• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    invention patent summary: "rotating electric machine rotor, rotating electric machine and method for producing rotating electric machine rotor". the present invention relates to a rotor for a rotating electrical machine that is able to minimize the increases in eddy current losses through a magnet, while rendering the processing of the insulating film on the surface of the magnet unnecessary. the rotor for the rotating electrical machine includes: a rotor core having a magnet insertion hole extended inside; a magnet inserted into the magnet insertion hole; and an insulating filler that is filled between the inner wall of the magnet insertion hole and the magnet, in order to secure the magnet. the magnet is secured by the filling in such a way that the surface of the magnet inside the magnet insertion hole is in an inclined position with respect to the direction of extension of the inner wall of the magnet insertion hole.
    公开号:BR112013031443B1
    申请号:R112013031443-5
    申请日:2011-06-09
    公开日:2020-02-11
    发明作者:Yoshitada YAMAGISHI；Yuta WATANABE
    申请人:Toyota Jidosha Kabushiki Kaisha；
    IPC主号:
    专利说明:

    Invention Patent Descriptive Report for ROTATING ELECTRIC MACHINE ROTOR, ROTATING ELECTRIC MACHINE AND METHOD FOR ROTATING ELECTRIC MACHINE ROTOR.
    TECHNICAL FIELD
    The present invention relates to rotating electric machine rotors, rotating electric machines themselves and methods for manufacturing rotating electric machine rotors and, in particular, to a rotating electric machine rotor or the like with a permanent magnet built into it.
    BACKGROUND TECHNIQUE
    Conventionally, rotors including a built-in permanent magnet are known for rotating electrical machines, such as motors and power generators. This type of rotor is also called an “indoor permanent magnet (IPM) type rotor”. In such an IPM type rotor, the rotor core formed of a cylindrical magnet body includes a magnet insertion hole that extends in the axial direction near the inner side of the outer circumferential surface of the rotor core. A permanent magnet is inserted into the magnet insertion hole and fixed with adhesive with a resin material.
    For example, JP 2011-4529 A (Patent Document 1) discloses an IPM type rotor. In this rotor, a cylindrical rotor core, in which electromagnetic steel plates 1 are laminated internally and include a permanent magnet embedded forming magnetic poles. Two end plates are provided at respective ends of the rotor core. The rotor core and the magnet are fixed by the end plates. Each of the end plates is provided with tongue portions that curve in the outer rim. The tongue portions press a portion of a lateral surface of the rotor core. It is described that this rotor can achieve a high strength structure and effectively suppress the dispersion flow of the permanent magnet.
    JP 2010-183692 A (Patent Document 2) describes a motor magnet that is inserted into a slot produced in one direction along the axial direction of a rotor. This motor magnet is formed by two or more segmented magnets that are stacked in the axial direction of the rotor. Film
    2/18 oxide is formed around each of the segmented magnets by the oxidation of the segmented magnets.
    Additionally, JP 2005-94845 A (Patent Document 3) describes a rotor of a rotating electrical machine of the permanent magnet type, in which a permanent magnet is inserted and fixed in a magnet insertion hole of an iron core of the rotor formed by laminating multiple elements of annular iron core plate. It is described that the permanent magnet is formed by two or more unit magnets that are aligned in a line in the axial direction and coated with resin to form a bar shape.
    RELATED TECHNICAL DOCUMENT
    Patent Document
    Patent Document 1: JP 2011-4529 A
    Patent Document 2: JP 2010-183692 A
    Patent Document 3: JP 2005-94845 A
    DESCRIPTION OF THE INVENTION
    Problems to be solved by the invention
    In a permanent magnet embedded in a rotor core in an IPM-type rotor described in Patent Document 1 above, processing of the insulation film can be performed with an oxide film, resin coating or the like as described in the Patent Documents 2 and 3 above. This is because such processing of the insulation film is effective in order to improve the motor efficiency by suppressing a loss by eddy current from the magnet, which increases as the eddy current flowing in the axial direction of the rotor through the surface and inside the permanent magnet increases even if the steel plates are isolated from each other, when a conductive permanent magnet directly contacts a rotor core made, for example, of a steel plate laminate.
    However, in order to create or form the oxide film on a permanent magnet surface to have a desired thickness, the permanent magnet must be left for two days, for example, in a particular atmosphere (refer to Patent Document 2 ). So an au
    3/18 cost increase cannot be avoided because of the longer manufacturing period of the permanent magnet.
    In addition, as described in Patent Document 3 above, when a resin coating is formed around a permanent magnet in advance, the torque yield is reduced due to a larger gap between the permanent magnet and the rotor core, in addition to the increase of the manufacturing cost on the permanent magnet.
    An objective of the present invention is to present a rotating electric machine rotor, the rotating electric machine itself and a method for manufacturing a rotating electric machine rotor that can suppress an increase in eddy current loss through a magnet while eliminating the need for processing the insulation film on a magnet surface.
    Means for solving problems
    A rotating electrical machine rotor according to the present invention is a rotating electrical machine rotor with a built-in magnet. The rotating electric machine rotor includes a rotor core with a magnet insertion hole that extends inside; a magnet inserted in the magnet insertion hole; and a full insulating pad between the inner wall of the magnet insertion hole and the magnet to secure the magnet; wherein the magnet is fixed with the filler, such that a surface of the magnet inside the magnet insertion hole is inclined with respect to the direction of extension of the inner wall of the magnet insertion hole.
    In a rotating electric machine rotor, according to the present invention, the magnet insertion hole can be formed along the axial direction of the rotor core; the magnet can have an elongated quadrilateral axial cross section; and the magnet can contact the inner wall of the magnet insertion hole in the corner on one side of the axial end and on the other corner on the other side of the axial end which is diagonally opposite the corner on the one side of the axial end.
