WO2022054149A1 - 回転子、電動機、送風機及び空気調和装置 - Google Patents
回転子、電動機、送風機及び空気調和装置 Download PDFInfo
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- WO2022054149A1 WO2022054149A1 PCT/JP2020/034033 JP2020034033W WO2022054149A1 WO 2022054149 A1 WO2022054149 A1 WO 2022054149A1 JP 2020034033 W JP2020034033 W JP 2020034033W WO 2022054149 A1 WO2022054149 A1 WO 2022054149A1
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- Prior art keywords
- magnet
- rotor
- rare earth
- width
- ferrite
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- 238000004378 air conditioning Methods 0.000 title 1
- 229910000859 α-Fe Inorganic materials 0.000 claims description 219
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 212
- 229920005989 resin Polymers 0.000 claims description 35
- 239000011347 resin Substances 0.000 claims description 35
- 230000004323 axial length Effects 0.000 claims description 16
- 150000002910 rare earth metals Chemical class 0.000 description 117
- 230000004907 flux Effects 0.000 description 69
- 230000000052 comparative effect Effects 0.000 description 39
- 238000004519 manufacturing process Methods 0.000 description 15
- 238000000465 moulding Methods 0.000 description 12
- 230000004048 modification Effects 0.000 description 10
- 238000012986 modification Methods 0.000 description 10
- 230000008859 change Effects 0.000 description 7
- 230000002093 peripheral effect Effects 0.000 description 6
- 239000002994 raw material Substances 0.000 description 6
- 230000000694 effects Effects 0.000 description 5
- 238000001746 injection moulding Methods 0.000 description 5
- 230000008602 contraction Effects 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- 239000004734 Polyphenylene sulfide Substances 0.000 description 3
- 229920000069 polyphenylene sulfide Polymers 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 2
- 102100029860 Suppressor of tumorigenicity 20 protein Human genes 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 229920006337 unsaturated polyester resin Polymers 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 102100035353 Cyclin-dependent kinase 2-associated protein 1 Human genes 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 229910052772 Samarium Inorganic materials 0.000 description 1
- PRQMIVBGRIUJHV-UHFFFAOYSA-N [N].[Fe].[Sm] Chemical compound [N].[Fe].[Sm] PRQMIVBGRIUJHV-UHFFFAOYSA-N 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 229910001172 neodymium magnet Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 239000003507 refrigerant Substances 0.000 description 1
- KZUNJOHGWZRPMI-UHFFFAOYSA-N samarium atom Chemical compound [Sm] KZUNJOHGWZRPMI-UHFFFAOYSA-N 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
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Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
- H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
- H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
- H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
- H02K1/278—Surface mounted magnets; Inset magnets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
- H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
- H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/02—Details of the magnetic circuit characterised by the magnetic material
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
- H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
- H02K1/2726—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of a single magnet or two or more axially juxtaposed single magnets
- H02K1/2733—Annular magnets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/14—Stator cores with salient poles
- H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
- H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
Definitions
- This disclosure relates to rotors, motors, blowers and air conditioners.
- the rotor described in Patent Documents 1 and 2 has a first permanent magnet supported by a rotating shaft and a second permanent magnet supported by the outer periphery of the first permanent magnet and having a stronger magnetic pole than the magnetic pole of the first permanent magnet. It has two permanent magnets.
- the second permanent magnet forms the outer circumference of the rotor. This makes it possible to increase the amount of magnetic flux flowing from the rotor to the stator of the motor.
- the object of the present disclosure is to sufficiently secure the amount of magnetic flux generated in the rotor while reducing the manufacturing cost of the rotor.
- the rotor according to one aspect of the present disclosure is supported by a rotating shaft, a first permanent magnet supported by the rotating shaft, and an outer periphery of the first permanent magnet, and is supported by a magnetic pole of the first permanent magnet. It has a second permanent magnet having a strong magnetic pole, and the second permanent magnet has a plurality of magnet portions arranged at intervals in the circumferential direction of the first permanent magnet, and the rotating shaft.
- the first width which is the circumferential width of each magnet portion of the plurality of magnet portions in the central portion of the first permanent magnet in the axial direction, is the end portion of the first permanent magnet in the axial direction. It is wider than the second width which is the width in the circumferential direction of each of the magnet portions in the above.
- FIG. It is a top view which shows the structure of the electric motor which concerns on Embodiment 1.
- FIG. It is a side view which shows the structure of the rotor and a part of the structure of a stator shown in FIG. 1.
- FIG. (A) is a side view showing the structure of the rotor according to Comparative Example 2.
- (B) is a cross-sectional view showing the structure of the rotor according to Comparative Example 2.
- each figure shows an xyz Cartesian coordinate system as necessary.
- the z-axis is a coordinate axis parallel to the rotor axis C1.
- the x-axis is a coordinate axis orthogonal to the z-axis.
- the y-axis is an axis orthogonal to both the x-axis and the z-axis.
- FIG. 1 is a plan view showing the configuration of the electric motor 100 according to the first embodiment.
- the motor 100 is, for example, a permanent magnet synchronous motor.
- the electric motor 100 has a rotor 1 and a stator 9.
- the rotor 1 is arranged inside the stator 9. That is, the electric motor 100 is an inner rotor type electric motor.
- An air gap G is formed between the rotor 1 and the stator 9.
- the air gap G is, for example, a gap of 0.5 mm.
- the rotor 1 has a shaft 10 as a rotation axis.
- the shaft 10 extends in the z-axis direction.
- the z-axis direction is also referred to as "axial direction”.
- the direction along the circumference of the circle centered on the axis C1 of the shaft 10 is the "circumferential direction", and the direction of the straight line perpendicular to the z-axis direction and passing through the axis C1. Is called “diametrically”.
- Other configurations of the rotor 1 will be described later.
- the stator 9 has a stator core 91 and a coil 92 wound around the stator core 91.
- the stator core 91 has an annular yoke 91a centered on the axis C1 and a plurality of teeth 91b extending radially inward from the yoke 91a.
- the plurality of teeth 91b are arranged at equal intervals in the circumferential direction R1.
- the radial inner tip of the teeth 91b faces the outer circumference 1a of the rotor 1 via the air gap G.
- the number of teeth 91b is 12, but the number is not limited to 12, and any number may be set.
- FIG. 2 is a side view showing a part of the configuration of the rotor 1 and the configuration of the stator 9 according to the first embodiment.
- FIG. 3 is a plan view showing the configuration of the rotor 1 shown in FIG. As shown in FIGS. 2 and 3, the rotor 1 has a shaft 10, a ferrite bond magnet 20 as a first permanent magnet, and a rare earth bond magnet 30 as a second permanent magnet.
- the axial length L1 of the rotor 1 is longer than the axial length L9 of the stator core 91 of the stator 9.
- the amount of magnetic flux of the interlinkage magnetic flux flowing from the permanent magnet of the rotor 1 that is, the ferrite bond magnet 20 and the rare earth bond magnet 30
- the coil 92 of the stator 9 can be increased.
- the ferrite bond magnet 20 is supported by the shaft 10.
- the ferrite bond magnet 20 includes a ferrite magnet and a resin.
- the resin contained in the ferrite bond magnet 20 is, for example, a nylon resin, a PPS (Polyphenylene sulfide) resin, an epoxy resin, or the like.
- the rare earth bond magnet 30 is supported by the outer circumference 20a of the ferrite bond magnet 20.
- the rare earth bond magnet 30 includes a rare earth magnet and a resin.
- the rare earth magnet is, for example, a neodymium magnet containing neodymium (Nd), iron (Fe) and boron (B), or a samarium iron-nitrogen magnet containing samarium (Sm), Fe and nitrogen (N).
- the resin contained in the rare earth bond magnet 30 is, for example, a nylon resin, a PPS resin, an epoxy resin, or the like, similarly to the resin contained in the ferrite bond magnet 20.
- the ferrite bond magnet 20 and the rare earth bond magnet 30 have different magnetic pole strengths (that is, magnetic charges) from each other. Specifically, the rare earth bond magnet 30 has a magnetic pole stronger than that of the ferrite bond magnet 20. In other words, the magnetic force of the rare earth bond magnet 30 is larger than the magnetic force of the ferrite bond magnet 20. Further, the ferrite bond magnet 20 and the rare earth bond magnet 30 have different linear expansion coefficients from each other.
