoidal or substantially V-shaped.

Further, the outer periphery of the first rotor part 100a and the outer periphery of the second rotor part 100b may be the same shape.

Further, the shape of each of the plurality of first bonded magnet arrangement holes 130 a may be an arc shape on a plane perpendicular to the rotation axis of the rotor 2.

Also, the shape of the central portion in the axial direction of each of the plurality of first bonded magnet arrangement holes 130a may be rectangular or V-shaped.

Further, the stator 1 and the rotor 2 may include electromagnetic steel plates.

Further, the stator winding of the stator 1 may include concentrated windings.

Further, the stator winding of the stator 1 may include a distributed winding.

Further, the stator winding of the stator 1 may include a wave winding.

Further, the stator winding of the stator 1 may include an insulated wire, and the insulated wire may include inevitable impurities and any of copper, copper alloy, aluminum, or aluminum alloy.

Further, the content of the magnet powder contained in the first bond magnet part 140 and the second bond magnet part 150 is preferably 93% by weight to 97% by weight.

The electric motor may also include an electric motor element 14.

The device may also include a motor element 14.

(Embodiment 2)
FIG. 8 is a cross-sectional view showing stator intermediate assembly 319, connector 316, and stator frame 314 included in the stator structure of the electric motor according to Embodiment 2 of the present invention. 9A is an enlarged cross-sectional view of a main part of the stator intermediate assembly 319 in FIG. 8, and FIG. 9B is a cross-sectional view of the main part corresponding to FIG. 9A as viewed from the upper side.

In the electric motor according to the present embodiment, the stator frame 314 is formed of a cylindrical metal, and the electric motor includes the stator 310 in the stator frame 314 as shown in FIG. The rotor described below and a printed wiring board 315 are accommodated. One surface of the cylindrical stator frame 314 is opened, and the stator intermediate assembly 319 and the like are placed from the open end 314a. In addition, a connector window 314b for arranging the connector 316 is provided in the vicinity of the opening end 314a of the stator frame 314.

Further, as shown in FIGS. 8, 9A, and 9B, the stator intermediate assembly 319 in the present motor includes a stator 310 and a printed wiring board 315, and the stator 310 further includes a stator magnetic core 311. The insulator 312 and the wound body 313 are included.

The stator magnetic core 311 is made of metal, and is configured by an annular yoke portion 311y and a plurality of tooth portions 311t as salient poles. FIG. 9B shows one tooth portion 311t of the plurality of tooth portions 311t and only a part of the yoke portion 311y that is a base portion of the tooth portion 311t. In the present embodiment, a configuration example of the stator structure in the inner rotor type motor in which the tooth portion 311t projects inward from the inner peripheral side of the yoke portion 311y is given. With respect to such a stator magnetic core 311, each of the plurality of tooth portions 311t is covered with an insulator 312 formed of an insulating material, and each of the tooth portions 311t is provided with a winding 313w that is an insulated wire via the insulator 312. The stator 310 is formed by providing the wound body 313 that is wound.

Further, in the stator frame 314, a printed wiring board 315 is disposed on the opening end 314a side with respect to the position where the stator 310 is disposed. Further, in the wound body 313 of the stator 310, as shown in FIG. 9A, the winding end of the winding 313w is only from the side where the printed wiring board 315 is disposed with respect to the position of the stator magnetic core 311. The part 313a is pulled out. Furthermore, in the wound body 313 which is the main body portion of the winding 313w, the wire surface of the winding 313w is insulated, whereas each of the winding end portions 313a exposes a metal portion in the wire. It is in a state that includes a live part. In the present embodiment, such a winding end 313 a is drawn from each winding body 313. The winding cores 313 are connected by the winding end portions 313a, the winding end portions 313a are connected to the terminals of the connector 316, and the stator core 311 is connected to the printed wiring board 315. In the space between the printed wiring board 315 and the printed wiring board 315, wiring by these winding end portions 313a is formed.

A wiring pattern is formed on the surface of the printed wiring board 315 by a printing method, and a predetermined winding end 313a is connected to a predetermined land included in the wiring pattern. For example, as shown in FIG. 9A, a certain winding end 313 a is drawn to a predetermined land on the printed wiring board 315. Then, soldering is performed on the land, and the solder connection portion 317 is formed, whereby the winding end portion 313a is connected to the printed wiring board 315. The printed wiring board 315 has an annular shape (doughnut shape), a fan shape (arc shape), a C-shape, and the like, and has a hollow portion in the center. The hollow portion has a rotor or an electric motor. The output shaft is inserted loosely.

