JP5561148B2 - Motor core with low iron loss degradation under compressive stress - Google Patents
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
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- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/64—Electric machine technologies in electromobility
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Description
本発明は、家庭用エアコンのコンプレッサーモータや、ハイブリッド電気自動車（ＥＶ；Ｅｌｅｃｔｒｉｃ Ｖｅｈｉｃｌｅ）の駆動モータや発電機（以降、単に「モータ」という。）などに用いられるモータコアに関し、具体的には、圧縮応力の存在下においても鉄損劣化が小さい（鉄損増加が小さい）モータコアに関するものである。 The present invention relates to a motor core used in a compressor motor of a home air conditioner, a drive motor or a generator (hereinafter simply referred to as “motor”) of a hybrid electric vehicle (EV), and more specifically, compression. The present invention relates to a motor core that is small in iron loss degradation (small increase in iron loss) even in the presence of stress.
家庭用エアコンのコンプレッサーモータは、一般に最高周波数が２００〜４００Ｈｚ程度で可変速運転が行われており、さらに、ＰＷＭ（Ｐｕｌｓｅ Ｗｉｄｔｈ Ｍｏｄｕｌａｔｉｏｎ）方式のインバータ制御がなされているものでは、数ｋＨｚのキャリア周波数が重畳されて使用されている。また、最近、急速に普及しているハイブリッド電気自動車の駆動モータや発電機も、高出力化や小型化を図る観点から、数ｋＨｚ程度の周波数で駆動されている。 Compressor motors for home air conditioners are generally operated at variable speeds with a maximum frequency of about 200 to 400 Hz, and are further controlled by PWM (Pulse Width Modulation) type inverter control. Are superimposed and used. Recently, drive motors and generators of hybrid electric vehicles that are rapidly spreading are also driven at a frequency of about several kHz from the viewpoint of achieving high output and miniaturization.
上記のようなモータのステータ（固定子）やロータ（回転子）等のコアに用いられる素材（コア材）には、エネルギー効率を向上する観点から、鉄損が低いことが求められる。そこで、上記モータコア材には、使用される高周波域における鉄損を低減するため、ＳｉとＡｌを合計で３〜４ｍａｓｓ％程度添加したハイグレードの無方向性電磁鋼板が使用されている。 A material (core material) used for a core such as a stator (stator) or a rotor (rotor) of the motor as described above is required to have low iron loss from the viewpoint of improving energy efficiency. Therefore, high-grade non-oriented electrical steel sheets to which Si and Al are added in a total amount of about 3 to 4 mass% are used for the motor core material in order to reduce iron loss in the high frequency range to be used.
ところで、エアコンのコンプレッサーモータやハイブリッド電気自動車のモータでは、ステータをハウジング（モータケース）に固定する方法として、焼き嵌め法や圧入法が採用されており、これに起因して、ステータの円周方向には数１０〜１００ＭＰａ程度の圧縮応力が発生している。また、ハイブリッド電気自動車の駆動モータには、一般に樹脂モールドが施されるため、やはりモータコアには圧縮応力が加わることとなる。このような圧縮応力の存在下では、コアを構成する電磁鋼板の磁気特性が大きく劣化する（鉄損が増加する）ことが知られている。 By the way, in a compressor motor of an air conditioner or a motor of a hybrid electric vehicle, a shrink fitting method or a press-fitting method is adopted as a method for fixing the stator to the housing (motor case). , A compressive stress of about several tens to 100 MPa is generated. Moreover, since the resin motor is generally applied to the drive motor of the hybrid electric vehicle, a compression stress is also applied to the motor core. In the presence of such compressive stress, it is known that the magnetic properties of the electrical steel sheet constituting the core are greatly deteriorated (iron loss increases).
そのため、圧縮応力による鉄損劣化が小さい電磁鋼板の開発が望まれており、斯かる材料としては、例えば、特許文献１には、Ｓｉ：２．６〜４ｍａｓｓ％を添加して比抵抗を５０〜７５×１０−８Ωｍとし、さらに、平均結晶粒径を６０μｍ超１６５μｍ以下とした無方向性電磁鋼板が開示されている。 Therefore, it is desired to develop an electromagnetic steel sheet with small iron loss degradation due to compressive stress. As such a material, for example, Si: 2.6 to 4 mass% is added to Patent Document 1 and the specific resistance is 50. A non-oriented electrical steel sheet having a grain size of ˜75 × 10 −8 Ωm and an average crystal grain size of more than 60 μm and 165 μm or less is disclosed.
しかしながら、特許文献１の無方向性電磁鋼板は、現在市販されているハイグレード電磁鋼板と同等レベルの固有抵抗、結晶粒径でしかない。そのため、この材料を用いてモータコアを製造したとしても、圧縮応力による鉄損劣化の程度は従来材と大きく異なるものではない。そのため、鉄損の応力依存性をさらに小さくできる技術の開発が求められている。 However, the non-oriented electrical steel sheet of Patent Document 1 has only a specific resistance and a crystal grain size equivalent to those of a currently available high-grade electrical steel sheet. Therefore, even if a motor core is manufactured using this material, the degree of iron loss deterioration due to compressive stress is not significantly different from that of conventional materials. Therefore, development of a technique that can further reduce the stress dependence of iron loss is required.