    In that case, the magnet may have an axial cross section of a parallelogram shape and axial end surfaces that are level
    4/18 with the axial end surfaces of the rotor core. Alternatively, the magnet may have an axial cross section of a rectangular shape.
    In a rotating electric machine rotor, according to the present invention, the magnet can be segmented into a plurality of magnetic pieces; and the filling can be filled between each of the magnet pieces in an integrated manner in addition to between the inner wall of the magnet insertion hole and the magnet.
    A rotating electrical machine, according to another aspect of the present invention, is presented with the rotor having any of the above structures and a stator arranged around the rotor.
    A method for manufacturing a rotating electrical machine rotor in accordance with yet another aspect of the present invention is a method of manufacturing a rotating electrical machine rotor with a built-in magnet, including preparing a magnet and a rotor core with a bore hole. insertion of the extended magnet inside; insert the magnet into the magnet insertion hole; position, in a mold matrix, the rotor core with the magnet inserted inside; holding the magnet with a portion of the mold matrix, such that the surface of the magnet inside the magnet insertion hole is inclined with respect to an extension direction of the inner wall of the magnet insertion hole; fill an insulating filler between the inner wall of the magnet insertion hole and the magnet through an entrance provided with the mold matrix to fix the magnet to the rotor core and mount the rotor core on which the magnet is located on the shaft. fixed with the filling.
    In a method for fabricating a rotating electric machine rotor according to the present invention, the magnet may have an axial cross section of a parallelogram shape and axial end surfaces that can be flush with the axial end surfaces of the core. rotor and, in clamping, the flat inner side surfaces of the mold die can abut the surfaces of the axial end of the rotor core and the surfaces of the axial end of the magnet, such that the magnet can be held in an inclined position within the magnet insertion hole.
    5/18
    In addition, in a method for manufacturing a rotating electric machine rotor according to the present invention, the magnet may have an axial cross section of a rectangular shape and, in bonding, the inclined surfaces of the projected portions projecting on the lateral surfaces internal parts of the mold matrix can touch the surfaces of the axial end of the magnet and press the magnet in the axial direction, such that the magnet can be held in an inclined position inside the magnet insertion hole.
    Additionally, in a method for fabricating the rotating electrical machine rotor according to the present invention, the magnet may have an axial cross section of a rectangular shape; in clamping, the sloping surfaces of the projected portions that are elastically provided with the mold matrix and capable of moving back and forth can touch corner portions of the axial end portions of the magnet and press the axial end portion of the magnet in a direction substantially perpendicular to the axial direction, such that the magnet can be held in an inclined position within the magnet insertion hole.
    Effects of the invention
    According to the rotating electric machine rotor of the present invention, the contact area between the magnet and the rotor core is minimized by placing the magnet, such that the surface of the magnet is inclined with respect to the direction of extension of the inner wall of the hole inserting the magnet. In this way, even without the insulating film formed on the surface of the magnet, it is possible to prevent the path of the circuit, through which the eddy current flows to the rotor core through the magnet, from becoming large. Therefore, it becomes possible to suppress the increased eddy current loss through the magnet while eliminating the need for processing the insulation film on the magnet surface.
    BRIEF DESCRIPTION OF THE DRAWINGS
    FIG. 1 shows a cross-sectional view along the axial direction of the rotor of the rotating electrical machine according to an embodiment of the present invention.
    6/18
    FIG. 2 shows a surface of the axial end of the rotor core shown in FIG. 1.
    FIG. 3 shows an enlarged view of a magnetic pole of the rotor core shown in FIG. 2.
    FIG. 4 shows a cross-sectional view taken along line A-A in FIG. 3.
    FIG. 5 shows a cross-sectional view similar to FIG. 4, with an example with a permanent magnet having a rectangular axial cross section.
    FIG. 6 shows a schematic diagram describing how eddy current flows to the magnetic steel plates forming a rotating core through a permanent magnet surface on which no insulation film processing is performed.
    FIG. 7 shows a flowchart describing the manufacturing method of the rotating electric machine rotor according to the present modality.
    FIG. 8 shows a view in which the permanent magnet having the axial cross section in the form of a parallelogram is held in an inclined position within the magnet insertion hole of the rotor core by a mold die.
    FIG. 9 shows a view in which the permanent magnet having the axial cross section of the rectangular shape is held in an inclined position within the magnet insertion hole of the rotor core by a mold die.
    FIG. 10 shows another example in which a permanent magnet having the axial cross section of the rectangular shape is held in an inclined position within the magnet insertion hole of the rotor core by a mold die.
    FIG. 11 shows a view similar to FIG. 3, with a variation of the rotating electric machine rotor according to the present invention.
    FIG. 12 shows a view similar to FIG. 3, with another variation of the rotating electric machine rotor according to the present invention.
    7/18
    FIG. 13 shows a view similar to FIG. 9, with the rotor core of the variation shown in FIG. 12 placed in a mold matrix.
    BEST MODE FOR CARRYING OUT THE INVENTION
    Modalities according to the present invention (hereinafter referred to as "modality") are described below with reference to the accompanying drawings. In the description, specific shapes, materials, numerals, directions or the like are provided merely as examples in order to facilitate the understanding of the present invention and can be appropriately altered according to uses, purposes and specifications. It is assumed from the beginning that when two or more modalities and variations are included in the description below, the described characteristics of these modalities will be appropriately combined to be used.