As described above, the stator intermediate assembly 319 is placed inside the stator frame 314 as shown in FIG.

Further, when the stator intermediate assembly 319 is placed in this manner, a space is generated in the stator frame 314 between the stator frame 314 and the stator intermediate assembly 319 or the like. For this reason, in this Embodiment, it is set as the structure which fills the specific location of these spaces with resin, and has aimed at the improvement of the heat dissipation in an electric motor. And in this Embodiment, in order to fill with resin, the resin injection port 314d is further provided in the part or several location of the wall part of the stator frame 314. FIG. In the present embodiment, a resin injection port 314d is provided in a wall portion that is lower than the stator intermediate assembly 319 and is close to the bottom portion of the stator frame 314. Further, a self-close valve 329 is provided at the resin injection port 314d. The self-closing valve 329 has an opening / closing mechanism using rubber elasticity or the like, and is configured to automatically close the valve by the opening / closing mechanism when the needle of the dispenser is pulled out.

Next, the procedure for forming the stator structure in the present embodiment will be described.

First, the stator intermediate assembly 319 as described above is placed inside the stator frame 314 in the following procedure. That is, the stator frame 314 is installed so that the opening end 314a of the stator frame 314 is upward and the shaft hole 314c of the stator frame 314 is downward. The stator intermediate assembly 319 is inserted into the stator frame 314 in this state from the open end 314a side of the stator frame 314.

At this time, the stator intermediate assembly 319 is positioned so that the printed wiring board 315 is disposed on the opening end 314a side of the stator frame 314. At the same time, a cylindrical center jig 318 is in close contact with the inner wall of the hollow portion of the stator magnetic core 311 as shown in FIG. In this embodiment, the stator intermediate assembly 319 is inserted into the stator frame 314 in such a state.

Then, the connector 316 is disposed in the connector window 314b of the stator frame 314, and the connector 316 disposed in the connector window 314b and the stator intermediate assembly 319 are electrically connected.

In this way, when the stator intermediate assembly 319 is arranged in the stator frame 314, a space is generated between the stator frame 314 and the stator intermediate assembly 319 or the like. As such a space, as shown in FIG. 10, the lower space 320 d between the inside of the bottom of the stator frame 314 and the lower part of the stator intermediate assembly 319, the inner peripheral surface of the stator frame 314 The peripheral space 320s which is a gap between the inner wall and the outer peripheral surface of the stator core 311, the gap (not shown) formed between the adjacent wound bodies 313, and the printed wiring board 315 There is an upper space 320u between the lower surface and the upper part of the stator 310.

In this embodiment, among these spaces, the lower space portion 320d and the peripheral space portion 320s are roughly filled with resin.

In the present embodiment, these spaces are filled with resin in the following procedure. That is, as shown in FIG. 10, a self-closing valve 329 is provided at the resin injection port 314 d, a dispenser nozzle or needle 331 is inserted into the self-closing valve 329, and the liquid resin 321 enters the stator frame 314. inject.

When the injection is started, first, the resin 321 is supplied to the lower space portion 320d of the stator frame 314, and the resin 321 further includes a circumferential space portion 320s that is a gap between the stator magnetic core 311 and the stator frame 314. And flow into the gap between the wound bodies 313. At this time, the resin 21 flows while discharging air inside the gap from the upper side of the stator intermediate assembly 319. For this reason, bubbles are not included in the resin 321, and an air pocket (void) in the cured resin 321 is also reduced. In this embodiment, since the resin 321 is filled in the specific space as described above, a highly reliable stator structure having stable heat dissipation characteristics after the resin 321 is cured, It can be provided at low cost. The cylindrical center jig 318 inserted into the hollow portion of the stator magnetic core 311 is removed after the resin 321 is cured.

The method for injecting the resin 321 will be further described. A needle 331 of a resin injection dispenser is inserted into the self-close valve 329 of the stator frame 314, and a heat radiating resin 321 such as a liquid epoxy resin is injected via the needle 331. The resin 321 is supplied into the lower space 320d where the stator 310 is located, and the gap between the outer peripheral surface of the stator magnetic core 311 and the stator frame 314 and the adjacent windings are mainly from the lower space 320d. The gaps between the bodies 13 are used as flow paths, and these gaps are also filled.

