Rotating electric machine and manufacturing method of rotating electric machine

Abstract

The present application provides a kind of rotating electrical machine with improved positioning accuracy of magnet.In rotating electrical machine (100) comprising: stator (4);Rotor core (12) is arranged to the inner circumferential side of stator (4) and is fixed to the output shaft (2) of rotor (3);A plurality of magnets (13) are arranged along the circumferential direction and are fixed to the outer circumferential part (18) of rotor core (12);Magnet holder (14) is used to fix magnet (13) to the outer circumferential part (18) of rotor core (12), and magnet holder (14) has: the base portion (22) that output shaft (2) is inserted through;Arm portion (21) is connected with base portion (22), base portion (22) has: the inner circumferential part (23) of circular ring shape;Circular ring-shaped outer circumferential beam (24) is arranged to the outer circumferential side of inner circumferential part (23) and is connected with arm portion (21);Connecting beam (25) connects inner circumferential part (23) and outer circumferential beam (24), therefore, the positioning accuracy of magnet can be improved, and the performance of rotating electrical machine can be improved.

Description

Technical Field

[0001] The present disclosure relates to a rotating electrical machine such as a motor and a generator. Background Art

[0002] A technology has been developed in which a plurality of magnets are arranged circumferentially on the outer periphery of a rotor core in an inward-turning rotating electrical machine, and the magnets are fixed to the outer periphery of the rotor core using a non-magnetic magnet holder. The magnet holder includes a comb-shaped arm portion extending along the axial direction of the output shaft, and the movement of the magnet is restricted by the arm portion. When the magnet holder is used to fix the magnet, in order to prevent the magnet from loosening, which is a cause of performance degradation of the rotating electrical machine, it is necessary to suppress the radial expansion of the arm portion. Conventionally, the radial expansion of the arm portion has been suppressed by including a base portion fixed to the output shaft and an arm portion extending from the base portion along the axial direction of the output shaft in the magnet holder, and making the circumferential width of the bridge portion connecting the base portion and the arm portion smaller than the circumferential width of the arm portion (for example, refer to Patent Document 1).

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: International Publication No. 2007 / 080888 Summary of the Invention

[0006] Technical problem to be solved by the invention

[0007] However, if the circumferential width of the bridge portion is made smaller than that of the arm portion, deformation will occur starting from the bridge portion, causing the arm portion to expand, and a gap will be created between the end of the arm portion opposite the end where the bridge portion is provided and the magnet. This will make it difficult to prevent the magnet from loosening, and the positioning accuracy of the magnet cannot be improved, resulting in a technical problem of deteriorating the performance of the rotating electrical machine.

[0008] The present disclosure is made to solve the above-mentioned technical problems, and its purpose is to provide a rotating electric machine that suppresses loosening of magnets fixed to a rotor core and improves the positioning accuracy of the magnets.

[0009] Technical solutions used to solve technical problems

[0010] The rotating electric machine disclosed herein includes: a stator; a rotor core, which is arranged on the inner peripheral side of the stator and fixed to the output shaft of the rotor; a plurality of magnets, which are arranged along the circumferential direction and fixed to the outer peripheral part of the rotor core; and a magnet holder, which fixes the plurality of magnets to the outer peripheral part of the rotor core, and the magnet holder has: a base, which is arranged on one axial surface side of the rotor core and has the output shaft inserted therethrough; and an arm, one end of the arm is connected to the base and extends along the axial direction, the base having: an annular inner peripheral part; an annular outer peripheral beam, which is arranged on the outer peripheral side of the inner peripheral part and is connected to one end of the arm; and a connecting beam, which connects the inner peripheral part and the outer peripheral beam.

[0011] In addition, the manufacturing method of the rotating electric machine disclosed in the present invention includes: a process of arranging a plurality of magnets along the circumferential direction and arranging them on the outer peripheral portion of the rotor core; a process of arranging a base portion of a magnet retaining frame having an annular inner peripheral portion, an annular outer peripheral beam arranged on the outer peripheral side of the inner peripheral portion, and a connecting beam connecting the inner peripheral portion and the outer peripheral beam on one axial side of the rotor core; and a process of arranging an arm portion of the magnet retaining frame having one end connected to the outer peripheral beam and extending along the axial direction on the outer peripheral surface of the magnet, and pressing the magnet from the arm portion by the outer peripheral beam to fix the magnet between the arm portion and the outer peripheral portion of the rotor core.

[0012] Effects of the Invention

[0013] According to the present disclosure, since looseness is suppressed by the magnet holder and the magnet is fixed to the rotor core, the positioning accuracy of the magnet can be improved, and the performance of the rotating electric machine can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a cross-sectional view schematically showing the rotating electrical machine according to the first embodiment.

[0015] Figure 2 This is an exploded perspective view showing the rotor according to the first embodiment.

[0016] Figure 3 This is a perspective view showing the rotor core according to the first embodiment.

[0017] Figure 4 This is a cross-sectional view showing the rotor core according to the first embodiment.

[0018] Figure 5 This is a perspective view showing the magnet holder according to the first embodiment.

[0019] Figure 6 This is a partially enlarged view showing the magnet holder according to the first embodiment.

[0020] Figure 7It is a plan view showing a part of the rotating electrical machine according to the first embodiment.

[0021] Figure 8 It is an explanatory diagram of the assembly procedure of the rotor in the first embodiment.

[0022] Figure 9 These are explanatory diagrams for explaining a modification of the magnet holder according to the first embodiment.