- FIG. 4 is a plan view showing the configuration of the ferrite bond magnet 20 shown in FIG.
- the planar shape of the ferrite bond magnet 20 parallel to the xy plane is an annular shape centered on the axis C1.
- the outer circumference 20a of the ferrite bond magnet 20 forms a part of the outer circumference 1a (see FIG. 1) of the rotor 1.
- the ferrite bond magnet 20 has a plurality of groove portions 21 arranged at intervals in the circumferential direction R1 with the axis C1 as the center.
- the plurality of groove portions 21 are arranged at equiangular positions in the circumferential direction R1 with the axis C1 as the center.
- the groove 21 is recessed from the outer circumference 20a of the ferrite bond magnet 20 toward the inner circumference 20b.
- the groove portion 21 is a long groove that is long in the axial direction.
- the ferrite bond magnet 20 is oriented so as to have polar anisotropy.
- the plurality of groove portions 21 have an S-pole groove portion 21a and an N-pole groove portion 21b. That is, the plurality of groove portions 21a and 21b adjacent to the circumferential direction R1 have magnetic poles having different polarities from each other.
- the arcuate arrow F2 shown in FIG. 4 indicates the direction of the magnetic flux in the ferrite bond magnet 20.
- the magnetic flux flowing from the radial outside of the groove portion 21a of the S pole advances to the groove portion 21b of the N pole adjacent to the circumferential direction R1. Therefore, the rotor 1 (see FIG. 2) does not require a rotor core forming a magnetic path inside the ferrite bond magnet 20 in the radial direction. As a result, the number of parts in the rotor 1 can be reduced, and the weight of the rotor 1 can be reduced.
- the ferrite bond magnet 20 is supported by the shaft 10 via the resin portion 60.
- the resin portion 60 is formed of, for example, an unsaturated polyester resin.
- the resin portion 60 has an inner cylinder portion 61, an outer cylinder portion 62, and a plurality of (four in the first embodiment) ribs 63.
- the inner cylinder portion 61 has a cylindrical shape and is fixed to the outer peripheral portion 10a of the shaft 10.
- the outer cylinder portion 62 has a cylindrical shape and is fixed to the inner circumference 20b of the ferrite bond magnet 20.
- the plurality of ribs 63 connect the inner cylinder portion 61 and the outer cylinder portion 62.
- the plurality of ribs 63 extend radially outward from the inner cylinder portion 61.
- the plurality of ribs 63 are arranged at equiangular positions in the circumferential direction R1 with the axis C1 as the center.
- the ferrite bond magnet 20 may be directly fixed to the shaft 10 without passing through the resin portion 60.
- the rare earth bond magnet 30 has a plurality of rare earth magnet portions 31 as a plurality of magnet portions arranged at intervals in the circumferential direction R1.
- the outer circumference 31a of each of the plurality of rare earth magnet portions 31 forms a part of the outer circumference 1a (see FIG. 1) of the rotor 1.
- the outer circumference 31a and the inner circumference 31b of the rare earth magnet portion 31 are located on concentric circles. That is, the radial thickness of the rare earth magnet portion 31 is constant in the circumferential direction R1.
- Each of the plurality of rare earth magnet portions 31 is oriented so as to have polar anisotropy.
- the plurality of rare earth magnet portions 31 adjacent to the circumferential direction R1 have magnetic poles having different polarities from each other.
- the arcuate arrow F3 shown in FIG. 3 indicates the direction of the magnetic flux in the rare earth magnet portion 31.
- the magnetic flux flowing from the radial outside of the rare earth magnet portion 31 of the S pole advances to the rare earth magnet portion 31 of the N pole adjacent to the circumferential direction R1.
- the rotor 1 has eight magnetic poles.
- the number of poles of the rotor 1 is not limited to eight, and may be 2n or more. n is a natural number of 1 or more.
- the rare earth magnet portion 31 is arranged in the groove portion 21 (see FIG. 4) of the ferrite bond magnet 20.
- the ferrite bond magnet 20 and the rare earth magnet portion 31 are joined to each other.
- the ferrite bond magnet 20 and the rare earth bond magnet 30 are integrally molded (also referred to as “two-color molding”), so that the rare earth magnet portion 31 is joined to the groove portion 21 of the ferrite bond magnet 20.
- the integral molding of the ferrite bond magnet 20 and the rare earth bond magnet 30 means molding the rare earth bond magnet 30 in a state where the previously manufactured ferrite bond magnet 20 is arranged in a mold. ..
- a plurality of rare earth bond magnets 30 are compared with the configuration in which the ferrite bond magnet 20 is molded in a state where the rare earth bond magnets 30 (that is, a plurality of rare earth magnet portions 31) are arranged in the mold. Since the work of arranging the rare earth magnet portion 31 in the mold becomes unnecessary, the productivity of the rotor main body 50 can be improved.
- the central portion 20c of the ferrite bond magnet 20 in the axial direction faces the stator core 91 in the radial direction. Further, the width of each rare earth magnet portion 31 of the plurality of rare earth magnet portions 31 in the circumferential direction gradually increases from the end portion 20d of the ferrite bond magnet 20 in the axial direction toward the central portion 20c.
- the width of the circumferential direction R1 of each rare earth magnet portion 31 of the plurality of rare earth magnet portions 31 in the central portion 20c of the axial ferrite bond magnet 20 is the width W1 of the first width, and the width of each of the end portions 20d of the axial ferrite bond magnet 20.
- the width of the rare earth magnet portion 31 in the circumferential direction is the second width W2
- the first width W1 is wider than the second width W2. That is, the first width W1 and the second width W2 satisfy the following equation (1).
- the magnetic pole of the rare earth magnet portion 31 at the central portion 20c of the ferrite bond magnet 20 facing the stator core 91 in the radial direction is stronger than the magnetic pole of the rare earth magnet portion 31 at the axial end portion 20d of the ferrite bond magnet 20. Become. Therefore, it is possible to sufficiently secure the amount of magnetic flux of the magnetic flux generated in the rotor 1.
- the axial end portion of the rotor 1 (that is, the end shown in FIG. 5 described later).
- Leakage magnetic flux may be included in the magnetic flux flowing from the part 1d) to the stator 9.
- the first width W1 is wider than the second width W2
- the magnetic pole of the rare earth magnet portion 31 in the central portion 20c of the ferrite bond magnet 20 in the axial direction is axial. It becomes stronger than the magnetic pole of the rare earth magnet portion 31 at the end portion 20d of the ferrite bond magnet 20. Therefore, it is possible to sufficiently secure the amount of magnetic flux of the magnetic flux flowing from the rotor 1 to the stator 9.
- FIG. 5 is a cross-sectional view showing the configuration of the rotor 1 according to the first embodiment.
- the ferrite bond magnet 20 has a first ferrite magnet portion 41 as a first split magnet portion and a second ferrite magnet portion 42 as a second split magnet portion.
- the first ferrite magnet portion 41 and the second ferrite magnet portion 42 are arranged in the axial direction. That is, in the first embodiment, the ferrite bond magnet 20 is divided into two magnet portions at the central portion 20c in the axial direction. In the axial direction, the first ferrite magnet portion 41 and the second ferrite magnet portion 42 are in contact with each other.
- the shaft 10 (see FIG. 2) is not shown.
- FIG. 6 is a cross-sectional view showing the ferrite bond magnet 20 shown in FIG. 5 cut along the A6-A6 line.
- the A6-A6 line shown in FIG. 5 is a straight line passing through the central portion 20c (see FIG. 2) of the ferrite bond magnet 20 in the axial direction. That is, FIG. 6 is a cross-sectional view showing the configuration of the central portion 20c of the ferrite bond magnet 20 in the axial direction.
- the width of the circumferential direction R1 of the groove portion 21 in the axial central portion 20c of the ferrite bond magnet 20 is the width W21, and the circumference of the groove portion 21 at the axial end portion 20d of the ferrite bond magnet 20.
- the width W21 is wider than the width W22. That is, the width W21 and the width W22 satisfy the following equation (2). W21> W22 (2)
- the width W21 is equal to the first width W1 shown in FIG. 2
- the width W22 is equal to the second width W2 shown in FIG. That is, the shape of the groove portion 21 of the ferrite bond magnet 20 corresponds to the shape of the rare earth magnet portion 31.
- FIG. 7 is a flowchart showing the manufacturing process of the rotor 1.
- a magnetizer is used in the manufacturing process of the rotor 1.