    FIG. 1 is a cross-sectional view along the axial direction of a rotating electrical machine rotor 10 according to an embodiment of the present invention (hereinafter simply called "rotor"). A cylindrical stator 11 is arranged around the rotor 10 with a predetermined opening between them to build a rotating electrical machine. Two or more teeth are provided on the internal circumference of the stator 11 with an equal space between them, such that the teeth project inwards in the radial direction. Between adjacent teeth, open slits of the same number as the teeth are provided on the inner circumferential side and at both axial ends. Stator coils (not shown) wrapped around the teeth are inserted into the slots. Thus, when electrical energy is applied to the stator coils, a rotating magnetic field that rotates the rotor 10 is formed on the inside of the stator 11.
    The rotor 10 is provided with a cylindrical rotor core 12 having a shaft bore 23 in the radial center; an axis 14 which is fixed so as to penetrate through the axis hole 23 of the rotor core 12; end plates 16 placed to contact both sides of the rotor core 12 in the axial direction (shown with the X arrow) of the axis 14 (and rotor core 12) and a fixing element 18 that secures the rotor core 12 and the plates end 16 on axis 14.
    The core of rotor 12 is formed of many electro-steel plates
    8/18 magnetic laminated in axial direction. Each of the electromagnetic steel plates is processed by cutting an annular plate of silicon steel plates or the like having a thickness of, for example, 0.3 mm. The electromagnetic steel plates forming the core of the rotor 12 are integrally coupled by a method, such as pleating, adhesion and welding in blocks in which the core of the rotor 12 is segmented into two or more blocks in the axial direction or the electromagnetic steel plates forming the core of the rotor 12 are integrally coupled as a set. Each of the electromagnetic steel plates forming the core of the rotor 12 is electrically isolated from the others by the insulation film formed on the surface of the steel plate.
    In addition, two or more magnetic poles 24 (with reference to FIG. 2) are equally spaced from each other in the circumferential direction of the rotor core 12. Each of the magnetic poles 24 includes a pair of permanent magnets described in detail below. Additionally, the rotor core 12 is located in a predetermined circumferential position on the axis 14 by the interference fit or the key fit.
    In addition to the modality with a lamination of the electromagnetic steel plates, the core of the rotor 12 can be formed of a pressed powder magnetic core made of magnetic powder, such as sweet magnetic metal powder or sweet magnetic metal oxide powder, both of which are coated with resin binder, such as silicon resin. The magnetic sweet metal powder can include iron, ferro-silicon based alloy, ferro-nitrogen based alloy, ferro-nickel based alloy, ferro-carbon based alloy, ferro-boron based alloy, alloy based on ferrocobalt, alloy based on iron-phosphorus, alloy based on iron-nickelcobalt and alloy based on iron-aluminum-silicon.
    The shaft 14 is formed, for example, from a round steel bar. A flange portion 15 projecting outwardly in the radial direction is formed along the outer circumference. When the rotor 10 is mounted, that flange portion 15 touches one of the end plates 16 and functions as a contact portion that determines the position of the rotor core 12 in the
    9/18 axis 14 in the axial direction.
    Each of the end plates 16 is formed of a circular plate having an external shape almost identical to the surface of the axial end of the rotor core 12. It is preferable that the end plates 16 are formed of a non-magnetic metal material, such as aluminum and copper. The reason for using a non-magnetic metal material is to eliminate the short circuit of the magnetic flux in the axial end portions of the permanent magnet forming the magnetic pole. However, as the material is not limited to a metal material as long as the material is not magnetic, the end plates 16 can be made of resin. Additionally, the cost can be reduced by making the end plates 16 smaller than the rotor core 12 or by eliminating the end plates 16.
    The fixture 18 includes a cylindrical fixation portion 20 that is fixed to the axis 14 and an annular pressing portion 22 that projects outwardly in the radial direction from an end portion of the fixation portion 20. The fixation element 18 is attached to the shaft 14, such that with the rotor core 12 and the two end plates 16 being pressed into the flange portion 15 by the pressing portion 22, the attachment portion 20 is attached to the shaft 14 by a clamping method , such as pleating, welding or screwing. In this way, the rotor core 12 is fixed on the shaft 14 together with the end plates 16.
    In the following, the structure of the rotor core 12 is described with reference to FIGS. 2, 3 and 4. Although FIG. 2 show an axial end surface of the rotor core 12, the cross section of the rotor core 12 vertical the axial direction has the same structure. FIG. 3 shows an enlarged view of one of the poles of the magnet 24 in FIG. 2. Additionally, FIG. 4 is a cross-sectional view taken along line A-A in FIG. 3.
    In the center of the rotor core 12 having an external cylindrical shape, a hole in the shaft 23 is provided penetrating through the core of the rotor 12, through which the shaft 14 is inserted and fixed. When the rotor core 12 is attached to the shaft 14 by the interference fit, the shaft hole 23 has a circular shape and no key is provided in the edge portion as
    10/18 shown in FIG. 2. In contrast, when the rotor core 12 is installed on the shaft 14 by the keyway, keys (or keyways) are produced to project (or be recessed) into the edge portion of the shaft hole 23.
    Two or more magnetic poles 24 are also provided separately along the outer circumference of the rotor core 12. The present embodiment shows, as an example, eight magnetic poles 24 which are arranged at 45 degree intervals in the circumferential direction. As each magnetic pole 24 has an identical structure, except for the magnetized direction of the permanent magnet 26, a magnetic pole 24 is described below.