Since the self-close valve 329 that is open when the needle 331 is inserted has an opening / closing mechanism, it is automatically closed after resin injection. Therefore, the resin 321 injected into the stator frame 314 does not flow back or leak from the stator frame 314 to the outside. For this reason, the scattered resin does not adhere to the production line equipment and the product itself, and troubles such as cleaning and malfunction operation of the production equipment are suppressed, so that the production capacity of the production line becomes high. Naturally, there is no increase in production tact and no increase in the number of man-hours in the manufacturing process, and it is possible to provide a highly reliable product at a low cost, and the industrial value is great.

In addition, although it is the self-close valve 329, as long as it has a function which prevents a resin leak before and after resin injection | pouring, another structure may be sufficient. For example, as a simple one, a configuration in which the resin inlet is opened and closed by plugging and opening with a stopper made of an elastic body may be used.

FIG. 11 is a cross-sectional view of the stator structure 339 of the present invention completed by the procedure as described above. As shown in FIG. 11, the resin 321 fills the lower space 320d and the peripheral space 320s, and the upper space 320u is not filled with the resin 321.

The main resin component of the resin 21 in FIG. 13 is a thermosetting resin material such as epoxy, polyester, or polyurethane, and the resin 321 is any one of a thermosetting epoxy resin, a polyester resin, and a polyurethane resin. Is included. In order to improve the heat dissipation characteristics of the stator 310, the resin 321 is blended with a filler having high thermal conductivity such as aluminum oxide (commonly referred to as alumina) or silicon nitride. In addition, the air inside the stator hinders the heat dissipation characteristics of the stator 310 by the resin entering the gaps between the adjacent wound bodies 313 or the minute gaps between the stator core 311 and the stator frame 314. This layer is replaced with a resin layer having a low thermal resistance to improve heat dissipation.

Further, when the viscosity of the resin 321 is high, the penetration of the resin 321 into the above-described gap is accompanied by difficulty. For this reason, it is preferable that the resin 321 has low viscosity and high fluidity. In addition, even if it is a highly viscous resin material, the penetration of the resin 321 into the voids can be facilitated by increasing the fluidity of the resin 321 by preheating the stator 310 and the resin 321.

As described above, in the present embodiment, the resin 321 is filled in the space between the inside of the stator frame 314 and the stator intermediate assembly 319 to form the stator structure 339. .

Here, in the present embodiment, the space portion filled with the resin 321 is a gap between the lower space portion 320d, the peripheral space portion 320s, and the wound body 313, and the upper space portion 320u includes the resin 321. It is set as the structure which is not filled. That is, in the present embodiment, a resin-filled portion filled with the resin 321 and a resin non-filled portion not filled with the resin 321 are provided in the space in the stator frame 314 before filling with the resin. The structure is as follows.

Further, as described above, in the upper space portion 320u, the wound bodies 313 are connected to each other by the winding end portion 313a, or the winding end portion 313a is connected to the terminal of the connector 316 or connected to the printed wiring board 315. Wiring has been applied. That is, the upper space portion 320u includes an active portion of the winding end portion 313a drawn from the winding body, an active portion of a wiring pattern of the printed wiring board 315 such as the solder connection portion 317, and an electrical connection of the connector 316. It is a space including a live part that is a location (connection terminal) 316t. In this embodiment, the upper space 320u, which is a space including these live parts, is not filled with the resin 321 and the upper space 320u is not filled with the resin.

FIG. 12 is an enlarged cross-sectional view of the main part of the stator structure 339 of the present invention, and shows the boundary between the resin-filled portion 333 and the resin-unfilled portion 332.

When manufacturing the stator structure 339 of the present invention, it is easy to manage the liquid level of the resin 321 that flows after injection due to the structure of the present invention as described above. For this reason, the electrical connection part (live part) of the coil | winding edge part 313a for connecting the winding bodies 313, and the electrical connection for connecting the winding body 313 and the wiring pattern of the printed wiring board 315 are performed. The connection part (live part), the electrical connection part (live part) that is the connection terminal 316t for connecting the wound body 313 or the wiring pattern and the connector 316, etc. remain unfilled with the resin 321. Since the resin non-filling portion 332 is used, the resin 321 does not adhere.