- step ST1 the rotor body 50 is formed.
- the details of step ST1 will be described later.
- step ST2 the rotor body 50 is connected to the shaft 10.
- the rotor body 50 and the shaft 10 are integrated via the resin portion 60, so that the rotor body 50 is connected to the shaft 10.
- a magnetizer is used to magnetize the rotor body 50. Specifically, the ferrite bond magnet 20 and the rare earth bond magnet 30 are magnetized so that the ferrite bond magnet 20 and the rare earth bond magnet 30 have polar anisotropy.
- FIG. 8 is a flowchart showing a process of forming the rotor main body 50.
- a first mold for molding the first ferrite magnet portion 41 and the second ferrite magnet portion 42 and a second mold for molding the rare earth bond magnet 30 are formed.
- a mold and a magnet for orientation are used.
- step ST11 the raw materials of the first ferrite magnet portion 41 and the second ferrite magnet portion 42 are placed inside the first mold for molding the first ferrite magnet portion 41 and the second ferrite magnet portion 42.
- the first ferrite magnet portion 41 and the second ferrite magnet portion 42 are molded, for example, by injection molding.
- the first ferrite magnet portion 41 and the second ferrite magnet portion 42 may be molded not only by injection molding but also by other molding methods such as pressure molding.
- step ST12 while orienting the raw materials of the first ferrite magnet portion 41 and the second ferrite magnet portion 42, the first ferrite magnet portion 41 and the second ferrite magnet portion 42 having a predetermined shape are formed. do.
- step ST12 for example, the first ferrite magnet portion 41 and the second ferrite magnet portion are generated in a state where a magnetic field having polar anisotropy is generated inside the first mold by using an orientation magnet.
- the first ferrite magnet portion 41 and the second ferrite magnet portion 42 are molded.
- the ferrite bond magnet 20 having polar anisotropy is formed.
- step ST12 the end face 41a of the first ferrite magnet portion 41 and the end face 42a of the second ferrite magnet portion 42 are formed so as to face the + z axis direction.
- step ST13 the molded first ferrite magnet portion 41 and the second ferrite magnet portion 42 are cooled.
- step ST14 the first ferrite magnet portion 41 and the second ferrite magnet portion 42 are taken out from the first mold.
- step ST15 the first ferrite magnet portion 41 and the second ferrite magnet portion 42 taken out in step ST14 are demagnetized.
- step ST16 the first ferrite magnet portion 41 and the second ferrite magnet portion 42 are arranged inside the second mold for injection molding the rare earth bond magnet 30.
- step S16 the first ferrite magnet portion 41 and the second ferrite magnet portion are in contact with each other so that the axial end surface 41a of the first ferrite magnet portion 41 and the axial end surface 42a of the second ferrite magnet portion 42 are in contact with each other.
- 42 is arranged inside the second mold. That is, in step ST16, by reversing the first ferrite magnet portion 41 formed in step ST12 in the axial direction, the end face 41a of the first ferrite magnet portion 41 becomes the end face 42a of the second ferrite magnet portion 42. It is stuck to.
- the first ferrite magnet portion 41 And the second ferrite magnet portion 42 can be easily positioned.
- the groove portion 21 of the ferrite bond magnet 20 arranged in the second mold is filled with the raw material of the rare earth bond magnet 30.
- the rare earth bond magnet 30 is molded, for example, by injection molding.
- the rare earth bond magnet 30 is not limited to injection molding and may be molded by another molding method such as pressure molding.
- step ST18 the rare earth bond magnet 30 having a predetermined shape is formed while orienting the raw material of the rare earth bond magnet 30.
- step ST18 for example, using a magnet for orientation, the raw material of the rare earth bond magnet 30 is oriented while a magnetic field having polar anisotropy is generated inside the second mold, and the rare earth bond magnet is used.
- 30 that is, a plurality of rare earth magnet portions 31
- the rotor body 50 in which the ferrite bond magnet 20 and the rare earth bond magnet 30 are integrally molded is formed.
- step ST19 the rotor body 50 formed in step ST18 is cooled.
- step ST20 the cooled rotor body 50 is taken out from the second mold.
- step ST21 the rotor body 50 taken out in step ST20 is demagnetized.
- FIG. 9 is a plan view showing the configuration of the rotor 101a according to Comparative Example 1. In FIG. 9, the shaft 10 is not shown.
- an annular rare earth bond magnet 130a is arranged on the outer circumference 120c of the annular ferrite bond magnet 120a. That is, in the rotor 101a according to Comparative Example 1, the entire outer circumference 101c of the rotor 101a is formed by the rare earth bond magnet 130a.
- the outer circumference 1a of the rotor 1 is the outer circumference 20a of the ferrite bond magnet 20 and the plurality of rare earth magnet portions 31 of the rare earth bond magnet 30. It is formed by the outer circumference 31a of.
- the amount of the rare earth bond magnet 30 used can be reduced as compared with the rotor 101a according to the comparative example 1.
- the amount of the rare earth bond magnet 30 used can be reduced by about 20% as compared with the rotor 101a according to the comparative example 1.
- the rare earth bond magnet 30 is more expensive than the ferrite bond magnet 20.
- the material unit price of the rare earth bond magnet 30 is 10 times or more the material unit price of the ferrite bond magnet 20. Therefore, since the outer circumference 1a of the rotor 1 is formed by the outer circumference 20a of the ferrite bond magnet 20 and the outer circumference 31a of each of the plurality of rare earth magnet portions 31, the amount of the rare earth bond magnet 30 used can be reduced. .. Therefore, the manufacturing cost of the rotor 1 according to the first embodiment can be reduced.
- FIG. 10A is a side view showing the configuration of the rotor 101b according to Comparative Example 2.
- FIG. 10B is a cross-sectional view showing the configuration of the rotor 101b according to Comparative Example 2.
- the shaft 10 is not shown.
- the rotor 101b has a ferrite bond magnet 120b and a rare earth bond magnet 130b.
- the rare earth bond magnet 130b has a plurality of rare earth magnet portions 131b arranged at intervals in the circumferential direction R1. Therefore, the amount of the rare earth bond magnet 130b used in the rotor 101b according to Comparative Example 2 is the same as the amount of the rare earth bond magnet 30 used in the rotor 1 according to the first embodiment, and the rotor 1 according to Comparative Example 1 is used. It is different from the amount of the rare earth bond magnet 130a used in the above.
- the width W10 in the circumferential direction R1 of the rare earth magnet portion 131b is constant in the axial direction. Therefore, the rotor 101b according to Comparative Example 2 is different from the rotor 1 according to the first embodiment and the rotor 101a according to Comparative Example 1 in the shape of the rare earth magnet portion 131b. Further, in the rotor 101b according to Comparative Example 2, the ferrite bond magnet 120b is not divided in the axial direction. Therefore, the rotor 101b according to Comparative Example 2 is different from the rotor 1 according to the first embodiment in the shape of the ferrite bond magnet 120b.
- FIG. 11 is a graph showing the distribution of the surface magnetic flux density of the rotor 101a according to Comparative Example 1 and the distribution of the surface magnetic flux density of the rotor 101b according to Comparative Example 2.
- the horizontal axis indicates the position [degree] in the circumferential direction R1 on the outer peripheral 101c of the rotor 101a or the outer peripheral 101d of the rotor 101b
- the vertical axis represents the surface magnetic flux density [a. u. ] Is shown.
- the solid line shows the distribution of the surface magnetic flux density of the rotor 101a according to Comparative Example 1
- the broken line shows the distribution of the surface magnetic flux density of the rotor 101b according to Comparative Example 2.
- the distribution of the surface magnetic flux density of the rotor 101a according to Comparative Example 1 is represented by the uniform sine wave waveform S1.
- the distribution of the surface magnetic flux density of the rotor 101b according to Comparative Example 2 is also represented by a substantially uniform sine wave waveform S2. That is, as compared with the rotor 101a according to Comparative Example 1, the rotor 101b according to Comparative Example 2 suppresses a sudden change in the surface magnetic flux density in the circumferential direction R1.
- FIG. 12 is a graph showing the distribution of the surface magnetic flux density of the rotor 1 according to the first embodiment and the distribution of the surface magnetic flux density of the rotor 101a according to Comparative Example 1.
- the horizontal axis indicates the position [degree] of the circumferential direction R1 on the outer circumference 1a of the rotor 1 or the outer circumference 101c of the rotor 101a
- the vertical axis represents the surface magnetic flux density [a. u. ] Is shown.