[0023] Figure 10 These are explanatory diagrams for explaining a modification of the magnet holder according to the first embodiment.

[0024] Figure 11 It is a perspective view showing a magnet holder according to the second embodiment.

[0025] Figure 12 This is a perspective view showing a modified example of the magnet holder according to the second embodiment.

[0026] Figure 13 It is a perspective view showing a magnet holder according to a third embodiment.

[0027] Figure 14 It is a top view showing the magnet holder according to the third embodiment. DETAILED DESCRIPTION

[0028] Hereinafter, embodiments will be described based on the drawings.

[0029] Implementation Method 1

[0030] Figure 1 This is a cross-sectional view schematically illustrating a rotating electrical machine 100 according to Embodiment 1. Rotating electrical machine 100 includes a stator 4 fixed within a cylindrical motor housing 1, and a rotor 3 disposed on the inner circumference of stator 4 and having an output shaft 2 for outputting rotational torque to the exterior of rotating electrical machine 100. A gap is provided between rotor 3 and stator 4, and the outer circumferential surface of rotor 3 faces the inner circumferential surface of stator 4.

[0031] The stator 4 has a stator core (not shown) on which an armature winding 5 is wound. The stator 4 is fixed to the inner surface of the motor housing 1 by, for example, press-fitting. Figure 1 The upper annular wiring portion 6 disposed near the armature winding 5 is connected to the end of the armature winding 5 by, for example, TIG welding (Tungsten Inert Gas: non-metallic inert gas arc welding).

[0032] The winding end 7 extends axially from the annular wiring portion 6 through the frame 8 and is connected to the end of the armature winding 5 via the annular wiring portion 6. Furthermore, three conductors are integrated at the winding end 7, each connected to the end of the U-phase winding, the end of the V-phase winding, and the end of the W-phase winding of the armature winding 5. Rotation of the rotor 3 is achieved by sequentially supplying a predetermined current to the U-phase, V-phase, and W-phase windings of the armature winding 5 using a control device (not shown) based on the phase of the rotor 3. Hereinafter, the axial direction refers to the axial direction of the output shaft 2.

[0033] Next, the rotor 3 will be described. The output shaft 2 of the rotor 3 is supported by a first bearing 9 and a second bearing 10 so as to be rotatable. Figure 1 In the example, the first bearing 9 is provided at the center of the frame 8 that seals the interior of the rotating electrical machine 100, and the second bearing 10 is provided on the output side of the rotating shaft ( Figure 1 In this way, the first bearing 9 and the second bearing 10 are arranged above and below the rotor 3, respectively.

[0034] Here, a sensor rotor 11 having a rotation sensor (not shown) may be fixed to the side of the output shaft 2 opposite to the output side ( Figure 1 In this case, a rotation sensor can be provided on the axial end face of the sensor rotor 11 with a gap therebetween. For example, the sensor rotor 11 is a so-called magnetic sensor type rotor having one or more pairs of permanent magnets. If the sensor rotor 11 is provided in the rotating electrical machine 100, the rotation sensor can detect changes in the magnetic field from the permanent magnets of the sensor rotor 11, which rotate along with the output shaft 2, and convert them into electrical signals, thereby obtaining information such as the rotation speed of the output shaft 2. Alternatively, as long as the sensor rotor 11 can obtain information such as the rotation speed of the output shaft 2, it may be a resolver, a Hall effect sensor, or the like.

[0035] Figure 2 This is an exploded perspective view of the rotor 3 according to the first embodiment. The rotor 3 includes: an output shaft 2; a rotor core 12 fixed to the output shaft 2; magnets 13 fixed to the outer periphery 18 of the rotor core 12; and a magnet holder 14 that secures the magnets 13 to the rotor core 12. Furthermore, the rotor 3 includes a cylindrical cover 15 provided on the outer periphery of the rotor core 12, the magnets 13, and the magnet holder 14. Providing the cover 15 on the rotor 3 can prevent the magnets 13 from scattering when damaged, thereby preventing the rotating electrical machine 100 from rotating. Furthermore, the magnets 13 are, for example, so-called segmented permanent magnets.

[0036] In addition, the rotor 3 is a so-called step-skew rotor. Figure 2In the example shown in FIG. 3 , the rotor cores 12 are arranged in two rows along the axial direction, and eight magnets 13 are fixed to the outer periphery 18 of each rotor core 12 along the circumferential direction of the rotor 3 .

[0037] On each of the adjacent rows of rotor cores 12, magnets 13 of the same polarity are circumferentially staggered by a predetermined angle, i.e., a predetermined step angle. This reduces cogging torque pulsation and energization torque pulsation. Reducing cogging torque pulsation and energization torque pulsation can prevent vibrations caused by cogging torque pulsation and energization torque pulsation from being transmitted to the driver via the steering wheel, for example, when the rotating electrical machine 100 is used in an electric power steering system. Here, cogging torque refers to the fluctuation in torque generated by the rotation of the rotor 3 when no power is supplied to the rotor 3, and energization torque pulsation refers to the fluctuation in torque during the rotation of the rotor 3.

[0038] Figure 3 1 is a perspective view of the rotor core 12 according to the first embodiment. The rotor core 12 is formed of a magnetic material such as an electromagnetic steel plate, for example, by stacking core plates having a thickness of about 0.5 mm, and is arranged on the inner circumference of the stator 4. The core plates constituting the rotor core 12 are stacked core plates fixed to each other by methods such as punching, riveting, welding, or bonding. In addition, a fixing hole 17 is provided in the central portion of the rotor core 12 when viewed from above (from the viewpoint of viewing the rotor core 12 from the axial direction), and the output shaft 2 is inserted through the fixing hole 17, thereby fixing the rotor core 12 and the output shaft 2.