そこで、本発明の目的は、圧縮応力の存在下においても高周波での鉄損特性の劣化が小さいモータコアを提供することにある。 Accordingly, an object of the present invention is to provide a motor core in which deterioration of iron loss characteristics at high frequency is small even in the presence of compressive stress.
発明者らは、上記課題の解決に向けて鋭意検討した。その結果、ステータを構成する、ガラス質の絶縁被膜を塗布した電磁鋼板（以降、「ステータコア材」とも称する。）のバックヨーク部に電子ビーム照射することにより、圧縮応力による鉄損特性の劣化を抑制できることを見出し、本発明を完成させた。 The inventors diligently studied to solve the above problems. As a result, by irradiating the back yoke portion of a magnetic steel sheet (hereinafter also referred to as “stator core material”) coated with a glassy insulating film constituting the stator with an electron beam, the iron loss characteristics are deteriorated due to compressive stress. The inventors have found that it can be suppressed, and completed the present invention.
すなわち、本発明は、絶縁被膜を塗布した電磁鋼板を積層し、周方向に１０ＭＰａ以上の圧縮応力が付与されるモータコアにおいて、上記モータコアを構成する電磁鋼板のバックヨーク部に電子ビーム照射されてなることを特徴とするモータコアである。 That is, according to the present invention, electromagnetic steel sheets coated with an insulating coating are laminated, and in a motor core to which a compressive stress of 10 MPa or more is applied in the circumferential direction, the back yoke portion of the electromagnetic steel sheets constituting the motor core is irradiated with an electron beam. The motor core is characterized by that.
本発明のモータコアにおける上記電磁鋼板は、バックヨーク部に０．２〜５ｍｍの間隔で電子ビーム照射されてなることを特徴とする。 The magnetic steel sheet in the motor core of the present invention is characterized in that the back yoke portion is irradiated with an electron beam at an interval of 0.2 to 5 mm.
また、本発明のモータコアにおける上記電磁鋼板は、電子ビーム照射後、絶縁被膜の上にさらに絶縁被膜が再塗布されてなることを特徴とする。 The magnetic steel sheet in the motor core of the present invention is characterized in that an insulating coating is further re-applied on the insulating coating after electron beam irradiation.
また、本発明のモータコアにおける上記電磁鋼板は、上記電磁鋼板は、Ｓｉ：７ｍａｓｓ％以下、Ａｌ：３ｍａｓｓ％以下、Ｍｎ：５ｍａｓｓ％以下、Ｓ：０．０１ｍａｓｓ％以下、Ｎ：０．００５ｍａｓｓ％以下、Ｏ：０．０１ｍａｓｓ％以下を含有し、残部がＦｅおよび不可避不純物からなる成分組成を有することを特徴とする。 In the motor core of the present invention, the electromagnetic steel sheet is composed of Si: 7 mass% or less, Al: 3 mass% or less, Mn: 5 mass% or less, S: 0.01 mass% or less, N: 0.005 mass% or less. , O: 0.01% by mass or less, with the remainder having a component composition composed of Fe and inevitable impurities.
本発明によれば、圧縮応力の存在下においても高周波での鉄損増加が小さいモータコアを提供することができる。したがって、本発明のモータコアは、焼き嵌めや圧入あるいは樹脂モールド等によって圧縮応力が付与された状態で使用されるエアコンのコンプレッサ用モータや、ハイブリッド自動車（ＨＶ）や電気自動車（ＥＶ）の駆動モータや発電機、燃料電池自動車（ＦＣＥＶ）の駆動モータ、高速発電機の高周波回転機等に好適に用いることができる。 According to the present invention, it is possible to provide a motor core with a small increase in iron loss at high frequencies even in the presence of compressive stress. Accordingly, the motor core of the present invention is a compressor motor for an air conditioner used in a state where compressive stress is applied by shrink fitting, press fitting, resin molding, or the like, a drive motor for a hybrid vehicle (HV) or an electric vehicle (EV), It can be suitably used for a generator, a drive motor of a fuel cell vehicle (FCEV), a high-frequency rotating machine of a high-speed generator, and the like.
先ず、本発明の基本的な技術思想について説明する。
家電用エアコンのコンプレッサ用モータやハイブリッド電気自動車用等の駆動モータでは、コアをモータケースに固定する手段として、一般に焼き嵌め法や圧入法が採用されている。この焼き嵌め法や圧入法によってモータコアの周方向に付与される圧縮応力は、２０〜１５０ＭＰａ程度であると言われている。この圧縮応力は、モータコアを構成する電磁鋼板の鉄損特性を劣化させ、ひいては、モータ効率を大きく低下させる。そのため、圧縮応力下においても鉄損特性の劣化が小さいモータコアが望まれている。
First, the basic technical idea of the present invention will be described.