- the solid line shows the distribution of the surface magnetic flux density in the central portion 1c of the rotor 1 in the axial direction according to the first embodiment, and the alternate long and short dash line is the axial end of the rotor 1 according to the first embodiment.
- the distribution of the surface magnetic flux density in the part 1d is shown.
- the broken line indicates the distribution of the surface magnetic flux density of the rotor 101a according to Comparative Example 1.
- the distribution of the surface magnetic flux density of the rotor 101a according to Comparative Example 1 is represented by the waveform S1 of a uniform sine wave.
- the distribution of the surface magnetic flux density at the axial end 1d of the rotor 1 according to the first embodiment is also represented by a substantially uniform sine wave waveform S11. That is, at the axial end 1d of the rotor 1 according to the first embodiment, a sudden change in the surface magnetic flux density is suppressed in the circumferential direction R1. This is because the second width W2 (see FIG.
- the second width W2 of the rare earth magnet portion 31 at the central portion 20c of the ferrite bond magnet 20 in the axial direction is the second width W2 of the rare earth magnet portion 31 at the central portion 20c of the ferrite bond magnet 20 in the axial direction. This is because the width W1 (see FIG. 2) of 1 is narrower, and the amount of the ferrite bond magnet 20 used at the axial end portion 20d is larger than the amount of the ferrite bond magnet 20 used at the axial central portion 20c.
- the distribution of the surface magnetic flux density in the central portion 1c of the rotor 1 according to the first embodiment is represented by the waveform S12 of a substantially sinusoidal wave.
- the magnetic flux density equivalent to that of the rotor 101a according to Comparative Example 1 can be obtained at the magnetic pole center portion (N pole or S pole), but the interpole portion (N pole and S). (Between the poles), a magnetic flux density slightly inferior to that of the rotor 101a according to Comparative Example 1 can be obtained. This is because in the rare earth magnet portion 31 shown in FIG.
- the first width W1 is wider than the second width W2, and the amount of the ferrite bond magnet 20 used in the central portion 20c in the axial direction is the ferrite bond at the end portion 20d. This is because the amount used is less than that of the magnet 20.
- the rotor 1 according to the first embodiment is provided with a plurality of rare earth magnet portions 31, it is possible to compensate for the decrease in the magnetic flux density in the interpolar portion of the central portion 1c. As a result, the rotor 1 according to the first embodiment can obtain an induced voltage equivalent to that of the rotor 101a according to the comparative example 1.
- the rare earth bond magnet 30 has a plurality of rare earth magnet portions 31 arranged at intervals in the circumferential direction R1.
- the rare earth bond magnet 30 is more expensive than the ferrite bond magnet 20.
- the rare earth bond magnet 30 has a plurality of rare earth magnet portions 31 arranged at intervals in the circumferential direction R1, so that the amount of the rare earth bond magnet 30 used is reduced. Therefore, the manufacturing cost of the rotor 1 can be reduced.
- the first width W1 which is the circumferential width of each rare earth magnet portion 31 of the plurality of rare earth magnet portions 31 in the central portion 20c of the ferrite bond magnet 20 in the axial direction is the axial direction.
- the width is wider than the second width W2, which is the width in the circumferential direction of each rare earth magnet portion 31 at the end portion 20d of the ferrite bond magnet 20.
- the permanent magnet of the rotor 1 (that is, the ferrite bond magnet). 20 and the rare earth bond magnet 30) can increase the amount of magnetic flux of the interlinkage magnetic flux flowing from the coil 92 of the stator 9.
- a part of the magnetic flux flowing from the axial end 1d of the rotor 1 that does not face the stator core 91 in the radial direction to the coil 92 may become a leakage flux. In this case, it is not possible to sufficiently secure the amount of magnetic flux of the magnetic flux flowing from the rotor 1 to the stator 9.
- the first width W1 of the rare earth magnet portion 31 is wider than the second width W2.
- the magnetic pole of the rare earth magnet portion 31 in the central portion 20c of the ferrite bond magnet 20 in the axial direction becomes stronger than the magnetic pole of the rare earth magnet portion 31 in the end portion 20d of the ferrite bond magnet 20 in the axial direction. Therefore, it is possible to sufficiently secure the amount of magnetic flux of the magnetic flux flowing from the rotor 1 to the stator 9.
- the rare earth bond magnet 30 has a plurality of rare earth magnet portions 31 arranged at intervals in the circumferential direction R1, so that the surface magnetic flux density of the rotor 1 is abruptly changed. Since it is suppressed, the rotor 1 can obtain an induced voltage equivalent to that of the rotor 101a according to Comparative Example 1. Therefore, the rotor 1 according to the first embodiment can obtain the same rotation control accuracy as the rotor 101a according to the comparative example 1.
- the ferrite bond magnet 20 supported by the shaft 10 has polar anisotropy. As a result, it is not necessary to arrange the rotor core constituting the magnetic path inside the ferrite bond magnet 20 in the radial direction, so that the number of parts in the rotor 1 can be reduced and the weight of the rotor 1 can be reduced. Can be done.
- the ferrite bond magnet 20 has a first ferrite magnet portion 41 and a second ferrite magnet portion 42 arranged in the axial direction.
- the width W21 of the circumferential direction R1 in the central portion 20c in the axial direction is at the end portion 20d in the axial direction.
- the mold structure becomes complicated. Therefore, the equipment for molding the ferrite bond magnet 20 becomes expensive.
- the ferrite bond magnet 20 has a first ferrite magnet portion 41 and a second ferrite magnet portion 42 divided by a central portion 20c in the axial direction. This eliminates the need for a mold for integrally molding the groove portion 21, so that the productivity of the ferrite bond magnet 20 can be increased.
- FIG. 13 is a side view showing the configuration of the rotor 2 according to the second embodiment.
- the same or corresponding components as in FIG. 2 are designated by the same reference numerals as those in FIG.
- the rotor 2 according to the second embodiment is different from the rotor 1 according to the first embodiment in the shape of the rare earth magnet portion 231.
- the rotor 2 according to the second embodiment is the same as the rotor 1 according to the first embodiment. Therefore, in the following description, FIG. 2 will be referred to. Note that, in FIG. 13, the shaft 10 (see FIG. 2) is not shown.
- the rotor 2 has a ferrite bond magnet 20 and a rare earth bond magnet 230.
- the rare earth bond magnet 230 has a plurality of rare earth magnet portions 231 arranged at intervals in the circumferential direction R1.
- the first width W1 which is the width of the circumferential direction R1 of each rare earth magnet portion 231 in the central portion 20c of the ferrite bond magnet 20 in the axial direction, is the width W1 of each rare earth magnet portion 231 in the end portion 20d of the ferrite bond magnet 20 in the axial direction. It is wider than the second width W2, which is the width of the circumferential direction R1.
- the magnetic pole of the rare earth magnet portion 231 at the central portion 20c of the ferrite bond magnet 20 becomes stronger than the magnetic pole of the rare earth magnet portion 231 at the end portion 20d of the ferrite bond magnet 20. Therefore, it is possible to sufficiently secure the amount of magnetic flux of the magnetic flux flowing from the rotor 2 to the stator 9.
- the rare earth magnet portion 231 has a first portion 231a and a plurality of second portions 231b and 231c connected to the first portion 231a axially outside the first portion 231a.
- the first portion 231a is a wide portion having a first width W1 in the rare earth magnet portion 231.
- the width of the first portion 231a in the circumferential direction is constant in the axial direction. That is, in the second embodiment, the width of the first portion 231a in the circumferential direction R1 (that is, the first width W1) is constant in the axial direction.
- each of the plurality of second portions 231b and 231c in the circumferential direction R1 gradually widens toward the first portion 231a. That is, when the rotor 2 is viewed from the radial direction, the shape of the second portion 231b is trapezoidal.
- the width of the second portion 231b in the circumferential direction R1 may be constant in the axial direction.
- the rare earth magnet portion 231 may have a second portion of any one of a plurality of second portions 231b and 231c.
- the axial length L21 of the first portion 231a is longer than the axial length L22 of the second portion 231b and 231c.