[0039] In addition, a protrusion 19 is provided at the end portion of the outer peripheral portion 18 of the rotor core 12 to which the magnets 13 are fixed, on the axially opposite side to the side on which the base portion 22 of the magnet holder 14 described later is provided. The protrusion 19 protrudes radially outward from the rotor 3. Figure 3 In the example shown, the protrusion 19 is provided on the rotor core 12. Figure 3 If a protrusion 19 is provided on the outer peripheral portion 18 of the rotor core 12, when the magnet 13 is fixed to the outer peripheral portion 18 of the rotor core 12, the magnet 13 abuts against the protrusion 19, which can limit the axial movement of the magnet 13 and improve the axial positioning accuracy of the magnet 13.

[0040] Furthermore, the rotor core 12 is provided with a fitting portion 20 formed in a groove shape. Figure 4 : is a cross-sectional view showing the rotor core 12 of the first embodiment. Figure 4 (a) shows the Figure 3 The cross section of the rotor core 12 at the dotted line A is Figure 4 (b) shows the Figure 3The cross section of the rotor core 12 at the dotted line B. The rotor core 12 is composed of Figure 4 (a) and Figure 4 The core plate 16a provided with the protrusion 19 and the core plate 16b not provided with the protrusion 19 are stacked. In addition, the core plates 16a and 16b are respectively arranged along the axial direction ( Figure 4 The fitting portion 20 is continuously provided in the direction of the through-paper surface. The fitting portion 20 is formed in an L-shape when viewed from above, and an arm portion 21 of the magnet holder 14 described next is fitted into the fitting portion 20.

[0041] Hereinafter, the magnet holder 14 of this embodiment will be described. Figure 5 This is a perspective view of magnet holder 14 according to Embodiment 1. Magnet holder 14 is formed of, for example, a non-magnetic resin and includes a base portion 22 disposed on one axial surface of rotor core 12, and an arm portion 21 connected at one end to base portion 22 and extending axially in the output shaft 2. Each of the plurality of magnets 13 is secured to outer circumference 18 of rotor core 12 via arm portion 21.

[0042] Furthermore, the base portion 22 of the magnet holder 14 includes an annular inner portion 23, an annular outer beam 24 surrounding the inner portion 23 and provided on the outer circumference of the inner portion 23, and a connecting beam 25 connecting the inner portion 23 and the outer beam 24. An insertion hole 26 is provided in the center of the inner portion 23 when viewed from above, and the output shaft 2 is inserted through the insertion hole 26, thereby fixing the magnet holder 4 and the output shaft 2.

[0043] In addition, if Figure 5 As shown, the outer peripheral beam 24 has a circular ring portion 27 and a receiving portion 28 formed from the ring portion 27 to the inner peripheral side. Figure 5 In the example of FIG, one end of the arm portion 21 is connected to the annular portion 27 and the receiving portion 28 , so that the outer peripheral beam 24 and the arm portion 21 are connected.

[0044] Furthermore, the inner circumference portion 23 is separated from the outer circumference beam 24, and the inner circumference portion 23 and the outer circumference beam 24 are connected via a connecting beam 25 extending radially from the inner circumference portion 23. Thus, as long as the base portion 22 of the magnet holder 14 includes the annular inner circumference portion 23, the annular outer circumference beam 24 provided to surround the inner circumference portion 23, and the connecting beam 25 connecting the inner circumference portion 23 and the outer circumference beam 24, deflection of the arm portion 21 can be prevented, and the arm portion 21 can be suppressed from opening. The reason why the arm portion 21 can be suppressed from opening will be described in detail later.

[0045] Furthermore, it is preferable that receiving portion 28 protrude from arm portion 21 in plan view, that is, the projected area of ​​receiving portion 28 in plan view is larger than the projected area of ​​arm portion 21 in plan view. In this manner, if foreign matter is generated during assembly of rotating electrical machine 100, such as when arm portion 21 is partially damaged when inserted into fitting portion 20 of rotor core 12, the foreign matter can be trapped between receiving portion 28 and rotor core 12, thereby preventing malfunction of rotating electrical machine 100.

[0046] Furthermore, the outer peripheral beam 24 and the connecting beam 25 of the magnet holder 14 are provided with an axial holding portion 29 for holding the axial side surface of the magnet 13. Figure 5 In the example, the axial retaining portion 29 spans the annular portion 27 of the outer peripheral beam 24 and the connecting beam 25, and is respectively provided on the surface opposite to the magnet 13. Furthermore, when the magnet holder 14 is mounted on the rotor core 12, the axial retaining portion 29 is arranged on the side of the rotor core 12 opposite to the protrusion 19, and is opposite to the magnet 13. By arranging the axial retaining portion 29 and the protrusion 19 opposite each other, the magnet 13 is clamped from both axial sides by the axial retaining portion 29 and the protrusion 19, and the elastic force generated by the deformation of the axial retaining portion 29 acts on the magnet 13, thereby firmly retaining the magnet 13.

[0047] Furthermore, a guide portion 30 is formed on the surface of the base portion 22 opposite to the surface connected to the arm portion 21, for example, by chamfering, so as to reduce the angle of the outer peripheral end. Providing the guide portion 30 on the base portion 22 eliminates the outer peripheral end of the base portion 22 from being caught during assembly of the rotating electrical machine 100, thereby facilitating the insertion of the cover 15.