Thus, in the present embodiment, the live parts, which are electrical connection parts, are not in direct contact with the resin 321 but through air (atmosphere). Even if some gas is generated from the resin 321, it does not stay around the live part and diffuses and disappears, and no malfunction occurs. Thereby, the configuration of the electrical connection portion is adapted to a severe use environment, and it is possible to provide an electric motor and a stator structure with higher reliability.

FIG. 13 is a cross-sectional view of electric motor 340 according to Embodiment 2 of the present invention. The electric motor 340 includes the stator structure 339 described above, a rotor 341 disposed on the inner peripheral side of the stator structure 339 via a gap, a bearing 350 that rotatably holds the rotor 341, and a stator. And a lid portion 351 mounted so as to close the open end 314a of the frame body 314.

The rotor 341 includes a columnar magnet holder 344 that holds a permanent magnet 343 in the circumferential direction, and a shaft 345 that fastens the magnet holder 344 so as to penetrate the center of the magnet holder 344. Yes.

Further, the rotor 341 in the second embodiment has the same configuration as the rotor described in the first embodiment. The rotor 341 may have the same configuration as the rotor described in the first embodiment. The rotor 341 includes a first rotor core part 343a, a second rotor core part 343b, a first bond magnet part 344a, and a second bond magnet part 344b.

The shaft 345 is rotatably held by two bearings 350 that support the shaft 345.

Thus, since the electric motor 340 of the present embodiment has the above-described highly reliable stator structure 339, a highly reliable electric motor can be provided.

(Embodiment 3)
As an example of an apparatus equipped with an electric motor according to the present invention, first, the configuration of an air conditioner indoor unit will be described in detail as a third embodiment.

In FIG. 14, an electric motor 401 is mounted in a housing 411 of the air conditioner indoor unit 410. A cross flow fan 412 is attached to the shaft of the electric motor 401. The electric motor 401 is driven by an electric motor driving device 413. The electric motor 401 rotates by energization from the electric motor driving device 413, and the cross flow fan 412 rotates accordingly.

The rotation of the cross flow fan 412 blows air conditioned by an indoor unit heat exchanger (not shown) into the room. Here, for example, the electric motor 401 of the second embodiment can be applied to the electric motor 401.

Further, as another example of the apparatus equipped with the electric motor according to the present invention, the configuration of the air cleaner will be described in detail with reference to FIG.

In FIG. 15, an electric motor 543 is mounted in the housing 541 of the air purifier 540. An air circulation fan 542 is attached to the shaft of the electric motor 543. The electric motor 543 is driven by an electric motor driving device 544.

The electric motor 543 is rotated by energization from the electric motor driving device 544, and the fan 542 is rotated accordingly. Air is circulated by the rotation of the fan 542. Here, for example, the electric motor 401 of the second embodiment can be applied to the electric motor 543.

In the above description, electric motors mounted on air conditioner indoor units, air purifiers, and the like have been taken as examples of the apparatus according to the present invention. However, electric motors mounted on other information devices, Needless to say, the present invention can also be applied to electric motors used in industrial equipment.

According to the present invention, the leakage magnetic flux from both axial end portions of the rotor core can be suppressed. Thereby, the linkage magnetic flux of a stator can be increased and the effective magnetic flux amount which contributes to the torque generation of an electric motor element can be increased. Therefore, it can contribute to the improvement of the characteristics of electric equipment.