    Each magnetic pole 24 includes a pair of permanent magnets 26. Each pair of permanent magnets 26 is embedded in the rotor core 12 in a position close to the outer circumferential surface 13. As shown in FIG. 3, two permanent magnets 26 included in each magnetic pole 24 are identical in shape and size. Specifically, each permanent magnet 26 has an axial end surface (and cross section) of an elongated rectangular shape with two short side surfaces and two long side surfaces. The permanent magnet 26 is formed to have substantially the same length as the rotor core 12 in the axial direction. However, the shape and size of the permanent magnet 26 are not limited to the arrangements described above and each permanent magnet 26 can have different shapes and sizes.
    Each of the pair of permanent magnets 26 at each of the magnetic poles 24 is inserted and fixed in the magnet insertion hole 32. The two permanent magnets 26 are arranged in a substantially V-shaped opening for the outer circumferential surface 13 of the core. rotor
    12. Each of the pair of permanent magnets 26 is arranged to be symmetrical around the center line C of the magnetic pole which is a line drawn in the radial direction passing through the circumferential center of the magnetic pole. However, the pair of permanent magnets 26 is not limited to this arrangement and each of the pair of permanent magnets 26 can be arranged asymmetrically around the center line C of the magnetic pole.
    11/18
    For each of the permanent magnets 26 according to the present embodiment, a first polarity is magnetized on one of the two long side surfaces that are on the outside in the radial direction, while a second polarity that is different from the first polarity is magnetized on the other surface. long side that is on the inside in the radial direction. Specifically, in a pair of permanent magnets 26 included in a magnetic pole 24, a pole N is magnetized on one side surface on the outside in the radial direction, while a pole S is magnetized on the other side surface. In contrast, in another pair of permanent magnets 26 of magnetic poles 24 that is placed adjacent to the first pair of permanent magnets 26 along the circumferential direction, a pole S is magnetized on a side surface that is on the outside in the radial direction, while a pole N is magnetized on the other side surface. Therefore, in permanent magnets 26, the direction of magnetization is through the thickness in the direction perpendicular to the two long side surfaces, while the two short side surfaces are arranged along the direction of magnetization.
    The magnet insertion hole 32 into which the permanent magnet 26 is inserted includes a portion of the magnet housing 33c to enclose the permanent magnet 26. The housing portion of the magnet 33c is structured to have a rectangular shape substantially identical to, but slightly larger than the cross section of the permanent magnet 26. Additionally, cavity portions 33a, 33b are formed at the two circumferential ends of the magnet insertion hole 32, such that the cavity portions 33a, 33b extend outwardly from the surfaces short sides of the permanent magnet 26 to communicate with the housing portion of the magnet 33c. The cavity portions 33a, 33b are formed narrower than the permanent magnet 26 in order to prevent the permanent magnet 26 from entering the cavity portions 33a, 33b.
    As shown in FIG. 4, the permanent magnet 26 has an elongated quadrilateral axial cross section. More specifically, the permanent magnet 26 has an axial cross section in a shape of
    12/18 elongated parallelogram. The magnet insertion hole 32 is formed along the axial direction of the rotor core 12, so as to internally include a rectangular space extended in the axial direction. The permanent magnet 26 is arranged in a position in which the long side surfaces 26a, 26b (magnet surfaces) within the magnet insertion hole 32 are inclined with respect to the inner wall of the magnet insertion hole 32 which is arranged in parallel axial direction.
    Because the permanent magnet 26 is formed to have an axial length substantially equal to that of the rotor core 12, the axial end surfaces 26c, 26d are substantially flush with both surfaces of the axial end of the rotor core 12. Additionally , a corner portion 27a on one side of the axial end (top in FIG. 4) of the permanent magnet 26 and another corner portion 27b on the other side of the axial end (bottom in FIG. 4) that is diagonally opposite the corner portion 27a contact the inner wall of the magnet insertion hole 32, which is the core of the rotor 12. It should be noted that on the permanent magnet 26, the corner portion 27a is an edge portion defined by the long side surface 26b and the surface of the axial end 26c, while the corner portion 27b is an edge portion defined by the long side surface 26a and the surface of the axial end 26d.
    As described above, spaces having a conical shape extended in the axial direction are respectively formed between the long side surfaces 26a, 26b of the permanent magnet 26 which is placed in an inclined position within the magnet insertion hole 32 and the inner wall of the hole for inserting the magnet 32. An insulating filler 34 is filled into the space, thereby fixing the permanent magnet 26 inside the insertion hole of the magnet 32.
    As filler 34, a resin material having a thermo-rigid property, such as epoxy resin and silicon resin, is preferably used. However, since filler 34 is not limited to such a resin material, a thermoplastic resin material can be used as filler 34. Additionally, a filler having a high conductivity
    13/18 thermal (such as silicon filler) can be mixed with filler 34 in order to eliminate the temperature rise of the permanent magnet 26 improving the thermal conductivity to the rotor core 12. A filler having a high permeability ( for example, iron powder) can be mixed with the filler 34 in order to eliminate the decline in the amount of the magnetic flux from the permanent magnet 26 increasing the permeability of the filler 34.
    Although it is preferable for the filler 34 to be filled between the long side surfaces 26a, 26b of the permanent magnet 26 and the inner wall of the magnet insertion hole 32 without any openings, an opening can be left in the fill, provided a resistance is obtained enough adhesive from the permanent magnet 26 on the rotor core 12.
    As shown in FIG. 3, the insulating filler 34 is also filled within the cavity portions 33a, 33b of the magnet insertion hole 32. In this way, it can be assumed that the cavity portions 33a, 33b of the magnet insertion hole 32 are an area having a relatively low permeability. By providing such an area of low permeability facing the short side surfaces that are arranged along the direction of magnetization of the permanent magnet 26, it becomes possible to effectively eliminate the flow dispersion and the short circuit between the front and rear surfaces in the portions circumferential end of the permanent magnet 26. In this way, the decline in the amount of flow directed from the permanent magnet 26 to the external circumference of the rotor can be eliminated, obtaining greater motor efficiency.