[0048] Next, the arm portion 21 of the magnet holder 14 will be described. Figure 6 It is a partially enlarged view of the magnet holder 14 of embodiment 1. The arm portion 21 has: a magnet holding portion 31, which covers the outer peripheral surface of the magnet 13 and holds the magnet 13; a first pressing surface 32 and a second pressing surface 33, which respectively abut the circumferential side surfaces of the magnet 13 and limit the circumferential movement of the magnet 13; and an anti-slip portion 34, which has an angle with respect to the first pressing surface 32 and the second pressing surface 33 provided on the inner peripheral side of the arm portion 21. Here, covering the outer peripheral surface of the magnet 13 also includes covering a part of the outer peripheral surface of the magnet 13. In addition, the arm portion 21 is provided between circumferentially adjacent magnets 13 among the plurality of magnets 13, and the number of the arm portions 21 corresponds to the number of magnets 13 to be fixed.

[0049] like Figure 6As shown, the first pressing surface 32, the second pressing surface 33 and the anti-slip portion 34 are formed into an L shape when viewed from above. Here, the angle formed between the first pressing surface 32 and the anti-slip portion 34 is preferably a right angle. If so, when the magnet 13 is fixed by the magnet holder 14, the arm portion 21 can be prevented from deforming in the circumferential direction, thereby achieving high-precision positioning and suppressing looseness between the magnet 13. In addition, the arm portions 21 possessed by the magnet holder 14 are preferably of the same shape. If so, the performance of the rotating electrical machine 100 can be improved without deflection when the rotor 3 rotates. In addition, the components of the rotating electrical machine 100 can be made common and manufacturing costs can be reduced.

[0050] In addition, if the first pressing surface 32 of the arm 21 is designed to be perpendicular to the outer peripheral surface of the rotor core 12, the first pressing surface 32 is pressed into and fixed to the interlocking portion 20 when the magnet holder 14 is installed on the rotor core 12. Therefore, the magnet 13 can be fixed to the rotor core 12 with the first pressing surface 32 of the magnet holder 14 as a positioning reference, and the positioning accuracy of the magnet 13 is improved.

[0051] Figure 7 FIG. 1 is a plan view showing a portion of the rotating electrical machine 100 according to the first embodiment. Figure 7 FIG shows a diagram of the magnet holder 14 being mounted on the rotor core 12. The magnet holder 14 is fixed to the rotor core 12 by engaging the arm portion 21 with the engaging portion 20 of the rotor core 12. In other words, Figure 7 As shown, a portion of each of the first pressing surface 32 and the second pressing surface 33 of the arm 21 and the retaining portion 34 are fitted into the fitting portion of the rotor core 12 , so that the magnet holder 14 is fixed to the rotor core 12 .

[0052] Here, it is preferable that the fitting portion 20 of the rotor core 12 is formed larger than the anti-detachment portion 34 of the magnet holder 14, that is, the width of the fitting portion 20 ( Figure 7 Wf) is greater than the thickness of the anti-slip portion 34 ( Figure 7 If so, the anti-slip portion 34 can be displaced toward the outer peripheral side in the gap formed between the interlocking portion 20 and the anti-slip portion 34. Therefore, when the magnet 13 is pressed into the magnet holder 14, the load applied to the arm portion 21 can be suppressed, and the load resistance of the magnet holder 14 can be improved.

[0053] Next, a method for manufacturing the rotating electrical machine 100 will be described. Figure 8 This is an explanatory diagram for explaining the assembly steps of the rotor 3 of the first embodiment. First, after the rotor core 12 and the magnet 13 are fixed to the assembly jig, as shown in FIG. Figure 8 As shown in FIG. 1( a ), a plurality of magnets 13 are arranged along the circumferential direction and disposed on the outer peripheral portion 18 of the rotor core 12 .

[0054] Then, if Figure 8 As shown in (b), the base portion 22 of the magnet holder is arranged on one side of the axial direction of the rotor core 12, and the magnet holder 14 is inserted into the rotor core 12 from the axial direction. Figure 8 In the example (b), the magnet holder 14 is inserted from the side of the protrusion 19 of the rotor core 12. At this time, a portion of each of the first pressing surface 32 and the second pressing surface 33 of the arm portion 21 of the magnet holder 14 and the anti-slip portion 34 are pressed into the fitting portion 20 fixed to the rotor core 12, thereby positioning and fixing the magnet holder 14 relative to the rotor core 12. In addition, since the arm portions 21 are provided in a number corresponding to the number of magnets 13, the plurality of magnets 13 arranged on the outer peripheral portion 18 of the magnet core 12 can be positioned and fixed at the same time by the magnet holder 14.

[0055] Next, the base portion 22 of the magnet holder 14 is arranged on one axial surface side of the rotor core 12. The magnet 13 is fixed between the outer peripheral portion 18 of the rotor core 12 and the arm portion 21 of the magnet holder 14 by the elasticity of the outer peripheral beam 24 possessed by the base portion 22. That is, the elastic force of the outer peripheral beam 24 acts on the magnet 13 in the direction toward the inner periphery, and the magnet 13 is pressed against the outer peripheral portion 18 of the rotor core 12 and fixed. In addition, although Figure 8 Only one set of rotor cores 12, magnets 13 and magnet holders 14 is shown in (b), but in the case of a rotor 3 having a stepped skew structure, it is sufficient to install multiple rotor cores 12, magnets 13 and magnet holders 14 separately.