DESCRIPTION OF SYMBOLS 1 Stator 2 Rotor 3 Shaft hole 4 Yoke part 5 Tooth part 6 Winding body 7 Stator magnetic core 8 Insulator 9a 1st rotor core 9b 2nd rotor core 11 Arrangement | positioning hole 12 Virtual line 13 Virtual line 14 Electric motor element 100a 1st rotor part 100b 2nd rotor part 110a 1st rotor core part 110b 2nd rotor core part 120a 1st core sheet 120b 2nd core sheet 130a 1st bond magnet Arrangement hole portion 130b Second bond magnet arrangement bay portion 140 First bond magnet portion 141 First radius of curvature of first bond magnet portion 142 Second radius of curvature of first bond magnet portion 143 Virtual radius of curvature Center of circle 144 Virtual circle with first radius of curvature 145 Virtual circle with second radius of curvature 150 Second bonded magnet portion 151 Bonded magnet connecting portion 15 Bond magnet extension portion 180 Core sheet 310 Stator 311 Stator magnetic core 311t Tooth portion 311y Yoke portion 312 Insulator 313 Winding body 313a Winding end portion 313w Winding 314 Stator frame body 314a Open end 314b Connector window portion 314c Shaft hole 314d Resin injection port 315 Printed wiring board 316 Connector 316t Electrical connection location (connection terminal)
317 Solder connection portion 318 Central jig 319 Stator intermediate assembly 320d Lower space portion 320s Circumferential space portion 320u Upper space portion 321 Resin 329 Self-close valve 331 Nozzle and needle 332 Resin unfilled portion 333 Resin filled portion 339 Stator configuration Body 340 Electric motor 341 Rotor 343 Permanent magnet 343a First rotor core part 343b Second rotor core part 344 Magnet holding part 344a First bond magnet part 344b Second bond magnet part 345 Shaft 350 Bearing 351 Cover part 401 Electric motor 410 Air conditioner indoor unit 411 Housing 412 Cross flow fan 413 Motor driving device 540 Air cleaner 541 Housing 542 Fan 543 Motor 544 Motor driving device

Claims (12)

An electric motor element including at least a stator and a rotor,
The rotor includes a first rotor portion disposed in a portion excluding both end portions of the rotor cylindrical body, and a second rotor portion disposed in each of both end portions of the rotor cylindrical body. Including
The first rotor portion includes a plurality of d-axis magnetic flux paths for generating magnet torque out of rotational torque components generated by a rotating magnetic field from the stator, and reluctance out of the rotational torque components. A plurality of q-axis magnetic flux passages for generating torque, and a first bond magnet portion is included in at least a part of each of the plurality of d-axis magnetic flux passages;
The second rotor portion includes a plurality of second bond magnet portions that are integral with the first bond magnet portion,
Each of the second bonded magnet portions includes a bonded magnet connecting portion where the second bonded magnet portion and the first bonded magnet portion are in contact, and from the bonded magnet connecting portion to an outer peripheral portion of the rotor. A bonded magnet extending portion that extends and is in contact with a first rotor core portion of the first rotor portion excluding the first bonded magnet portion;
The magnetic pole of the magnetic pole surface facing the outer peripheral surface of the rotor in the first bonded magnet portion has a different magnetic pole in the adjacent magnetic pole surface,
The magnetic pole of the surface in contact with the first rotor core portion in the bonded magnet extending portion that forms a surface that is continuous with the magnetic pole surface of the first bonded magnet portion is the first that forms the continuous surface. The electric motor element which has the same magnetic pole as the magnetic pole surface of the bonded magnet part. The first rotor portion includes a first rotor core portion in which a plurality of annular first core sheets are stacked, and the first bond magnet portion is disposed on the first rotor core portion. A plurality of first bonded magnet arrangement holes,
The second rotor portion includes a second rotor core portion in which a plurality of star-shaped second core sheets are stacked, and the second bond magnet portion is disposed on the second rotor core portion. A plurality of second bonded magnet placement bays to
2. The electric motor element according to claim 1, wherein a shape of each of the second bonded magnet portions positioned on an outer periphery of the second rotor portion is the same shape as an outer periphery of the first rotor portion. Each of the plurality of first bonded magnet arrangement holes has a substantially arc shape, a substantially rectangular shape, and a substantially trapezoidal shape in a plane perpendicular to the rotation axis of the rotor. The electric motor element according to claim 1, wherein the electric motor element is substantially V-shaped. 2. The electric motor element according to claim 1, comprising a configuration in which an outer shape of the first rotor portion and an outer shape of the second rotor portion are the same shape. The motor element according to claim 1, wherein the stator and the rotor include electromagnetic steel plates. The motor element according to claim 1, wherein the stator winding of the stator includes a concentrated winding. The motor element according to claim 1, wherein the stator winding of the stator includes a distributed winding. The motor element according to claim 1, wherein the stator winding of the stator includes a wave winding. The motor element according to claim 1, wherein the stator winding of the stator includes an insulated wire, and the insulated wire includes inevitable impurities and any of copper, copper alloy, aluminum, or aluminum alloy. The electric motor element according to claim 1, wherein the content of the magnet powder contained in the first bond magnet part and the second bond magnet part is 93 wt% to 97 wt%. An electric motor comprising the electric motor element according to claim 2. A device comprising the motor element according to claim 2.

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