    Although the permanent magnet 26 is described as having an axial cross section of a parallelogram shape, the shape of the permanent magnet 26 is not limited to that shape. As shown in FIG. 5, the permanent magnet 26 having an axial cross section of a rectangular shape can be used. By applying such a way to the permanent magnet 26, it becomes possible to improve the yields when manufacturing the permanent magnets of the blocks of magnetic material by cutting, achieving lower manufacturing cost.
    14/18
    FIG. 6 shows a view in which the permanent magnet 26 with conductivity in which the insulation film processing is not applied is fixed so as to contact the inner wall of the magnet insertion hole 32 on one side. In that case, as shown in area B circled by a dash and dot line in FIG. 6, the contact surface 26b between the permanent magnet 26 and the rotor core 12 becomes conductive with many laminated electromagnet steel plates, being isolated from each other, resulting in a large circuit path of the eddy current flowing through the surface of the 26a magnet. This increases the eddy current loss of the rotor that rotates in a variable magnetic field, decreasing the efficiency of the torque rate in the rotating electrical machine.
    On the contrary, according to the rotor 10 described above, because the permanent magnet 26 is provided in an inclined position with respect to the direction of extension of the inner wall of the magnet insertion hole 32, the contact portion between the magnet permanent 26 and the rotor core 12 can be limited to a small area, which is the corner portion 27a on one side of the axial end and the corner portion 27b on the other side of the axial end.
    More specifically, the contact portion between the permanent magnet 26 and the rotor core 12 can be limited, for example, to approximately two or more plates at the two axial ends between the electromagnetic steel plates that form the rotor core 12. Thus In this way, it becomes possible to avoid the formation of a large circuit path of the eddy current in which the eddy current flows to the rotor core 12 through the permanent magnet 26 even when the insulation film is not formed on the surface of the permanent magnet 26 .
    Therefore, it is possible to suppress the increase in eddy current loss through the permanent magnet 26 while eliminating the need to process the insulation film in the permanent magnet 26.
    Additionally, because it becomes possible to use permanent magnet 26 without processing the insulation film, such as oxide coating and resin coating, the cost reduction can be
    15/18 reached because of the reduced period and processes required to manufacture the permanent magnet 26.
    In the following, a method of manufacturing the rotor 10 according to the present embodiment is described with reference to FIG. 7. FIG. 7 is a flow chart showing a manufacturing process for the rotor 10.
    First, in step S10, the permanent magnets 26 and the rotor core 12, in which the magnet insertion holes 32 are formed, are prepared.
    Subsequently, in step S12, the permanent magnets 26 are inserted into the magnet insertion holes 32 of the rotor core 12 from the axial direction.
    In step S14, as shown in FIG. 8, the rotor core 12 with the permanent magnets 26 inserted is fitted within the die matrix 40.
    Each of the upper die 42 and the lower die 44 that form the die matrix 40 includes a flat inner side surface to form a wide surface contacting the axial end surfaces of the rotor core 12. Because the surfaces of the axial end 26c, 26d of the permanent magnet 26 being flush with the rotor end surfaces contact the inner side surfaces of the upper die 42 and the lower die 44, the permanent magnet 26 is held in an inclined position within the magnet insertion hole 32 from the rotor core 12 in the subsequent step S16.
    Then, in step S18, a resin material is injected into the matrix from an inlet 43 formed with the upper matrix 42 of the mold matrix 40 to be filled into the cavity portions 33a, 33b of the magnet insertion hole 32 and in an opening between the long side surfaces 26a, 26b of the permanent magnet 26 and the inner wall of the magnet insertion hole 32. In this way, the permanent magnet 26 is fixed inside the magnet insertion hole 32 of the rotor core 12.
    The rotor core 12 to which the permanent magnet 26 is attached as described above is recovered from the mold matrix 40. In the next step
    16/18 hot S20, the rotor core 12 is mounted with the shaft 14, the end plates 16 and the fixing element 18. In this way, the manufacture of the rotor 10 is completed.
    FIG. 9 shows a view in which the permanent magnet 26 having an axial cross section of a rectangular shape is held in an inclined position within the magnet insertion hole 32 of the rotor core 12 by the mold matrix 40. In this case, a projected portion 46 that corresponds to the magnet insertion hole 32 and has a slanted end surface is produced on each of the inner side surfaces of the upper matrix 42 and the lower matrix 44 of the mold matrix 40. In this way, the permanent magnet 26 inserted in the magnet insertion hole 32 it is held in an inclined position within the magnet insertion hole 32 by the inclined end surfaces of the projected portions 46 that touch and press the axial end surfaces 26c, 26d in the axial direction.
    FIG. 10 shows another example in which a permanent magnet 26 having a rectangular axial cross section is held in an inclined position within a magnet insertion hole 32 of a rotor core 12 by a die template 40. In this case, pins 48, which are projected elements, are respectively provided with the upper die 42 and the lower die 44 of the mold die, such that pins 48 can be moved back and forth. A conical surface is formed at the tip portion of the pins 48. The pins 48 are pressed into the die matrix 40 by an elastic element 50, such as a spring or rubber. In this way, the tapered surfaces of the pins 48 elastically provided touch and press the corner portions of the axial end portions of the permanent magnet 26 in a direction substantially perpendicular to the axial direction, such that the permanent magnet 26 is held in an inclined position within the magnet insertion hole 32. Because pins 48 are elastically provided, so pins 48 can be moved back and forth, excessive contact pressure applied to permanent magnet 26 by pins 48 can be avoided, preventing the permanent magnet 26 from being damaged.