In drive motors such as compressor motors for home appliance air conditioners and hybrid electric vehicles, shrink fitting or press-fitting methods are generally employed as means for fixing the core to the motor case. It is said that the compressive stress applied in the circumferential direction of the motor core by this shrink-fitting method or press-fitting method is about 20 to 150 MPa. This compressive stress degrades the iron loss characteristics of the electrical steel sheet that constitutes the motor core, and consequently greatly reduces the motor efficiency. Therefore, there is a demand for a motor core with little deterioration in iron loss characteristics even under compressive stress.
発明者らは、モータのステータを構成する電磁鋼板の圧縮応力下における高周波鉄損特性について調査したところ、圧縮応力の存在下では、ヒステリシス損だけでなく、渦電流損も増加していることが明らかとなった。なお、エアコンのコンプレッサ用モータやハイブリッド自動車等のモータは、基本周波数が高周波であることに加えて、インバータ制御するために数ｋＨｚの高調波も重畳されて駆動されているのが一般的である。したがって、高周波鉄損特性を改善するには、渦電流損の増加を抑制することが重要な課題となる。 The inventors investigated the high-frequency iron loss characteristics under the compressive stress of the magnetic steel sheet constituting the stator of the motor, and found that not only the hysteresis loss but also the eddy current loss increased in the presence of the compressive stress. It became clear. In general, motors such as compressor motors for air conditioners and hybrid vehicles are driven with harmonics of several kHz superimposed on them in order to control the inverter in addition to the high fundamental frequency. . Therefore, in order to improve the high frequency iron loss characteristic, it is an important issue to suppress an increase in eddy current loss.
そこで、圧縮応力の存在下で渦電流損が増加する原因について調査したところ、材料に圧縮応力が付与されると、鋼板内の磁化ベクトルは、圧縮応力を緩和するため、鋼板の板面内で圧縮応力と直角方向に向くよう変化する。そのため、この鋼板を磁化しようとすると、圧縮応力がない場合と比べて磁化ベクトルの向きを大きく変化させることが必要となり、そのための渦電流が鋼板板面内に流れるため、無応力のときに比べて渦電流損が増加することが明らかとなった。 Therefore, the cause of the increase in eddy current loss in the presence of compressive stress was investigated. It changes to face the direction perpendicular to the compressive stress. Therefore, when trying to magnetize this steel plate, it is necessary to change the direction of the magnetization vector greatly compared to the case where there is no compressive stress, and the eddy current for that flow flows in the steel plate surface. As a result, eddy current loss increased.
さらに、発明者らは、圧縮応力が付与されても、渦電流損が増大しないモータコア（ステータ）について検討を重ねた。その結果、ステータを構成する積層された電磁鋼板（ステータコア材）のバックヨーク部の周方向に引張応力を付与することができれば、焼き嵌めにより発生する圧縮応力を緩和することができ、鉄損特性の低下を抑制できるのではないかと考えた。そして、その引張応力付与手段として、電子ビーム照射に着目し、以下の実験を行った。 Furthermore, the inventors have studied a motor core (stator) in which eddy current loss does not increase even when compressive stress is applied. As a result, if tensile stress can be applied in the circumferential direction of the back yoke portion of the laminated electromagnetic steel sheets (stator core material) constituting the stator, the compressive stress generated by shrink fitting can be relieved, and the iron loss characteristics I thought that I could suppress the decline of The following experiment was conducted focusing on electron beam irradiation as the tensile stress applying means.
Ｓｉ：２．８ｍａｓｓ％、Ａｌ：１．０ｍａｓｓ％、Ｍｎ：１．０ｍａｓｓ％、Ｓ：０．００１８ｍａｓｓ％、Ｎ：０．００１９ｍａｓｓ％、Ｏ：０．００１５ｍａｓｓ％の成分組成からなる板厚：０．３０ｍｍの鋼板表面に、絶縁被膜として、クロム酸およびアクリル樹脂を含有する有機・無機複合塗液を塗布した無方向性電磁鋼板を用いて、外径：１００ｍｍφ、バックヨーク幅：２０ｍｍで、１２スロットのステータコア材を打抜加工し、次いで、上記ステータコア材のバックヨーク部に、図１に示したように、周方向に同心円状に２ｍｍ間隔で電子ビーム照射した。なお、電子ビーム照射は、電子ビーム加工機（ＭＩＴＳＵＢＩＳＨＩ製 ｅフラッシュ（登録商標））を用いて、加速電圧４０ｋＶ、ビーム電流５ｍＡ、ビーム径０．０７ｍｍの条件で鋼板表面に照射した。 Thickness: 0 comprising Si: 2.8 mass%, Al: 1.0 mass%, Mn: 1.0 mass%, S: 0.0018 mass%, N: 0.0019 mass%, O: 0.0015 mass%: 0 Using a non-oriented electrical steel sheet in which an organic / inorganic composite coating solution containing chromic acid and an acrylic resin is applied as an insulating coating on the surface of a 30 mm steel sheet, the outer diameter is 100 mmφ, the back yoke width is 20 mm, The stator core material of the slot was punched, and then the back yoke portion of the stator core material was irradiated with an electron beam at intervals of 2 mm concentrically in the circumferential direction as shown in FIG. Electron beam irradiation was performed on the surface of the steel sheet using an electron beam processing machine (eFlash (registered trademark) manufactured by MITSUBISHI) under the conditions of an acceleration voltage of 40 kV, a beam current of 5 mA, and a beam diameter of 0.07 mm.