- the magnetic pole of the rare earth magnet portion 231 at the central portion 20c of the ferrite bond magnet 20 becomes stronger than the magnetic pole of the rare earth magnet portion 231 at the end portion 20d of the ferrite bond magnet 20. Therefore, it becomes easy to sufficiently secure the amount of magnetic flux of the magnetic flux flowing from the rotor 2 to the stator 9.
- the rare earth bond magnet 230 has a plurality of rare earth magnet portions 231 arranged at intervals in the circumferential direction R1.
- the rare earth bond magnet 230 is more expensive than the ferrite bond magnet 20.
- the rare earth bond magnet 230 has a plurality of rare earth magnet portions 231 arranged at intervals in the circumferential direction R1, so that the amount of the rare earth bond magnet 230 used is reduced. Therefore, the manufacturing cost of the rotor 2 can be reduced.
- the first width W1 which is the circumferential width of each rare earth magnet portion 231 of the plurality of rare earth magnet portions 231 in the central portion 20c of the ferrite bond magnet 20 in the axial direction is the axial direction.
- the width is wider than the second width W2, which is the width in the circumferential direction of each rare earth magnet portion 231 at the end portion 20d of the ferrite bond magnet 20.
- the magnetic flux amount of the magnetic flux flowing from the rotor 2 to the stator 9 can be sufficiently secured.
- the rare earth magnet portion 231 is connected to the first portion 231a and the second portion 231b, 231c axially outside the first portion 231a to the first portion 231a.
- the first portion 231a has a constant first width W1 in the axial direction, and the axial length L21 of the first portion 231a is the axial direction of the second portions 231b and 231c. Length is longer than L22.
- the magnetic pole of the rare earth magnet portion 231 at the central portion 20c of the ferrite bond magnet 20 becomes stronger than the magnetic pole of the rare earth magnet portion 231 at the end portion 20d of the ferrite bond magnet 20. Therefore, it becomes easy to sufficiently secure the amount of magnetic flux of the magnetic flux flowing from the rotor 2 to the stator 9.
- FIG. 14 is a plan view showing the configuration of the rotor 3 according to the third embodiment.
- components that are the same as or correspond to the components shown in FIG. 3 are designated by the same reference numerals as those in FIG.
- the rotor 3 according to the third embodiment is different from the rotor 1 according to the first embodiment in the shape of the rare earth magnet portion 331.
- the shaft 10 and the resin portion 60 are not shown.
- the rotor 3 has a ferrite bond magnet 20 and a rare earth bond magnet 330.
- the rare earth bond magnet 330 has a plurality of rare earth magnet portions 331 arranged at intervals in the circumferential direction R1.
- the circumferential width of the portion 331c located at the innermost radial direction of the rare earth magnet portion 331 is the third width W3, and the circumferential width of the portion 331d located at the outermost radial direction of the rare earth magnet portion 331.
- the fourth width W4 is set, the third width W3 is wider than the fourth width W4. That is, the third width W3 and the fourth width W4 satisfy the following equation (3). W3> W4 (3) As a result, the bonding area between the ferrite bond magnet 20 and the rare earth bond magnet 330 increases.
- the rare earth bond magnet 330 falls off from the ferrite bond magnet 20. Can be prevented.
- the third width W3 is wider than the fourth width W4, so that the groove portion 221 of the ferrite bond magnet 20 in which the rare earth magnet portion 331 is arranged is formed. It is a dovetail groove.
- the third width W3 which is the circumferential width of the portion 331c located on the innermost side in the radial direction of the rare earth magnet portion 331, is the largest diameter of the rare earth magnet portion 331. It is wider than the fourth width W4, which is the width in the circumferential direction of the portion 331d located outside the direction. As a result, the bonding area between the ferrite bond magnet 20 and the rare earth bond magnet 330 increases.
- the rare earth bond magnet 330 falls off from the ferrite bond magnet 20. Can be prevented.
- FIG. 15 is a cross-sectional view showing the configuration of the rotor 4 according to the fourth embodiment.
- FIG. 16 is a cross-sectional view of the rotor 4 shown in FIG. 15 cut along the line A16-A16.
- the rotor 4 according to the fourth embodiment is different from the rotor 1 according to the first embodiment in the shape of the ferrite bond magnet 420 and the rare earth bond magnet 430.
- the rotor 4 according to the fourth embodiment is the same as the rotor 1 according to the first embodiment. Therefore, in the following description, FIG. 2 will be referred to.
- FIGS. 15 and 16 the illustration of the shaft 10 is omitted.
- the rotor 4 has a ferrite bond magnet 420 and a rare earth bond magnet 430.
- the ferrite bond magnet 420 has a first ferrite magnet portion 441 and a second ferrite magnet portion 442 arranged in the axial direction.
- a step portion 420f is formed in the central portion 420c of the ferrite bond magnet 420 in the axial direction.
- the step portion 420f is recessed from the outer circumference 420a of the ferrite bond magnet 420 toward the inner circumference 420b.
- the step portion 420f is composed of a first step portion 441f formed on the first ferrite magnet portion 441 and a second step portion 442f formed on the second ferrite magnet portion 442.
- the first step portion 441f is formed on the axial end surface 441a of the first ferrite magnet portion 441 in contact with the second ferrite magnet portion 442.
- the second step portion 442f is formed in the second ferrite magnet portion 442 on the end surface 442a in the axial direction in contact with the first ferrite magnet portion 441.
- the rare earth bond magnet 430 has a plurality of rare earth magnet portions 431 arranged at intervals in the circumferential direction R1.
- the rare earth magnet portion 431 has an overhanging portion 431f formed in a central portion 431c in the axial direction facing the stator core 91 (see FIG. 2) in the radial direction.
- the overhanging portion 431f extends radially inward from the axially central portion 431c of the rare earth magnet portion 431.
- the magnetic pole of the rare earth magnet portion 431 in the central portion 420c of the ferrite bond magnet 420 becomes stronger than the magnetic pole of the rare earth magnet portion 431 in the end portion 420d of the ferrite bond magnet 420. Therefore, the amount of magnetic flux of the interlinkage magnetic flux flowing from the rotor 4 to the coil 92 can be further increased.
- the overhanging portion 431f and the stepped portion 420f are joined to each other.
- the bonding area between the ferrite bond magnet 20 and the rare earth bond magnet 30 increases. Therefore, even if the interface between the ferrite bond magnet 420 and the rare earth bond magnet 430 is peeled off due to expansion or contraction due to a temperature change or centrifugal force acting on the rotor 4, the rare earth bond magnet 430 falls off from the ferrite bond magnet 420. Can be prevented.
- the rare earth magnet portion 431 has an overhanging portion 431f formed in the central portion 431c in the axial direction facing the stator core 91 in the radial direction.
- the magnetic pole of the rare earth magnet portion 431 in the central portion 420c of the ferrite bond magnet 420 becomes stronger than the magnetic pole of the rare earth magnet portion 431 in the end portion 420d of the ferrite bond magnet 420. Therefore, the amount of magnetic flux of the interlinkage magnetic flux flowing from the rotor 4 to the coil 92 can be increased. That is, it is possible to increase the amount of magnetic flux of the effective magnetic flux required for driving the motor.
- the overhanging portion 431f of the rare earth magnet portion 431 and the stepped portion 420f of the ferrite bond magnet 420 are joined to each other.
- the bonding area between the ferrite bond magnet 20 and the rare earth bond magnet 30 increases. Therefore, even if the interface between the ferrite bond magnet 420 and the rare earth bond magnet 430 is peeled off due to expansion or contraction due to a temperature change or centrifugal force acting on the rotor 4, the rare earth bond magnet 430 falls off from the ferrite bond magnet 420. Can be prevented.
- FIG. 17 is a cross-sectional view showing the configuration of the rotor 5 according to the fifth embodiment.
- FIG. 18 is a partial cross-sectional view showing the configuration of the rotor 5 shown in FIG.
- the rotor 5 according to the fifth embodiment is different from the rotor 4 according to the fourth embodiment in the shape of the overhanging portion 531f of the rare earth magnet portion 531.
- the shaft 10 is not shown.
- the rotor 5 has a ferrite bond magnet 420 and a rare earth bond magnet 530.
- the rare earth bond magnet 530 has a plurality of rare earth magnet portions 531 arranged at intervals in the circumferential direction R1.
- the rare earth magnet portion 531 has an overhanging portion 531f formed in a central portion 531c in the axial direction facing the stator core 91 (see FIG. 2) in the radial direction.