    17/18
    It should be noted that a rotor according to the present invention is not limited to the above embodiments and variations thereof. Various changes and improvements are possible, as long as they do not deviate from the essential aspects within the scope of the claims.
    For example, although a pair of permanent magnets 26 is described as included in each magnetic pole 24 of rotor 10 in the above embodiments, the number of permanent magnets included in each magnetic pole can also be one or more than three.
    Additionally, in the case where a pair of permanent magnets 26 is included in a magnetic pole 24 as shown in FIG. 11, a permanent magnet 26 and the other permanent magnet 26 can have different inclined directions within the magnet insertion hole 32. In other words, on a surface of the axial end of the rotor core 12, a permanent magnet 26 can contact the core of the rotor 12 in the corner on the outer circumferential side and the other permanent magnet 26 can contact in the corner on the inner circumferential side. In this way, it becomes possible to obtain the advantage that the amount of magnetic flux from a magnetic pole 24 in the axial direction can be uniformized.
    Additionally, as shown in FIG. 12, each permanent magnet 26 included in the magnetic pole 24 can be segmented, for example, into two or more towards the long side surface. In such a case, the filler 34 is completely filled between each of the segmented pieces of the magnet in addition to between the permanent magnet 26 and the insertion hole of the magnet 32. In this way, it is possible to obtain insulation properties between each of the pieces of the magnet, obtaining the suppression of the loss by eddy current of the magnet. This can be accomplished by providing, between the two pieces of magnet placed in the magnet insertion hole 32a, thin plate shaped spacers 52 that project from the upper matrix 42 and the lower matrix 44, respectively, as shown in FIG. 13, and fill the filler 34 in such a condition.
    REFERENCE NUMBERS rotor of the rotating electric machine, 11 stator, 12 wheel core
    18/18 tor, 13 outer circumferential surface, 14 shaft, 15 flange portion, 16 end plate, 18 fixing element, 20 fixing portion, 22 pressing portion, 23 shaft hole, 24 magnetic pole, 26 permanent magnet, 26a, 26b long side surfaces, 32 magnet insertion hole, 33a, 33b cavity portions 5, 33c magnet housing portion, 34 filler, 40 mold matrix, 42 upper matrix, 44 lower matrix, 46 projected portion, 48 pin, 50 elastic element and 52 spacer.
    权利要求:
    Claims (9)
    [1]
    1. Rotor of the rotating electric machine (10) with a built-in magnet, the rotor of the rotating electric machine, comprising:
    a rotor core (12) with a magnet insertion hole (32) extended inside, the magnet insertion hole being formed along the axial direction of the rotor core;
    a magnet inserted in the magnet insertion hole, the magnet having a radial external side (26a) and a radial internal side (26b); and an insulating filler (34) filled between an inner wall of the magnet insertion hole and the magnet to fix the magnet, characterized by the fact that the magnet is fixed with the filler, such that a surface on the outer side (26a) and a surface on the inner side (26b) in a radial direction of the magnet within the magnet insertion hole is inclined with respect to an extension direction of the inner wall of the magnet insertion hole, the magnet having an axial cross section of an elongated quadrilateral shape; and the magnet contacts the inner wall of the magnet insertion hole in the corner on one side of the axial end and on the other corner on the other side of the axial end which is diagonally opposite the corner on the one side of the axial end.
    [2]
    2. Rotating electric machine rotor according to claim 1, characterized by the fact that the magnet has an axial cross section of a parallelogram shape and axial end surfaces that are flush with the axial end surfaces of the rotor core .
    [3]
    3. Rotor of rotating electrical machine, according to claim 1, characterized by the fact that the magnet has an axial cross section of a rectangular shape.
    [4]
    4. Rotor of a rotating electrical machine according to any one of claims 1 to 3, characterized by the fact that the magnet is segmented into a plurality of magnetic piecesPetition 870190083673, of 27/08/2019, pg. 39/44
    2/3 cos; and the filling is integrally filled between each other of the magnet pieces in addition to between the inner wall of the magnet insertion hole and the magnet.
    [5]
    5. Electric rotating machine, comprising:
    the rotor, as defined in any one of claims 1 to
    4, characterized by the fact that a stator is arranged around the rotor.
    [6]
    6. Method for manufacturing a rotating electric machine rotor, with a built-in magnet, the method characterized by comprising:
    preparing a magnet and a rotor core with a magnet insertion hole extended inside, the magnet having a radial outer side (26a) and a radial inner side (26b);
    insert the magnet into the magnet insertion hole;
    position, in a mold matrix, the rotor core with the magnet inserted inside;
    keep the magnet with a portion of the mold matrix, such that a surface on the outer side (26a) and a surface on the inner side (26b) in a radial direction of the magnet within the magnet insertion hole is tilted with respect to one direction extension of the inner wall of the magnet insertion hole;
    fill an insulating filler between the inner wall of the magnet insertion hole and the magnet through an entrance provided with the mold matrix to fix the magnet in the rotor core; and mount, on the axis (14), the rotor core, in which the magnet is fixed to the filling, the magnet having an axial cross section in a parallelogram shape and axial end surfaces that are flush with the end surfaces axial of the rotor core; and in clamping, the flat inner side surfaces of the mold matrix touch the surfaces of the axial end of the rotor core and the surfaces of the axial end of the magnet, such that the magnet is held in an inclined position within the magnet insertion hole. .