次いで、上記ステータコア材を積み厚３０ｍｍに積層してステータコアを作製し、モータケースを模した非磁性のステンレス製リングに、焼き嵌め代を変化させて焼き嵌めし、周方向に０〜１００ＭＰａの圧縮応力を発生させた。なお、焼き嵌めにより発生する周方向の圧縮応力は、バックヨーク中央部に歪みゲージを貼り付けて測定した。ここで、焼き嵌め代が０μｍとは、ステータコアがリングにまったく固定されていないフリーな状態を意味している。 Next, the stator core material is laminated to a stack thickness of 30 mm, and a stator core is manufactured. The stator core material is shrink-fitted to a non-magnetic stainless steel ring imitating a motor case, with a shrinkage-fitting allowance being changed, and a compression of 0 to 100 MPa in the circumferential direction. Stress was generated. The circumferential compressive stress generated by shrink fitting was measured by attaching a strain gauge to the center of the back yoke. Here, the shrinkage allowance of 0 μm means a free state in which the stator core is not fixed to the ring at all.
次いで、上記ステンレス製リングに固定したステータコアに、図２のように、ステンレス製リングも含めてバックヨーク部の周囲に励磁コイルおよびピックアップコイルを巻き線し、モータコア円周方向の高周波鉄損（Ｗ１０／１ｋ）を測定した。図３は、上記測定の結果を、焼き嵌めによって発生したステータ周方向の圧縮応力と高周波鉄損との関係として示したものである。 Next, an excitation coil and a pickup coil are wound around the back yoke portion including the stainless steel ring on the stator core fixed to the stainless steel ring, as shown in FIG. 10 / 1k ) was measured. FIG. 3 shows the result of the above measurement as a relationship between the compressive stress in the circumferential direction of the stator generated by shrink fitting and the high-frequency iron loss.
図３から、焼き嵌めを行わない圧縮応力が０ＰＭａのモータコアでは、電子ビーム照射により鉄損は増加すること、しかし、電子ビーム照射をしないモータコアでは、圧縮応力が大きくなるのにともなって鉄損は急激に上昇するが、電子ビーム照射したモータコアでは、圧縮応力による鉄損の上昇が小さいこと、その結果、焼き嵌めによる圧縮応力が１０ＭＰａ以上発生しているモーコアでは、バックヨーク部に電子ビーム照射することによって、照射しない場合よりも圧縮応力による鉄損の増大を抑制できていることがわかる。 From FIG. 3, the iron loss increases due to electron beam irradiation in a motor core with 0 PMa compressive stress without shrink fitting. However, in a motor core without electron beam irradiation, iron loss increases as the compressive stress increases. The motor core irradiated with the electron beam has a small increase in iron loss due to the compressive stress, and as a result, the motor core in which the compressive stress due to shrink fitting is generated at 10 MPa or more irradiates the back yoke part with the electron beam. This shows that the increase in iron loss due to compressive stress can be suppressed more than when no irradiation is performed.
そこで、電子ビーム照射により鉄損が低下する原因を調査するため、焼き嵌めしたコアの鉄損分離を行ったところ、ヒステリシス損は電子ビーム照射により若干増加するが、渦電流損は、電子ビーム照射によって大きく低下していることが明らかとなった。電子ビーム照射により渦電流損が低下する原因は、まだ明確となっていないが、電子ビーム照射による熱歪により鋼板に引張応力が付与され、その結果、焼き嵌めによる圧縮応力が緩和されたためと考えられる。
なお、電子ビームは、レーザービームと比較して絶縁被膜の透過性が高い、即ち、絶縁被膜での発滅が少なく、主として地鉄部で発熱するため、絶縁被膜の損傷が少ないという利点がある。したがって、電子ビームを適用すると、絶縁被膜の再塗布を省略することができるので、生産性を向上することができる。
Therefore, in order to investigate the cause of the decrease in iron loss caused by electron beam irradiation, when the core loss of the shrink-fit core was separated, the hysteresis loss increased slightly by electron beam irradiation, but the eddy current loss increased by electron beam irradiation. It became clear that it was drastically reduced. The cause of the decrease in eddy current loss due to electron beam irradiation has not yet been clarified, but it is considered that tensile stress was applied to the steel sheet due to thermal strain due to electron beam irradiation, resulting in relaxation of compressive stress due to shrink fitting. It is done.
In addition, the electron beam has an advantage that the insulating film has high permeability compared to the laser beam, that is, the insulating film is less extinguished and heat is generated mainly in the ground iron portion, so that the insulating film is less damaged. . Therefore, when an electron beam is applied, re-application of the insulating film can be omitted, so that productivity can be improved.