- the overhanging portion 531f extends inward in the radial direction from the central portion 531c in the axial direction of the rare earth magnet portion 531.
- the overhanging portion 531f and the stepped portion 420f of the ferrite bond magnet 420 are joined to each other.
- the fifth width W5 which is the width of the circumferential direction R1 of the overhanging portion 531f, is wider than the width A2 of the peripheral direction R1 of the rare earth magnet portion 531.
- the "width of the circumferential direction R1 of the overhanging portion 531f" is the length of a straight line extending in the overhanging portion 531f in a direction perpendicular to the straight line M connecting the axis C1 and the overhanging portion 531f.
- the width W5 of the circumferential direction R1 of the overhanging portion 531f of the rare earth magnet portion 531 is wider than the first width W1 of the rare earth magnet portion 531.
- the bonding area between the overhanging portion 531f and the central portion 420c of the ferrite bond magnet 420 in the axial direction increases, so that the rare earth bond magnet 530 is more difficult to fall off from the ferrite bond magnet 420.
- FIG. 19 is a partial cross-sectional view showing the configuration of the rotor 6 according to the sixth embodiment.
- the same or corresponding components as those shown in FIGS. 15 and 16 are designated by the same reference numerals.
- the rotor 6 according to the sixth embodiment shown in FIGS. 15 and 16 is different from the rotor 4 according to the fourth embodiment in the shape of the ferrite bond magnet 620 and the rare earth bond magnet 630.
- the rotor 6 has a ferrite bond magnet 620 and a rare earth bond magnet 630.
- the ferrite bond magnet 620 has a first ferrite magnet portion 441 and a second ferrite magnet portion 442 arranged in the axial direction.
- the first ferrite magnet portion 441 has a first recess 641 g formed on the bottom surface 441s of the first step portion 441f.
- the second ferrite magnet portion 442 has a second recess 642g formed on the bottom surface 442s of the second step portion 442f.
- the ferrite bond magnet 620 may have one of the first recess 641 g and the second recess 642 g. Further, the ferrite bond magnet 620 may have a plurality of first recesses 641 g or a plurality of second recesses 642 g.
- the rare earth bond magnet 630 has a rare earth magnet portion 631.
- the rare earth magnet portion 631 has an overhanging portion 631f.
- the overhanging portion 631f has a first convex portion 631g that fits into the first concave portion 641g and a second convex portion 631h that fits into the second concave portion 642g. This makes it more difficult for the rare earth bond magnet 630 to fall off from the ferrite bond magnet 620.
- the overhanging portion 631f has the first convex portion 631g and the second convex portion 631h, the overhanging portion 631f in which the first convex portion 631g and the second convex portion 631h are formed is formed.
- the axial length of the inner peripheral side of the overhanging portion 631f is longer than the axial length of the outer peripheral side of the overhanging portion 631f.
- the first convex portion 631g of the overhanging portion 631f of the rare earth magnet portion 631 is formed on the first step portion 441f of the ferrite bond magnet 620. It is fitted in the first recess 641 g. This makes it more difficult for the rare earth bond magnet 630 to fall off from the ferrite bond magnet 620.
- the second convex portion 631h of the overhanging portion 631f is fitted into the second concave portion 642g formed in the second step portion 442f of the ferrite bond magnet 620. is doing. This makes it more difficult for the rare earth bond magnet 630 to fall off from the ferrite bond magnet 620.
- FIG. 20 is a cross-sectional view showing the configuration of the rotor 7 according to the seventh embodiment.
- the same or corresponding components as those shown in FIGS. 1 to 3 are designated by the same reference numerals as those shown in FIGS. 1 to 3.
- the rotor 7 according to the seventh embodiment is different from the rotor 1 according to the first embodiment in the configuration of the rare earth bond magnet 730.
- the rotor 7 has a ferrite bond magnet 20 and a rare earth bond magnet 730.
- the rare earth bond magnet 730 is a connecting portion 732 that connects a plurality of rare earth magnet portions 731 arranged at intervals in the circumferential direction R1 and a rare earth magnet portion 731 adjacent to the circumferential direction R1 among the plurality of rare earth magnet portions 731. And have.
- the rare earth magnet portion 31 has an overhanging portion 731f formed in the central portion 731c in the axial direction.
- the overhanging portion 731f and the recess 20f formed in the central portion of the ferrite bond magnet 20 in the axial direction are joined to each other.
- the recess 20f is an annular groove centered on the axis C1.
- the connecting portion 732 connects the overhanging portion 731f of the rare earth magnet portion 731 adjacent to the circumferential direction R1. As a result, the rigidity of the rare earth bond magnet 730 is increased, so that the rare earth bond magnet 730 is more difficult to fall off from the ferrite bond magnet 20.
- the connecting portion 732 and the recess 20f of the ferrite bond magnet 20 are joined to each other.
- the rare earth bond magnet 730 is a rare earth magnet portion adjacent to the circumferential direction R1 among a plurality of rare earth magnet portions 731 arranged at intervals in the circumferential direction R1. It has a connecting portion 732 for connecting 731. As a result, the rigidity of the rare earth bond magnet 730 is increased, so that the rare earth bond magnet 730 is more difficult to fall off from the ferrite bond magnet 20.
- FIG. 21 is a side view showing the configuration of the rotor 8 according to the eighth embodiment.
- FIG. 22 is a plan view showing the configuration of the rotor 8 according to the eighth embodiment.
- FIG. 23 is a cross-sectional view of the rotor 8 shown in FIG. 21 cut along the line A23-A23.
- the same or corresponding components as those shown in FIGS. 1 to 3 are designated by the same reference numerals as those shown in FIGS. 1 to 3.
- the rotor 8 according to the eighth embodiment is different from the rotor according to any one of the first to seventh embodiments in that the rotor 8 further includes the ring members 81 and 82.
- the shaft 10 and the resin portion 60 are not shown.
- the rotor 8 has a ferrite bond magnet 20, a rare earth bond magnet 30, and a plurality of ring members 81 and 82.
- the ring members 81 and 82 are annular members centered on the axis C1, respectively.
- the ring members 81 and 82 are formed of, for example, a resin such as an unsaturated polyester resin.
- the ring member 81 is located on the + z-axis side of the ferrite bond magnet 20 and the rare earth bond magnet 30.
- the ring member 81 is fixed to the end face 20j of the ferrite bond magnet 20 facing the + z-axis direction and the end face 31j of the rare earth magnet portion 31 facing the + z-axis direction.
- the ring member 82 is located on the ⁇ z-axis side of the ferrite bond magnet 20 and the rare earth bond magnet 30.
- the ring member 82 is fixed to the end face 20k of the ferrite bond magnet 20 facing the ⁇ z axis direction and the end face 31k of the rare earth magnet portion 31 facing the ⁇ z axis direction.
- the rotor 8 may have one of a plurality of ring members 81 and 82.
- the rotor 8 is a ring fixed to the end face 20j of the ferrite bond magnet 20 facing the + z-axis direction and the end face 31j of the rare earth magnet portion 31 facing the + z-axis direction. It has a member 81. As a result, the rare earth magnet portion 31 is connected to the ferrite bond magnet 20 via the ring member 81, so that the rare earth magnet portion 31 is less likely to fall off from the ferrite bond magnet 20.
- the rotor 8 has a ring member 82 fixed to the end face 20k of the ferrite bond magnet 20 facing the ⁇ z axis direction and the end face 31k of the rare earth magnet portion 31 facing the ⁇ z axis direction.
- the rare earth magnet portion 31 is connected to the ferrite bond magnet 20 via the plurality of ring members 81 and 82, so that the rare earth magnet portion 31 is less likely to fall off from the ferrite bond magnet 20.
- FIG. 24 is a plan view showing the configuration of the rotor 8A according to the first modification of the eighth embodiment.
- FIG. 22 is a cross-sectional view of the rotor 8A shown in FIG. 25 cut along the line A25-A25.
- the rotor 8A according to the first modification of the eighth embodiment is different from the rotor 8 according to the eighth embodiment in that the ring members 81A and 82A are connected to the resin portion 60A.
- the rotor 8A includes a shaft 10, a ferrite bond magnet 20, a rare earth bond magnet 30, ring members 81A and 82A as a first resin portion, and a second resin portion. It has a resin portion 60A as a base.
- the resin portion 60A includes an inner cylinder portion 61 supported by the shaft 10, an outer cylinder portion 62A fixed to the inner circumference 20b of the ferrite bond magnet 20, and a plurality of ribs connecting the inner cylinder portion 61 and the outer cylinder portion 62A. It has 63A.