[0056] At this time, the axially opposite side surfaces of the magnet 13 are held by the protrusions 19 of the rotor core 12 and the axially retaining portions 29 of the magnet holder 14. Therefore, the connecting beams 25 flex in the axial direction when the magnet holder 14 is inserted. Consequently, the connecting beams 25 elastically deform in the axial direction to absorb any axial dimensional deviations of the magnet 13, allowing the magnet 13 to abut against the protrusions 19 of the rotor core 12 while being retained by the elastic force generated by the deformation of the connecting beams 25. Consequently, the magnet 13 can be retained in the axial direction with high precision and a high holding force.

[0057] Here, deformation of the magnet holder 14 will be described. Figure 9 These are explanatory diagrams for explaining a modification of the magnet holder 14 according to the first embodiment. Figure 9 (a) is a perspective view showing the appearance of the magnet holder 14 after being installed on the rotor core 12. The magnet holder 14 is designed to be pressed into the magnet 13 and fixed to the rotor core 12. That is, the magnet holder 14 is designed to be sized to expand toward the outer circumference when installed, as shown in FIG. Figure 9As shown in (a), the magnet holder 14 is deformed when it is mounted on the rotor core 12 .

[0058] Figure 9 (b) is an explanatory diagram related to the deformation of the magnet holder 14, which is a top view of the rotor core 12, the magnet 13 and the magnet holder 14 observed from the side of the protrusion 19 of the rotor core 12. When the magnet holder 14 is installed on the rotor core 12, the arm portion 21 of the magnet holder 14 is displaced toward the outer peripheral side according to the dimensional relationship between the rotor core 12, the magnet 13 and the magnet holder 14. In addition, if there is a gap between the fitting portion 20 and the anti-slip portion 34 of the arm portion 21 of the magnet holder 14, since the outer peripheral beam 24 of the magnet holder 14 is deformed, the anti-slip portion 34 is toward the outer peripheral side, that is, Figure 9 The displacement is performed in the direction indicated by the arrow in (b).

[0059] At this time, due to deformation of the outer peripheral beam 24 of the base portion 22, the arm portion 21 is displaced toward the outer periphery. Therefore, the magnet 13 can be pressed into the magnet holder 14 and fixed to the rotor core 12 without bending the arm portion 21. In this way, the magnet 13 can be pressed against the outer periphery 18 of the rotor core 12 and fixed without bending the arm portion 21. Therefore, the arm portion 21 does not expand, and the magnet 13 does not become loose. Furthermore, it is preferable that the connection between the arm portion 21 and the base portion 22 is not thinner than the arm portion 21, that is, the arm portion 21 has a uniform width throughout the entire axial direction. This prevents deformation of the base portion 22 side of the arm portion 21, further suppressing expansion of the side of the arm portion 21 opposite to the connection with the base portion 22, i.e., the front end side, and further suppressing circumferential deformation of the arm portion 21.

[0060] The deformation of the base portion 22 will be described in more detail. Figure 10 These are explanatory diagrams for explaining a modification of the magnet holder 14 according to the first embodiment. Figure 10 The intensity of the color indicates the degree of stress acting on the magnet holder 14, and the stress acts strongly on the darker part of the color. In other words, the darker the color, the greater the deformation. Figure 10 The rotor core 12 and the magnet 13 are omitted in the figure.

[0061] like Figure 10As shown, a strong stress acts on the annular portion 27 of the peripheral beam 24 of the magnet holder 14, and a large deformation occurs in the annular portion 27. Since the peripheral beam 24 connected to the end of the arm 21 is deformed, the arm 21 that fixes the magnet 13 will not be deformed, and the position of the arm 21 can be adjusted by the peripheral beam 24. In this way, the magnet 13 can be fixed without bending the arm 21, so the arm 21 will not open and the magnet 13 will not become loose. In addition, the connecting beam 25 is connected to the position of the peripheral beam 24 without the receiving portion 28, that is, the annular portion 27 of the peripheral beam 24. Therefore, the deformation of the peripheral beam 24 will not be hindered by the connecting beam 25, and the position of the arm 21 can be better adjusted.

[0062] Back to Figure 8 , the assembly steps of the rotor 3 are described. Figure 8 (c) shows an example in which the rotor 3 has a stepped skew structure and includes two rotor cores 12. Two rotor cores 12 to which magnets 13 and magnet holders 14 are fixed are prepared, and the two rotor cores 12 are arranged one above the other.

[0063] Next, the output shaft 2 is inserted through the fixing holes 17 of each rotor core 12, securing the rotor core 12 and the output shaft 2. It is preferable to arrange the two rotor cores 12 so that the protrusions 19 of the two rotor cores 12 face each other. This ensures a gap between the magnets 13 of adjacent rotor cores 12 via the protrusions 19, further enhancing the effects of reducing cogging torque ripple and current-carrying torque ripple achieved by the stepped skew structure.

[0064] Then, if Figure 8 As shown in (d) of FIG. 1 , the cover 15 is inserted into the rotor core 12, the magnet 13 and the magnet holder 14. Figure 8 As shown in (e), a portion of the cover 15 is folded inward to provide a cover end surface 35. In addition, if the axial retaining portion 29 is provided, the magnet holder 14 and the rotor core 12 can also be retained using the pressing force. Therefore, compared with the case where the magnet 13 is retained in the axial direction only by the retaining force of the cover end surface 35 of the cover 15, the magnet 13 can be retained more firmly in the axial direction.