また、焼き嵌めしない（圧縮応力０）コアで、電子ビーム照射により鉄損が増加した理由は、電子ビーム照射による熱歪によってヒステリシス損が増加したためと考えられる。したがって、焼き嵌め応力が発生していないティース部に電子ビーム照射することは、却って鉄損の上昇を招くことになるので、本発明では、電子ビーム照射は、圧縮応力が付与されるコアバック部のみに行うこととした。
本発明は、上記の知見に基づいて開発したものである。
In addition, the reason why the core loss increased by electron beam irradiation in a core that does not shrink fit (compression stress 0) is considered to be that the hysteresis loss increased due to thermal strain due to electron beam irradiation. Therefore, irradiating the teeth portion where no shrink-fit stress is generated with an electron beam causes an increase in iron loss. Therefore, in the present invention, the electron beam irradiation is performed with a core back portion to which a compressive stress is applied. I decided to do it only.
The present invention has been developed based on the above findings.
次に、本発明のモータコアに用いる電磁鋼板について説明する。まず、本発明のモータコアに用いる電磁鋼板は、下記の成分組成を有するものであることが好ましい。
Ｓｉ：７ｍａｓｓ％以下
Ｓｉは、鋼の固有抵抗を高めるのに有効な元素であるが、７ｍａｓｓ％を超えて添加すると、飽和磁束密度の低下に伴い、モータコアの磁束密度も低下するようになる。また、最終板厚に圧延する際、たとえ温間圧延しても板破断を起こすおそれがあるため、上限は７ｍａｓｓ％とするのが好ましい。なお、下限は特に制限しないが、固有抵抗を高める観点からは、０．１ｍａｓｓ％以上であることが好ましい。より好ましくは０．５〜６．５ｍａｓｓ％の範囲である。
Next, the electromagnetic steel sheet used for the motor core of the present invention will be described. First, the electrical steel sheet used for the motor core of the present invention preferably has the following component composition.
Si: 7 mass% or less Si is an element effective for increasing the specific resistance of steel. However, when added in excess of 7 mass%, the magnetic flux density of the motor core also decreases as the saturation magnetic flux density decreases. Further, when rolling to the final plate thickness, there is a possibility that the plate breaks even if it is warm-rolled, so the upper limit is preferably 7 mass%. In addition, although a minimum in particular is not restrict | limited, From a viewpoint of raising specific resistance, it is preferable that it is 0.1 mass% or more. More preferably, it is the range of 0.5-6.5 mass%.
Ａｌ：３ｍａｓｓ％以下
Ａｌは固有抵抗を高めるのに有効な元素であるが、３ｍａｓｓ％を超えると飽和磁束密度が低下するのに伴い、モータコアの磁束密度も低下するため、上限は３ｍａｓｓ％とするのが好ましい。より好ましくは２ｍａｓｓ％以下である。
Al: 3 mass% or less Al is an element effective for increasing the specific resistance. However, if it exceeds 3 mass%, the magnetic flux density of the motor core decreases as the saturation magnetic flux density decreases. Therefore, the upper limit is set to 3 mass%. Is preferred. More preferably, it is 2 mass% or less.
Ｍｎ：５ｍａｓｓ％以下
Ｍｎは、固有抵抗を高め、また、Ｓによる赤熱脆性を防止するために必要な元素であり、０．０５ｍａｓｓ％以上添加するのが好ましい。一方、５ｍａｓｓ％を超えて添加すると、飽和磁束密度が低下するため、上限は５ｍａｓｓ％とするのが好ましい。より好ましくは、０．１〜４ｍａｓｓ％の範囲である。
Mn: 5 mass% or less Mn is an element necessary for increasing specific resistance and preventing red heat embrittlement due to S, and it is preferably added in an amount of 0.05 mass% or more. On the other hand, if the addition exceeds 5 mass%, the saturation magnetic flux density decreases, so the upper limit is preferably 5 mass%. More preferably, it is the range of 0.1-4 mass%.
Ｓ：０．０１ｍａｓｓ％以下
Ｓは、不可避的に混入してくる不純物であり、その含有量が多くなると、ＭｎＳ等硫化物系介在物が多量に形成されて、鉄損が増加する原因となる。よって、本発明では、上限を０．０１ｍａｓｓ％とするのが好ましい。より好ましくは０．００５ｍａｓｓ％以下である。
S: 0.01 mass% or less S is an impurity that is inevitably mixed. When the content of S is increased, a large amount of sulfide inclusions such as MnS are formed, which causes an increase in iron loss. . Therefore, in the present invention, the upper limit is preferably set to 0.01 mass%. More preferably, it is 0.005 mass% or less.
Ｎ：０．００５ｍａｓｓ％以下
Ｎは、Ｓと同様、不可避的に混入してくる不純物であり、含有量が多いとＡｌＮが多量に形成されて、鉄損が増加する原因となるため、上限は０．００５ｍａｓｓ％とするのが好ましい。
N: 0.005 mass% or less N is an impurity that is inevitably mixed in as in S, and if the content is large, a large amount of AlN is formed and iron loss increases, so the upper limit is It is preferable to set it as 0.005 mass%.