- the ring members 81A and 82A are connected to the resin portion 60A (specifically, the outer cylinder portion 62A and the rib 63A).
- the ring members 81A and 82A are integrally molded and connected to the outer cylinder portion 62A of the resin portion 60A. That is, in the first modification of the eighth embodiment, the shaft 10, the ferrite bond magnet 20, and the rare earth bond magnet 30 are connected via the resin portion 60A and the ring members 81A and 82A.
- the ring members 81A and 82A are connected to the resin portion 60A in the rotor 8A.
- the ring members 81A and 82A can also be molded at the same time, thus reducing the manufacturing process of the rotor 8A. be able to.
- the natural frequency of the rotor 8A changes depending on the rigidity of the rotor 8A.
- the rigidity of the rotor 8A can be adjusted, for example, by changing the width, radial length, and number of ribs 63A in the resin portion 60A in the circumferential direction R1.
- the first modification of the eighth embodiment since the rib 63A is connected to the ring members 81A and 82A, the length of the rib 63A in the radial direction is long. Thereby, the rigidity of the rotor 8A can be changed. That is, the natural frequency of the rotor 8A can be changed. Therefore, the occurrence of resonance can be suppressed, and the vibration characteristics of the rotor 8A can be adjusted.
- the moment of inertia of the rotor 8A changes depending on the mass of the rotor 8A.
- the mass of the rotor 8A can be adjusted by changing the width, radial length, and number of ribs 63A in the circumferential direction R1.
- the larger the moment of inertia the larger the starting torque is required, but the rotation of the rotor 8A can be stabilized.
- the rib 63A is connected to the ring members 81 and 82, the length of the rib 63A in the radial direction is long. As a result, the moment of inertia of the rotor 8A can be increased.
- the ring members 81A and 82A are connected to the resin portion 60A, so that the natural frequency and the moment of inertia of the rotor 8A can be adjusted.
- FIG. 26 is a diagram schematically showing the configuration of the air conditioner 900 according to the ninth embodiment.
- the air conditioner 900 has an indoor unit 910 and an outdoor unit 920 connected to the indoor unit 910 via a refrigerant pipe 930.
- a cooling operation in which cold air is blown from the indoor unit 910, a heating operation in which warm air is blown, or the like can be performed.
- the indoor unit 910 has an indoor blower 911 as a blower and a housing 912 that covers the indoor blower 911.
- the indoor blower 911 has an electric motor 100 and an impeller 911a fixed to the shaft 10 of the electric motor 100.
- the impeller 911a is driven by the electric motor 100 to generate an air flow.
- the impeller 911a is, for example, a cross-flow fan.
- the outdoor unit 920 has an outdoor blower 921 as a blower, a compressor 922, and a housing 923 that covers the outdoor blower 921 and the compressor 922.
- the outdoor blower 921 has an electric motor 100 and an impeller 921a fixed to a shaft 10 (see FIG. 1) of the electric motor 100.
- the impeller 921a is driven by the electric motor 100 to generate an air flow.
- the impeller 921a is, for example, a propeller fan.
- the compressor 922 has an electric motor 922a and a compression mechanism unit 922b driven by the electric motor 922a.
- the electric motor 100 according to the first embodiment is applied to the indoor blower 911 and the outdoor blower 921.
- the interlinkage magnetic flux flowing from the rotor 1 to the coil 92 can be increased, so that the reliability of the electric motor 100 is improved. Therefore, the reliability of the indoor blower 911 and the outdoor blower 921 having the motor 100 is also improved. Further, the reliability of the air conditioner 900 having the indoor blower 911 and the outdoor blower 921 is also improved.
- the electric motor 100 may be provided in either the indoor blower 911 or the outdoor blower 921. Further, the electric motor 100 may be applied to the electric motor 922a of the compressor 922. Further, the electric motor 100 according to the ninth embodiment is not limited to the air conditioner 900, and may be provided in other devices.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Permanent Field Magnets Of Synchronous Machinery (AREA)
- Motor Or Generator Cooling System (AREA)
Abstract
Description
図1は、実施の形態1に係る電動機100の構成を示す平面図である。電動機100は、例えば、永久磁石同期電動機である。電動機100は、回転子1と、固定子9とを有する。回転子1は、固定子9の内側に配置されている。つまり、電動機100は、インナロータ型の電動機である。回転子1と固定子9との間には、エアギャップGが形成されている。エアギャップGは、例えば、0.5mmの空隙である。
固定子9は、固定子鉄心91と、固定子鉄心91に巻き付けられたコイル92とを有する。固定子鉄心91は、軸線C1を中心とする環状のヨーク91aと、ヨーク91aから径方向内側に伸びる複数のティース91bとを有する。複数のティース91bは、周方向R1に等角度の間隔で配置されている。ティース91bの径方向内側の先端部は、エアギャップGを介して回転子1の外周1aに対向している。図1では、ティース91bの個数は12個であるが、12個に限らず、任意の個数に設定されてもよい。
図2は、実施の形態1に係る回転子1の構成及び固定子9の構成の一部を示す側面図である。図3は、図2に示される回転子1の構成を示す平面図である。図2及び3に示されるように、回転子1は、シャフト10と、第1の永久磁石としてのフェライトボンド磁石20と、第2の永久磁石としての希土類ボンド磁石30とを有する。
W1>W2 (1)
これにより、固定子鉄心91と径方向に対向するフェライトボンド磁石20の中央部20cにおける希土類磁石部31の磁極は、フェライトボンド磁石20の軸方向の端部20dにおける希土類磁石部31の磁極より強くなる。したがって、回転子1において発生する磁束の磁束量を十分に確保することができる。