[0065] Thus, the rotating electric machine 100 includes: a stator 4; a rotor core 12, which is provided on the inner peripheral side of the stator 4 and fixed to the output shaft 2 of the rotor 3; a plurality of magnets 13, which are arranged along the circumferential direction and fixed to the outer peripheral portion 18 of the rotor core 12; and a magnet holder 14, which fixes the plurality of magnets 13 to the outer peripheral portion 18 of the rotor core 12, and the magnet holder 14 has: a base portion 22, which is provided on one axial surface side of the rotor core 12 and through which the output shaft 2 is inserted; and an arm portion 21, which One end of the arm 21 is connected to the base 22 and extends axially along the output shaft 2. The base 22 has an annular inner portion 23; an annular outer beam 24, which is arranged on the outer side of the inner portion 23 and connected to one end of the arm 21; and a connecting beam 25, which connects the inner portion 23 and the outer beam 24. When the magnet 13 is pressed into the magnet holder 14, the outer beam 24 of the magnet holder 14 is deformed, and the magnet 13 can be fixed without bending the arm 21. Therefore, the arm 21 will not open and the magnet 13 will not loosen. Therefore, since the magnet holder 14 suppresses looseness and fixes the magnet 13 to the rotor core 12, the positioning accuracy of the magnet 13 can be improved, and the performance of the rotating electric machine 100 can be improved.

[0066] Furthermore, the magnets 13 are arranged on the outer peripheral portion 18 of the rotor core 12, and the base portion 22 of the magnet holder is arranged on one axial surface side of the rotor core 12. Furthermore, if the arm portion 21 of the magnet holder 14 is arranged on the outer peripheral surface of the magnet 13, and the outer peripheral beam 24 is used to press the magnet 13 from the arm portion 21, and the magnet 13 is fixed between the arm portion 21 and the outer peripheral portion 18 of the rotor core 12, the magnet holder 14 can suppress looseness and fix the magnet 13 to the rotor core 12, thereby obtaining a rotating electric machine 100 in which the magnet 13 is fixed with high positioning accuracy.

[0067] In addition, while this embodiment shows an example of applying the present invention to a rotating electric machine 100 having a stepped skew structure, the present invention can also be applied to a motor without a stepped skew structure, and can also be applied to a magnet holder 14 that is not divided in the axial direction. Furthermore, there is no limitation on the number of magnets 13.

[0068] Furthermore, in this embodiment, an example is described in which one end of the arm 21 is connected to the annular portion 27 and the receiving portion 28, thereby connecting the outer peripheral beam 24 to the arm 21. However, one end of the arm 21 may be connected only to the receiving portion 28. Even in this case, the arm 21 and the outer peripheral beam 24 can be connected, and the deformation of the outer peripheral beam 24 can be utilized to fix the magnet 13 to the outer peripheral portion 18 of the rotor core 12 without causing the arm 21 to flex. Therefore, the arm 21 will not open, and the magnet 13 will not become loose.

[0069] Furthermore, in this embodiment, the axial retaining portion 29 is described as being provided so as to span the annular portion 27 of the outer peripheral beam 24 and the connecting beam 25. However, the axial retaining portion 29 may be provided on either the outer peripheral beam 24 or the connecting beam 25. In this case, it is sufficient to provide the axial retaining portion 29 on the surface of the outer peripheral beam 24 or the connecting beam 25 that faces the magnet 13.

[0070] Implementation Method 2

[0071] Figure 11 : is a perspective view showing the magnet holder 36 of the second embodiment. Figure 11 (a) shows a perspective view of the magnet holder 36 viewed from the side where the arm 21 is provided. Figure 11 (b) shows a perspective view of the magnet holder 36 as viewed from the side where the base portion 37 is provided. The rotating electrical machine 100 of this embodiment differs from the first embodiment in that the connecting beam 38 of the magnet holder 36 is folded back. Structural elements identical to those of the first embodiment are denoted by the same reference numerals, and illustration and description thereof are omitted.

[0072] like Figure 11 (a) and Figure 11 As shown in (b), the connecting beam 38 connecting the inner peripheral portion 23 and the outer peripheral beam 24 of the magnet holder 36 has a bent portion 39 provided in a folded manner. Figure 11 (a) and Figure 11 In example (b), the connecting beam 38 is folded back once between the inner peripheral portion 23 and the outer peripheral beam 24 to form a U-shape, and a bent portion 39 is provided. If the bent portion 39 is provided in the connecting beam 38, the connecting beam 38 also deforms toward the outer peripheral side together with the outer peripheral beam 24 when the magnet holder 36 is inserted. Therefore, the arm portion 21 can be suppressed from opening, and the magnet 13 can be positioned more accurately.

[0073] Furthermore, if a bend portion 39 is provided on the connecting beam 38, the connecting beam 38 also deforms together with the peripheral beam 24 when the magnet holder 36 is inserted. Therefore, the load required to insert the magnet holder 36 is reduced, making it easier to insert the magnet holder 36, thereby improving the assemblability of the rotating electrical machine 100. Furthermore, the stress generated on the peripheral beam 24 when inserting the magnet holder 36 is also dispersed to the connecting beam 38, thereby suppressing damage to the magnet holder 36 and improving reliability. Furthermore, since the stress is dispersed to the connecting beam 38, the tolerance for dimensional deviation of the magnet 13 is also increased. Therefore, the processing accuracy of the magnet 13 can be reduced, making it possible to reduce the cost of the rotating electrical machine 100.