Ｏ：０．０１ｍａｓｓ％以下
Ｏは、ＳやＮと同様、不可避的に混入してくる不純物であり、含有量が多いと酸化物系介在物が多量に形成されて、鉄損が増加する原因となるため、上限は０．０１ｍａｓｓ％とするのが好ましい。
O: 0.01 mass% or less O, like S and N, is an impurity that is inevitably mixed in. If the content is large, a large amount of oxide inclusions are formed, and the iron loss increases. Therefore, the upper limit is preferably set to 0.01 mass%.
本発明のモータコアに用いる電磁鋼板は、上記成分以外の残部はＦｅおよび不可避不純物である。ただし、本発明の効果を害さない範囲内であれば、上記以外の成分の含有を拒むものではない。 In the electrical steel sheet used for the motor core of the present invention, the balance other than the above components is Fe and inevitable impurities. However, as long as the effects of the present invention are not impaired, the inclusion of components other than those described above is not rejected.
また、本発明のモータコアに用いる電磁鋼板は、上記成分組成を有する鋼板表面に絶縁被膜を塗布したものであることが必要である。上記絶縁被膜としては、有機成分のみや無機成分のみ、有機・無機複合物などのものを用いることができる。具体的には、有機成分としては、アクリル系、アクリルシリコン系、ポリエステル系、エポキシ系、フッ素系の樹脂等が、無機成分としては、クロム酸塩系、重クロム酸塩系、ホウ酸塩系、リン酸塩系、珪酸塩系等が挙げられ、また、有機・無機複合物（半有機）としては、前述した有機成分と無機成分の複合物等が挙げられる。 Moreover, the electrical steel sheet used for the motor core of the present invention needs to have an insulating coating applied to the steel sheet surface having the above component composition. As the insulating film, only an organic component, an inorganic component, an organic / inorganic composite, or the like can be used. Specifically, the organic component includes acrylic, acrylic silicon, polyester, epoxy, and fluorine resins, and the inorganic component includes chromate, dichromate, and borate. , Phosphate-based, silicate-based, and the like, and examples of the organic / inorganic composite (semi-organic) include the composite of the organic component and the inorganic component described above.
また、本発明のモータコアは、上記電磁鋼板を所定のステータコア形状に打ち抜き加工した後、あるいは、打ち抜き加工の前に、バックヨーク部に電子ビーム照射を施したものであることが必要である。上記電子ビーム照射は、加速電圧３０〜１５０ｋＶ、ビーム電流１〜３０ｍＡの範囲で鋼板表面に照射するのが好ましい。加速電圧やビーム電流が上記範囲より低いと、所望の効果が得られないためであり、一方、加速電圧やビーム電流が上記範囲より高すぎる、歪量が大きくなり、所望の特性が得られなくなるためである。 In addition, the motor core of the present invention needs to be obtained by irradiating the back yoke portion with an electron beam after punching the electromagnetic steel sheet into a predetermined stator core shape or before punching. The electron beam irradiation is preferably performed on the surface of the steel plate in the range of an acceleration voltage of 30 to 150 kV and a beam current of 1 to 30 mA. This is because if the acceleration voltage or beam current is lower than the above range, the desired effect cannot be obtained. On the other hand, the acceleration voltage or beam current is too higher than the above range, the amount of distortion increases, and desired characteristics cannot be obtained. Because.
また、照射する電子ビームの径は、０．０２〜０．５ｍｍの範囲とするのが好ましい。０．０２ｍｍ未満では、引張応力を残留させるために必要な熱歪を付与することができず、一方、０．５ｍｍ超えでは、逆に、熱歪領域が広くなりすぎて、ヒステリシス損が上昇するからである。 The diameter of the electron beam to be irradiated is preferably in the range of 0.02 to 0.5 mm. If it is less than 0.02 mm, the thermal strain necessary to retain the tensile stress cannot be applied. On the other hand, if it exceeds 0.5 mm, the thermal strain region becomes too wide and the hysteresis loss increases. Because.
なお、電子ビーム照射する方向は、バックヨーク部の周方向、径方向のいずれでもよく、また、図４に示したように、間隔を開けて不連続に照射してもよい。
また、電子ビーム照射の間隔は、０．２〜５ｍｍの範囲とするのが好ましい。０．２ｍｍ未満では、電子ビーム照射による熱歪によって鋼板に大きな歪が導入され、鉄損が上昇したり、コア材が変形したりする。一方、５ｍｍを超えると、電子ビーム照射による鉄損低減効果が充分に得られなくなるためである。なお、径方向に照射する場合、内径側、外径側のいずれも０．２〜５ｍｍの間隔とするのが好ましい。また、電子ビーム照射は、連続した線状、あるいは点状あるいは破線状に間隔をおいて行ってもよく、その場合の照射方向の間隔は、０．０１〜１ｍｍ程度とするのが好ましい。
Note that the direction of electron beam irradiation may be either the circumferential direction or the radial direction of the back yoke portion, or may be irradiated discontinuously at intervals as shown in FIG.