    Petition 870190083673, of 8/27/2019, p. 40/44
    3/3
    [7]
    7. Method for manufacturing the rotating electric machine rotor, according to claim 6, characterized by the fact that the magnet has a rectangular axial cross section; and
    5 in clamping, the sloping surfaces of the projected portions projecting on the inner side surfaces of the mold matrix touch the surfaces of the axial end of the magnet and press the magnet in an axial direction, such that the magnet is held in an inclined position within the magnet insertion hole.
    [8]
    10 8. Method for manufacturing the rotating electric machine rotor, according to claim 6, characterized by the fact that the magnet has an axial cross section of a rectangular shape; and in bonding, the sloping surfaces of the projected portions
    [9]
    15 which are elastically provided with the mold matrix and capable of moving back and forth touch the corner portions of the axial end portions of the magnet and press the axial end portions of the magnet in a direction substantially perpendicular to the axial direction, such as that the magnet is held in an inclined position within the magnet insertion hole.
    类似技术:
    公开号 | 公开日 | 专利标题
    BR112013031443B1|2020-02-11|ROTATING ELECTRIC MACHINE ROTOR, ROTATING ELECTRIC MACHINE AND METHOD FOR ROTATING ELECTRIC MACHINE ROTOR
    KR20130076779A|2013-07-08|Multi-grade magnet for an electric machine
    JP2018068059A|2018-04-26|Rotor unit and method of manufacturing the same
    JPWO2015146210A1|2017-04-13|Permanent magnet type rotating electrical machine and manufacturing method thereof
    JP2012244838A|2012-12-10|Rotor for rotary electric machine, rotary electric machine and method of manufacturing rotor for rotary electric machine
    JP2013066345A|2013-04-11|Rotary electric machine
    JP2015122838A|2015-07-02|Motor
    JP2016010176A|2016-01-18|Motor
    CN109155552A|2019-01-04|Rotating electric machine
    JP2011199947A|2011-10-06|Permanent magnet embedded rotor for rotary electric machine, and rotary electric machine
    JP2010141960A|2010-06-24|Insulating member
    JP2014023387A|2014-02-03|Motor and manufacturing method of the same
    JP2013121262A|2013-06-17|Rotor of rotary electric machine and method for manufacturing the same
    JP2015106946A|2015-06-08|Dynamo-electric machine rotor
    TW201328126A|2013-07-01|Permanent magnet motor and rotor thereof
    JP2013121274A|2013-06-17|Rotor structure of rotary electric machine
    JP2017135923A|2017-08-03|Rotor for motor
    CN111668951B|2021-12-21|Rotor core structure
    JP5961325B2|2016-08-02|A kind of permanent magnet rotor structure
    JP2015154686A|2015-08-24|Rotary electric machine rotor
    JP5411883B2|2014-02-12|Permanent magnet rotating machine
    JP2011166927A|2011-08-25|Electric motor
    JP2021027769A|2021-02-22|Manufacturing method of embedded magnet type rotor
    CN106575892B|2018-10-30|The rotor that can constitute to high number of poles for reluctance machine
    JP2020010466A|2020-01-16|Rotor of permanent magnet embedded type rotary electric machine and method for manufacturing the same
    同族专利:
    公开号 | 公开日
    US9608485B2|2017-03-28|
    RU2554119C1|2015-06-27|
    EP2722968B1|2019-04-10|
    BR112013031443A2|2016-12-13|
    CN103597714A|2014-02-19|
    CN103597714B|2015-12-09|
    EP2722968A1|2014-04-23|
    WO2012169043A1|2012-12-13|
    JPWO2012169043A1|2015-02-23|
    JP5614501B2|2014-10-29|
    AU2011370188B2|2015-02-12|
    AU2011370188A1|2013-12-05|
    EP2722968A4|2016-02-10|
    US20140077652A1|2014-03-20|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    DE19737391A1|1997-08-27|1999-03-04|Magnet Motor Gmbh|Electrical machine, the rotor of which is made up of permanent magnets and magnetic flux guide pieces|
    JPH11252838A|1998-03-02|1999-09-17|Nissan Motor Co Ltd|Rotor magnet positioning method|
    JP4097902B2|2001-02-06|2008-06-11|三菱電機株式会社|Rotor and compressor of permanent magnet motor and refrigeration cycle|
    JP2005094845A|2003-09-12|2005-04-07|Toshiba Industrial Products Manufacturing Corp|Rotor of permanent magnet type rotary electric machine|
    JP2005269804A|2004-03-19|2005-09-29|Toyota Motor Corp|Rotary electric machine|
    US7982350B2|2004-10-25|2011-07-19|Novatorque, Inc.|Conical magnets and rotor-stator structures for electrodynamic machines|
    JP4856990B2|2006-03-13|2012-01-18|トヨタ自動車株式会社|Rotor, method for manufacturing the same, and electric vehicle|
    JP2008109777A|2006-10-25|2008-05-08|Toyota Motor Corp|Rotor, rotary motor, and manufacturing method for the rotor|
    RU2386200C2|2007-08-29|2010-04-10|Государственное образовательное учреждение высшего профессионального образования Дальневосточный государственный технический университет |Rotor of electric generator|