[0074] Furthermore, it is preferred that Figure 11 The bent portion 39 of the folded connecting beam 38 shown in (b) is arranged to face the side opposite to the side where the magnet 13 is provided, that is, the direction where the base portion 37 is provided in the axial direction ( Figure 11 If so, the connecting beam 38 will not interfere with the magnet 13 and will not hinder the magnetic design of the rotating electrical machine 100.

[0075] Thus, in a rotating electric machine 100 including a magnet holder 36 having an arm portion 21 extending axially along the output shaft 2 and a base portion 27 disposed on one axial surface side of the rotor core 12 and through which the output shaft 2 of the rotor 3 is inserted, if a bent portion 39 is provided on the connecting beam 38 of the base portion 37, which connects the inner peripheral portion 23 to the outer peripheral beam 24, the connecting beam 38 deforms along with the outer peripheral beam 24 when the magnet holder 36 is inserted. This allows the magnet 13 to be secured without bending the arm portion 21, preventing the arm portion 21 from opening and the magnet 13 from loosening. Thus, the magnet 13 is secured to the rotor core 12 by the magnet holder 36, suppressing loosening of the magnet 13 and improving the positioning accuracy of the magnet 13, thereby improving the performance of the rotating electric machine 100. The manufacturing method of the rotating electric machine 100 of this embodiment is the same as the manufacturing method described in the first embodiment.

[0076] Modifications

[0077] Next, a modification of the magnet holder 40 of this embodiment will be described. Figure 12 This is a three-dimensional diagram showing a modified example of the magnet holder 40 of the second embodiment. In the above description, an example is described in which the bent portion of the folded connecting beam protrudes in the direction of the side where the base portion is provided in the axial direction. However, the direction in which the bent portion protrudes may not be the direction where the base portion is provided in the axial direction. In other words, Figure 12 (a) and Figure 12As shown in (b), the bent portion 43 of the connecting beam 42 provided on the base portion 41 may also protrude in the circumferential direction. In this way, since the bent portion 43 of the connecting beam 42 does not interfere with the folded portion of the cover 15, the entire rotating electrical machine 100 can be miniaturized.

[0078] Furthermore, in this embodiment, the example in which the connecting beams 38 and 42 of the magnet holders 36 and 40 are provided with a single bent portion 39 and 43 is described. However, the connecting beams 38 and 42 may also be provided with multiple bent portions 39 and 43. In other words, the connecting beams 38 and 42 may be formed by folding back multiple times. In this way, the magnet 13 can be fixed without causing the arm portion to flex in order to deform the connecting beams 38 and 42. This prevents the arm portion from spreading, thus preventing the magnet 13 from loosening.

[0079] Implementation 3

[0080] Figure 13 1 is a perspective view showing a magnet holder 44 according to Embodiment 3. Figure 14 This is a top view of a magnet holder 44 according to Embodiment 3. The rotating electrical machine 100 of this embodiment differs from Embodiment 1 in that a rib 46 is provided on the arm 45 of the magnet holder 44. The same components as those in Embodiment 1 are denoted by the same reference numerals, and illustration and description thereof are omitted.

[0081] like Figure 13 as well as Figure 14 As shown, ribs 46 are provided on the outer periphery of the anti-detachment portion 34 in the arm portion 45 of the magnet holder 44. The thickness of the ribs 46 is sufficient to ensure that the ribs 46 are pressed into the fitting portion 20. Providing the ribs 46 on the arm portion 45 eliminates any gap between the arm portion 45 and the fitting portion 20, thereby increasing the holding force of the magnet 13 by the arm portion 45 and preventing the magnet 13 from loosening.

[0082] In addition, it is preferable that the rib 46 is formed on the side of the arm 45 opposite to the side where the base portion is provided ( Figure 14 The thickness of the front end side of the arm portion 45 is thicker than the side of the arm portion 45 connected to the base portion ( Figure 14 If so, the insertion of the magnet holder 44 becomes easy. In addition, the length of the rib 46 can be appropriately changed.

[0083] Thus, in a rotating electric machine 100 including a magnet holder 44 having an axially extending arm 45 and a base portion provided on one axial surface of the rotor core 12 and through which the output shaft 2 of the rotor 3 is inserted, providing ribs 46 on the outer circumference of the retaining portion 34 of the arm 45 improves the holding force of the magnet 13 by the arm 45. Thus, loosening is suppressed by the magnet holder 44, and the magnet 13 is secured to the rotor core 12. Furthermore, the holding force of the magnet 13 by the arm 45 is increased, thereby improving the positioning accuracy of the magnet 13 and enhancing the performance of the rotating electric machine 100. The manufacturing method of the rotating electric machine 100 of this embodiment is the same as the manufacturing method described in the first embodiment.

[0084] Furthermore, in Embodiments 1 to 3, the terms "L-shaped" and "U-shaped" are used to describe the shapes of components, etc. However, these terms include a range that takes into account manufacturing tolerances, assembly variations, etc. In other words, the shapes of components of rotating electrical machine 100, etc., may also include manufacturing tolerances and assembly variations.

[0085] Furthermore, the embodiments disclosed in this specification can be freely combined within the scope of the embodiments, or can be appropriately modified or omitted.