The interval between the electron beam irradiations is preferably in the range of 0.2 to 5 mm. If the thickness is less than 0.2 mm, a large strain is introduced into the steel sheet due to thermal strain caused by electron beam irradiation, and iron loss increases or the core material is deformed. On the other hand, if the thickness exceeds 5 mm, the effect of reducing iron loss by electron beam irradiation cannot be obtained sufficiently. In addition, when irradiating to radial direction, it is preferable to set it as the space | interval of 0.2-5 mm on both an inner diameter side and an outer diameter side. Further, the electron beam irradiation may be performed in a continuous linear shape, a dotted shape, or a broken line shape, and the interval in the irradiation direction in that case is preferably about 0.01 to 1 mm.
また、本発明のモータコアは、電子ビーム照射後、電磁鋼板の表面に絶縁被膜を再度塗布することによってより確実に鉄損を低減することが可能となる。これは、電子ビーム照射の条件によっては絶縁被膜が局所的に破壊される場合があり、その部位で短絡を起こして積層間の層間抵抗が低下するのを防止するためである。電子ビーム照射後の絶縁被膜の塗布は、全面に行っても、電子ビーム照射部分だけでも構わない。また、上塗りする絶縁被膜は、層間抵抗を高めることができればよく、前述した被膜成分のいずれの種類でも構わない。 In addition, the motor core of the present invention can reduce the iron loss more reliably by re-applying the insulating coating on the surface of the electromagnetic steel sheet after the electron beam irradiation. This is because the insulating film may be locally broken depending on the electron beam irradiation conditions, and a short circuit is caused at that portion to prevent a decrease in interlayer resistance between layers. The insulating coating after the electron beam irradiation may be applied to the entire surface or only the electron beam irradiated portion. Moreover, the insulating film to be overcoated may be any kind of the above-described film components as long as the interlayer resistance can be increased.
また、本発明において、モータコアに発生した圧縮応力の値を１０ＭＰａ以上に制限する理由は、１０ＭＰａ未満ではモータコアを充分に固定することができないことのほか、図３に示したように、電子ビーム照射による鉄損低減効果が得られないからである。 Further, in the present invention, the reason why the value of the compressive stress generated in the motor core is limited to 10 MPa or more is that the motor core cannot be sufficiently fixed if it is less than 10 MPa, and as shown in FIG. This is because the iron loss reduction effect due to the above cannot be obtained.
なお、本発明のモータコアが適用できるモータは、モータコアに圧縮応力が付与されるものであれば、いずれの形式のものでもよく、例えば、集中巻形式の永久磁石モータ、分布巻き形式の永久磁石モータ、分割コアタイプの永久磁石モータ、誘導モータ、リラクタンスモータ等に適用することができる。 The motor to which the motor core of the present invention can be applied may be of any type as long as compressive stress is applied to the motor core. For example, a concentrated winding type permanent magnet motor or a distributed winding type permanent magnet motor. It can be applied to a split core type permanent magnet motor, an induction motor, a reluctance motor, and the like.
転炉−脱ガス処理等の通常公知の精錬プロセスで、表１に示す成分組成の鋼を溶製し、連続鋳造して鋼スラブとした。次いで、この鋼スラブを１１２０℃×１ｈｒの再加熱後、仕上圧延終了温度を８５０℃とする熱間圧延で板厚２．０ｍｍの熱延板とし、６００℃で巻き取った後、この熱延板を１０００℃×３０ｓｅｃで熱延板焼鈍し、酸洗し、冷間圧延して、板厚が０．３５ｍｍおよび０．２０ｍｍの冷延板とし、１０００℃×１０ｓｅｃの仕上焼鈍を施した後、表１に示した絶縁被膜を被成して、無方向性電磁鋼板を製造した。 Steel having the composition shown in Table 1 was melted and continuously cast into a steel slab by a generally known refining process such as converter-degassing. Next, this steel slab was reheated at 1120 ° C. × 1 hr, and hot rolled to a finish rolling finish temperature of 850 ° C. to obtain a hot rolled sheet having a thickness of 2.0 mm. After hot-rolled sheet annealing at 1000 ° C. × 30 sec, pickling, cold rolling to form cold-rolled sheets with sheet thicknesses of 0.35 mm and 0.20 mm, and finish annealing at 1000 ° C. × 10 sec A non-oriented electrical steel sheet was manufactured by applying the insulating coating shown in Table 1.