    RU2369953C1|2007-12-26|2009-10-10|Общество с ограниченной ответственностью "ЭНЕРГИЯ"|Multipole rotor of valve electric machine with permanent magnets |
    RU91483U1|2008-09-10|2010-02-10|Виктор Семенович Ломоносов|MULTIPLE MAGNETIC MOTOR|
    RU2382472C1|2008-12-01|2010-02-20|Александр Владимирович Левин|Rotor of high-speed electric machine |
    JP2010183692A|2009-02-04|2010-08-19|Toyota Motor Corp|Magnet for motor, rotor for ipm motor, and ipm motor|
    JP5268711B2|2009-03-02|2013-08-21|三菱電機株式会社|Electric motor and compressor, air conditioner and vacuum cleaner|
    JP2011004529A|2009-06-18|2011-01-06|Toyota Motor Corp|Ipm motor rotor and ipm motor|JP4509239B2|1998-11-19|2010-07-21|ダイセル化学工業株式会社|Cellulose triacetate and method for producing the same|
    KR101439004B1|2013-02-05|2014-09-05|현대자동차주식회사|Molding apparatus and method for positioning permanent magnet of rotor|
    JP5611405B1|2013-04-17|2014-10-22|三菱電機株式会社|Rotating electric machine|
    CN105229898B|2013-05-13|2017-08-15|三菱电机株式会社|The magnet embedded type rotor of electric rotating machine|
    JP6115448B2|2013-11-06|2017-04-19|トヨタ自動車株式会社|Manufacturing method of rotor for rotating electrical machine and rotor for rotating electrical machine|
    JP5999079B2|2013-12-13|2016-09-28|トヨタ自動車株式会社|Rotating electrical machine rotor|
    JP6403982B2|2014-04-30|2018-10-10|マブチモーター株式会社|Brushless motor|
    JP5818949B2|2014-07-03|2015-11-18|三菱電機株式会社|Rotating electric machine|
    JP6405788B2|2014-08-20|2018-10-17|株式会社デンソー|Rotating electrical machine rotor|
    JP2016073056A|2014-09-29|2016-05-09|トヨタ自動車株式会社|Manufacturing method of rotor|
    KR20160116999A|2015-03-31|2016-10-10|엘지이노텍 주식회사|Rotor and Fabricatin method of the same, Motor and using the same|
    JP6480789B2|2015-04-13|2019-03-13|本田技研工業株式会社|Rotating electrical machine rotor|
    JP6233355B2|2015-06-23|2017-11-22|トヨタ自動車株式会社|Rotor|
    US20180248453A1|2015-09-02|2018-08-30|Hitachi Automotive Systems, Ltd.|Rotor, Rotating Electric Machine Including Said Rotor, and Method of Manufacturing Said Rotor|
    JP6459869B2|2015-09-08|2019-01-30|トヨタ自動車株式会社|Resin injection method|
    DE102016201281B3|2016-01-28|2017-05-24|Continental Automotive Gmbh|Attachment of a permanent magnet within a rotor core|
    DE102016201970A1|2016-02-10|2017-08-10|Robert Bosch Gmbh|Electric machine|
    JP6383746B2|2016-03-10|2018-08-29|本田技研工業株式会社|Rotor for rotating electrical machine and method for manufacturing the same|
    DE112016003500T5|2016-03-16|2018-06-28|Fuji Electric Co., Ltd.|ELECTRIC CIRCULAR POWER MACHINE WITH PERMANENT MAGNET AND MANUFACTURING METHOD THEREOF|
    RU2610305C1|2016-03-25|2017-02-09|Федеральное Государственное Автономное Образовательное Учреждение Высшего Профессионального Образования "Дальневосточный Федеральный Университет" |Electric machine rotor|
    CN108781029B|2016-03-28|2020-11-03|爱信艾达株式会社|Method for manufacturing rotor|
    JP6095827B1|2016-04-14|2017-03-15|三菱電機株式会社|Manufacturing method of rotor for rotating electrical machine|
    CN106026558A|2016-06-29|2016-10-12|无锡新大力电机有限公司|Manufacturing technology of permanent magnet motor|
    WO2018011850A1|2016-07-11|2018-01-18|三菱電機株式会社|Rotor, electric motor, air blower, compressor, and air conditioning device|
    JP6597594B2|2016-12-27|2019-10-30|トヨタ自動車株式会社|Rotor manufacturing equipment|
    JP6627784B2|2017-01-11|2020-01-08|トヨタ自動車株式会社|Rotating electric machine rotor|
    JP6740940B2|2017-03-16|2020-08-19|トヨタ自動車株式会社|Rotating electric machine rotor|
    JPWO2018189822A1|2017-04-12|2019-07-25|三菱電機株式会社|IPM rotor|
    JP6787257B2|2017-06-06|2020-11-18|株式会社デンソー|Rotating machine|
    JP6874630B2|2017-10-05|2021-05-19|トヨタ自動車株式会社|Rotating electric rotor and its manufacturing method|
    JP6923004B2|2018-01-11|2021-08-18|株式会社アイシン|Rotor manufacturing method|
    JP2019134565A|2018-01-30|2019-08-08|本田技研工業株式会社|Rotor of rotary electric machine|
    US20190326790A1|2018-04-24|2019-10-24|GM Global Technology Operations LLC|Brushless starter rotor assembly|
    JP2020014300A|2018-07-17|2020-01-23|本田技研工業株式会社|Rotor unit|
    JP2020114077A|2019-01-09|2020-07-27|本田技研工業株式会社|Permanent magnet embedded type rotor and method for manufacturing the same|
    JP2020127294A|2019-02-05|2020-08-20|ファナック株式会社|Rotor core manufacturing apparatus and rotor core manufacturing method|
    法律状态:
    2018-12-26| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-07-02| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|
    2019-12-24| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-02-11| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 09/06/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    PCT/JP2011/063245|WO2012169043A1|2011-06-09|2011-06-09|Rotor for rotating electrical machine, rotating electric machine, and method for producing rotor for rotating electrical machine|
    [返回顶部]