W21>W22 (2)
また、幅W21は、図2に示される第1の幅W1と等しく、幅W22は、図2に示される第2の幅W2と等しい。つまり、フェライトボンド磁石20の溝部21の形状は、希土類磁石部31の形状に対応する。
以上に説明したように、実施の形態1によれば、希土類ボンド磁石30は、周方向R1に間隔をあけて配置された複数の希土類磁石部31を有する。希土類ボンド磁石30は、フェライトボンド磁石20より高価である。実施の形態1に係る回転子1では、希土類ボンド磁石30は、周方向R1に間隔をあけて配置された複数の希土類磁石部31を有することにより、希土類ボンド磁石30の使用量が削減されるため、回転子1の製造コストを低減することができる。
図13は、実施の形態2に係る回転子2の構成を示す側面図である。図13において、図2と同一又は対応する構成要素には、図2と同じ符号が付される。実施の形態2に係る回転子2は、希土類磁石部231の形状の点で、実施の形態1に係る回転子1と相違する。これ以外の点については、実施の形態2に係る回転子2は、実施の形態1に係る回転子1と同じである。そのため、以下の説明では、図2を参照する。なお、図13では、シャフト10(図2参照)の図示が省略されている。
以上に説明したように、実施の形態2によれば、希土類ボンド磁石230は、周方向R1に間隔をあけて配置された複数の希土類磁石部231を有する。希土類ボンド磁石230は、フェライトボンド磁石20より高価である。実施の形態2に係る回転子2では、希土類ボンド磁石230は、周方向R1に間隔をあけて配置された複数の希土類磁石部231を有することにより、希土類ボンド磁石230の使用量が削減されるため、回転子2の製造コストを低減することができる。
図14は、実施の形態3に係る回転子3の構成を示す平面図である。図14において、図3に示される構成要素と同一又は対応する構成要素には、図3と同じ符号が付される。実施の形態3に係る回転子3は、希土類磁石部331の形状の点で、実施の形態1に係る回転子1と相違する。なお、図14において、シャフト10及び樹脂部60(図3参照)の図示は、省略されている。
W3>W4 (3)
これにより、フェライトボンド磁石20と希土類ボンド磁石330との接合面積が増加する。したがって、温度変化による膨張若しくは収縮、又は回転子3に作用する遠心力によって、フェライトボンド磁石20と希土類ボンド磁石330との界面が剥離した場合でも、フェライトボンド磁石20から希土類ボンド磁石330が脱落することを防止できる。
以上に説明したように、実施の形態3によれば、希土類磁石部331の最も径方向内側に位置する部分331cの周方向の幅である第3の幅W3は、希土類磁石部331の最も径方向外側に位置する部分331dの周方向の幅である第4の幅W4より広い。これにより、フェライトボンド磁石20と希土類ボンド磁石330との接合面積が増加する。したがって、温度変化による膨張若しくは収縮、又は回転子3に作用する遠心力によって、フェライトボンド磁石20と希土類ボンド磁石330との界面が剥離した場合でも、フェライトボンド磁石20から希土類ボンド磁石330が脱落することを防止できる。
図15は、実施の形態4に係る回転子4の構成を示す断面図である。図16は、図15に示される回転子4をA16-A16線で切断した断面図である。実施の形態4に係る回転子4は、フェライトボンド磁石420及び希土類ボンド磁石430の形状の点で、実施の形態1に係る回転子1と相違する。これ以外の点については、実施の形態4に係る回転子4は、実施の形態1に係る回転子1と同じである。よって、以下の説明では、図2を参照する。なお、図15及び16において、シャフト10の図示は、省略されている。
以上に説明したように、実施の形態4によれば、希土類磁石部431は、固定子鉄心91と径方向に対向する軸方向の中央部431cに形成された張り出し部431fを有している。これにより、希土類磁石部431において、フェライトボンド磁石420の中央部420cにおける希土類磁石部431の磁極が、フェライトボンド磁石420の端部420dにおける希土類磁石部431の磁極より一層強くなる。したがって、回転子4からコイル92に流れる鎖交磁束の磁束量を増加させることができる。つまり、電動機の駆動に必要な有効磁束の磁束量を増加させることができる。
図17は、実施の形態5に係る回転子5の構成を示す断面図である。図18は、図17に示される回転子5の構成を示す部分断面図である。図17及び18において、図15及び16に示される符号と同じ符号が付される。実施の形態5に係る回転子5は、希土類磁石部531の張り出し部531fの形状の点で、実施の形態4に係る回転子4と相違する。なお、図17及び18において、シャフト10の図示は省略されている。
図19は、実施の形態6に係る回転子6の構成を示す部分断面図である。図19において、図15及び16に示される符号と同一又は対応する構成要素には、同じ符号が付される。図15及び16に実施の形態6に係る回転子6は、フェライトボンド磁石620及び希土類ボンド磁石630の形状の点で、実施の形態4に係る回転子4と相違する。
図20は、実施の形態7に係る回転子7の構成を示す断面図である。図20において、図1~3に示される構成要素と同一又は対応する構成要素には、図1~3に示される符号と同じ符号が付される。実施の形態7に係る回転子7は、希土類ボンド磁石730の構成の点で、実施の形態1に係る回転子1と相違する。
図21は、実施の形態8に係る回転子8の構成を示す側面図である。図22は、実施の形態8に係る回転子8の構成を示す平面図である。図23は、図21に示される回転子8をA23-A23線で切断した断面図である。図21~23において、図1~3に示される構成要素と同一又は対応する構成要素には、図1~3に示される符号と同じ符号が付される。実施の形態8に係る回転子8は、リング部材81、82を更に有している点で、実施の形態1から7のいずれかに係る回転子と相違する。なお、図21~23において、シャフト10及び樹脂部60(図3参照)の図示は省略されている。
以上に説明したように、実施の形態8によれば、回転子8は、フェライトボンド磁石20の+z軸方向を向く端面20j及び希土類磁石部31の+z軸方向を向く端面31jに固定されたリング部材81を有する。これにより、希土類磁石部31がリング部材81を介してフェライトボンド磁石20に連結されるため、フェライトボンド磁石20から希土類磁石部31が脱落し難くなる。
図24は、実施の形態8の変形例1に係る回転子8Aの構成を示す平面図である。図22は、図25に示される回転子8AをA25-A25線で切断した断面図である。実施の形態8の変形例1に係る回転子8Aは、リング部材81A、82Aが樹脂部60Aと繋がっている点で、実施の形態8に係る回転子8と相違する。
図26は、実施の形態9に係る空気調和装置900の構成を概略的に示す図である。図26に示されるように、空気調和装置900は、室内機910と、冷媒配管930を介して室内機910に接続された室外機920とを有する。空気調和装置900では、例えば、室内機910から冷たい空気を送風する冷房運転、又は温かい空気を送風する暖房運転等を行うことができる。
Claims (19)
- 回転軸と、
前記回転軸に支持された第1の永久磁石と、
前記第1の永久磁石の外周に支持され、前記第1の永久磁石の磁極より強い磁極を有する第2の永久磁石と
を有し、
前記第2の永久磁石は、前記第1の永久磁石の周方向に間隔をあけて配置された複数の磁石部を有し、
前記回転軸の軸方向の前記第1の永久磁石の中央部における前記複数の磁石部の各磁石部の前記周方向の幅である第1の幅は、前記軸方向の前記第1の永久磁石の端部における前記各磁石部の前記周方向の幅である第2の幅より広い
回転子。 - 前記磁石部の前記周方向の幅は、前記軸方向の前記第1の永久磁石の前記端部から前記中央部に向けて徐々に広くなる
請求項1に記載の回転子。 - 前記磁石部は、
第1の部分と、
前記第1の部分より前記軸方向の外側で前記第1の部分に接続された第2の部分と
を有し、
前記第2の部分の前記周方向の幅は、前記第1の部分に向けて徐々に広くなる
請求項1又は2に記載の回転子。 - 前記第1の部分の前記周方向の幅は、前記軸方向において、一定である
請求項3に記載の回転子。 - 前記第1の部分の前記軸方向の長さは、前記第2の部分の前記軸方向の長さより長い
請求項3又は4に記載の回転子。 - 前記第1の永久磁石は、前記軸方向に配列された第1の分割磁石部及び第2の分割磁石部を有する
請求項1から5のいずれか1項に記載の回転子。 - 前記磁石部において、前記第2の永久磁石の径方向の最も内側に位置する部分の前記周方向の幅である第3の幅は、前記径方向の最も外側に位置する部分の前記周方向の幅である第4の幅より大きい
請求項1から6のいずれか1項に記載の回転子。 - 前記第1の永久磁石は、前記軸方向の前記中央部に形成された段差部を有し、
前記磁石部は、前記段差部に嵌合する張り出し部を有する
請求項1から7のいずれか1項に記載の回転子。 - 前記張り出し部の前記周方向の幅である第5の幅は、前記第1の幅より広い
請求項8に記載の回転子。 - 前記第1の永久磁石は、前記段差部の底面に形成された凹部を有し、
前記張り出し部は、前記凹部に嵌合する凸部を有する
請求項8又9に記載の回転子。 - 前記第2の永久磁石は、前記複数の磁石部のうちの前記周方向に隣接する前記磁石部を連結する連結部を更に有する
請求項1から10のいずれか1項に記載の回転子。 - 前記軸方向において、前記第1の永久磁石及び前記第2の永久磁石に固定される第1の樹脂部を更に有する
請求項1から11のいずれか1項に記載の回転子。 - 前記回転軸と前記第1の永久磁石とを連結する第2の樹脂部を更に有し、
前記第1の樹脂部は、前記第2の樹脂部と繋がっている
請求項12に記載の回転子。 - 前記第1の永久磁石は、フェライトボンド磁石であり、
前記第2の永久磁石は、希土類ボンド磁石である
請求項1から13のいずれか1項に記載の回転子。 - 2n(nは、1以上の自然数)個の極数を有する前記回転子であって、
前記第1の永久磁石及び前記第2の永久磁石は、極異方性を有する
請求項1から14のいずれか1項に記載の回転子。 - 請求項1から15のいずれか1項に記載の前記回転子と、
固定子と
を有する電動機。 - 前記固定子は、固定子鉄心を有し、
前記回転子の前記軸方向の長さは、前記固定子鉄心の前記軸方向の長さより長い
請求項16に記載の電動機。 - 請求項16又は17に記載の前記電動機と、
前記電動機によって駆動される羽根車と
を有する送風機。 - 室内機と、
前記室内機に接続された室外機と
を有し、
前記室内機及び前記室外機のうちの少なくとも一方は、請求項16又は17に記載の前記電動機を有する
空気調和装置。
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US20230318372A1 (en) | 2023-10-05 |
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EP4213346A4 (en) | 2023-11-01 |
CN116034529A (zh) | 2023-04-28 |
AU2020467017B2 (en) | 2024-02-01 |
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JP7415024B2 (ja) | 2024-01-16 |
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