上記電磁鋼板について、以下の評価を行った。
＜磁束密度Ｂ５０の測定＞
上記電磁鋼板から、幅３０ｍｍ、長さ２８０ｍｍのエプスタイン試験片を圧延方向および圧延直角方向より採取し、ＪＩＳ Ｃ２５５０に準拠して、５０００Ａ／ｍで磁化したときの磁束密度Ｂ５０を測定した。
＜モータコアの鉄損測定＞
上記無方向性電磁鋼板を、図１と同じ１２スロットで、外径：１００ｍｍφ、バックヨーク幅：２０ｍｍのステータコア材に打抜加工した後、電子ビーム加工機（ＭＩＴＳＵＢＩＳＨＩ製 ｅフラッシュ（登録商標））を用いて、加速電圧４０ｋＶ、ビーム電流５ｍＡの条件で、照射方向を周方向または径方向とし、電子ビーム径および照射間隔を表１に示したよう変化させてステータコア材のバックヨーク部に電子ビーム照射した。なお、一部のステータコア材には、電子ビーム照射後、絶縁被膜の上に、さらに、電子ビーム照射前に塗布したものと同じ絶縁被膜を再塗布した。
次いで、電子ビーム照射したコア材を積み厚：３０ｍｍに積層し、ステータコアを作製し、このステータコアを、内径が約１００ｍｍφの非磁性ステンレスリングに、焼き嵌め代を変えて焼き嵌めし、ステータの周方向に０〜１００ＭＰａの圧縮応力を発生させた。なお、上記圧縮応力は、ステータのバックヨーク中央部に貼り付けた歪みゲージを用いて測定した。次いで、図２に示したように、ステンレス製リングも含めてバックヨーク部の周囲に励磁コイルおよびピックアップコイルを巻き線し、周波数１ｋＨｚ、最大磁束密度１Ｔにおけるモータコア円周方向の鉄損Ｗ１０／１ｋを測定した。
The following evaluation was performed on the electromagnetic steel sheet.
<Measurement of magnetic flux density B 50 >
From the magnetic steel sheet, an Epstein specimen having a width of 30 mm and a length of 280 mm was taken from the rolling direction and the direction perpendicular to the rolling direction, and the magnetic flux density B 50 when magnetized at 5000 A / m was measured according to JIS C2550.
<Motor core iron loss measurement>
The non-oriented electrical steel sheet is punched into a stator core material having an outer diameter of 100 mmφ and a back yoke width of 20 mm with the same 12 slots as in FIG. 1, and then an electron beam processing machine (eFlash (registered trademark) manufactured by MITSUBISHI) , The irradiation direction is set to the circumferential direction or the radial direction under the conditions of an acceleration voltage of 40 kV and a beam current of 5 mA, and the electron beam diameter and the irradiation interval are changed as shown in Table 1, and the electron beam is applied to the back yoke portion of the stator core material. Irradiated. A part of the stator core material was re-coated with the same insulating film as that applied before the electron beam irradiation on the insulating film after the electron beam irradiation.
Next, the core material irradiated with the electron beam is laminated to a stack thickness of 30 mm to produce a stator core, and this stator core is shrink-fitted to a nonmagnetic stainless steel ring having an inner diameter of about 100 mmφ while changing the shrink-fitting allowance. A compressive stress of 0 to 100 MPa was generated in the direction. The compressive stress was measured using a strain gauge attached to the center of the back yoke of the stator. Next, as shown in FIG. 2, an excitation coil and a pickup coil including the stainless steel ring are wound around the back yoke portion, and the iron loss W 10 / in the circumferential direction of the motor core at a frequency of 1 kHz and a maximum magnetic flux density of 1T. 1k was measured.
表１に、上記測定の結果を併記して示した。この結果から、本発明に適合する電子ビーム照射したステータコアは、圧縮応力下における鉄損特性の劣化を抑制できることが確認された。 Table 1 also shows the results of the above measurements. From this result, it was confirmed that the stator core irradiated with the electron beam suitable for the present invention can suppress the deterioration of the iron loss characteristic under the compressive stress.
本発明のモータコア技術は、ハイブリッド電気自動車の駆動モータや発電機、エアコンのコンプレッサ用モータ、工作機械の主軸モータ等、焼き嵌めして固定される高速モータに適用することができる。 The motor core technology of the present invention can be applied to high-speed motors that are fixed by shrinkage fitting, such as drive motors and generators for hybrid electric vehicles, compressor motors for air conditioners, and spindle motors for machine tools.
１：ステータコア
２：電子ビーム照射位置
３：ロータ
４：永久磁石
５：ステンレス製リング（非磁性）
６：巻き線
1: Stator core 2: Electron beam irradiation position 3: Rotor 4: Permanent magnet 5: Stainless steel ring (non-magnetic)
6: Winding
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| CN104603309B (en) * | 2012-08-30 | 2017-10-31 | 杰富意钢铁株式会社 | Iron core grain-oriented magnetic steel sheet and its manufacture method |
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| JPS6028130B2 (en) * | 1979-10-19 | 1985-07-03 | 新日本製鐵株式会社 | Method for improving iron loss in three-phase transformer core |
| JPH066745B2 (en) * | 1985-12-26 | 1994-01-26 | 川崎製鉄株式会社 | Iron loss improvement method for grain-oriented silicon steel sheet |
| JP2003217939A (en) * | 2002-01-18 | 2003-07-31 | Nippon Steel Corp | Iron core for electric apparatus |
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