[0086] (Explanation of Symbols)

[0087] 1. Motor housing; 2. Output shaft; 3. Rotor; 4. Stator; 5. Armature winding; 6. Annular wiring portion; 7. Winding end portion; 8. Frame; 9. First bearing; 10. Second bearing; 11. Sensor rotor; 12. Rotor core; 13. Magnet; 14. 36. 40. 44. Magnet holder; 15. Cover; 16a. 16b. Core plate; 17. Fixing hole; 18. Peripheral portion; 19. Protrusion; 20. Fitting portion; 21. 45. Arm portion; 22. 37. 41. Base portion; 23. Inner portion; 24. Peripheral beam; 25. 38. 42. Connecting beam; 26. Insertion hole; 27. Annular portion; 28. Receiving portion; 29. ​​Axial retaining portion; 30. Guide portion; 31. Magnet retaining portion; 32. First pressing surface; 33. Second pressing surface; 34. Anti-slip portion; 35. Cover end surface; 39. 43. Bend portion; 46. Rib; 100. Rotating electric machine.

Claims

1. A rotating electrical machine, characterized in that: include: stator; a rotor core, the rotor core being disposed on the inner circumference of the stator and fixed to the output shaft of the rotor; a plurality of magnets arranged along a circumferential direction and fixed to an outer periphery of the rotor core; as well as a magnet holder that fixes the plurality of magnets to the outer periphery of the rotor core; The magnet holder has: a base portion provided on one axial surface side of the rotor core portion and through which the output shaft is inserted; and an arm portion, one end of which is connected to the base portion and extends axially, The base portion has: The inner circumference of the ring; a circular outer peripheral beam, the outer peripheral beam being provided on the outer peripheral side of the inner peripheral portion; as well as A connecting beam connects the inner peripheral portion to a portion of the outer peripheral beam other than a portion connected to the one end of the arm portion.

2. The rotating electrical machine according to claim 1, wherein The peripheral beam has: a circular annular portion provided on the outer circumference side of the inner circumference portion; and a receiving portion, the receiving portion protruding from the annular portion toward the inner circumference and connected to one end of the arm portion, The connecting beam connects the inner peripheral portion and the annular portion.

3. The rotating electrical machine according to claim 1, wherein The rotor core has a fitting portion that is continuous in the axial direction. The arm has: a magnet holding portion that covers an outer peripheral surface of the magnet; and an anti-slip portion provided on an inner peripheral side of the magnet holding portion; The fitting portion fits with the retaining portion to fix the arm portion to the rotor core.

4. The rotating electrical machine according to claim 2, wherein: The rotor core has a fitting portion that is continuous in the axial direction. The arm has: a magnet holding portion that covers an outer peripheral surface of the magnet; and an anti-slip portion provided on an inner peripheral side of the magnet holding portion; The fitting portion fits into the retaining portion to fix the arm portion to the rotor core.

5. The rotating electrical machine according to claim 3, wherein: The arm portion has a first pressing surface and a second pressing surface for restricting the movement of the magnet in the circumferential direction. The anti-detachment portion has an angle with respect to the first pressing surface and the second pressing surface.

6. The rotating electrical machine according to claim 4, wherein: The arm portion has a first pressing surface and a second pressing surface for restricting the movement of the magnet in the circumferential direction. The anti-detachment portion has an angle with respect to the first pressing surface and the second pressing surface.

7. The rotating electrical machine according to any one of claims 3 to 6, characterized in that The width of the fitting portion is formed to be larger than the thickness of the retaining portion.

8. The rotating electrical machine according to claim 1, wherein The connecting beam has a folded portion.

9. The rotating electrical machine according to claim 2, wherein: The connecting beam has a folded portion.

10. The rotating electrical machine according to any one of claims 3 to 6, characterized in that The connecting beam has a folded portion.

11. The rotating electrical machine according to claim 7, wherein The connecting beam has a folded portion.

12. The rotating electrical machine according to any one of claims 3 to 6 and claim 11, characterized in that A rib is provided on an outer peripheral surface of the anti-detachment portion of the magnet holder.

13. The rotating electrical machine according to claim 7, wherein A rib is provided on an outer peripheral surface of the anti-detachment portion of the magnet holder.

14. The rotating electrical machine according to claim 10, wherein A rib is provided on an outer peripheral surface of the anti-detachment portion of the magnet holder.

15. The rotating electrical machine according to any one of claims 1 to 6, 8, 9, 11, 13 and 14, characterized in that: A plurality of rotor cores are arranged and fixed on the output shaft along the axial direction. In each of the plurality of rotor cores, the magnets of the same polarity are fixed at positions shifted by a predetermined angle in the circumferential direction.

16. The rotating electrical machine according to claim 7, wherein A plurality of rotor cores are arranged and fixed on the output shaft along the axial direction. In each of the plurality of rotor cores, the magnets of the same polarity are fixed at positions shifted by a predetermined angle in the circumferential direction.

17. The rotating electrical machine according to claim 10, wherein A plurality of rotor cores are arranged and fixed on the output shaft along the axial direction. In each of the plurality of rotor cores, the magnets of the same polarity are fixed at positions shifted by a predetermined angle in the circumferential direction.

18. The rotating electrical machine according to claim 12, wherein: A plurality of rotor cores are arranged and fixed on the output shaft along the axial direction. In each of the plurality of rotor cores, the magnets of the same polarity are fixed at positions shifted by a predetermined angle in the circumferential direction.

19. A rotating electrical machine, characterized in that: include: stator; a rotor core, the rotor core being disposed on the inner circumference of the stator and fixed to the output shaft of the rotor; a plurality of magnets arranged along a circumferential direction and fixed to an outer periphery of the rotor core; as well as a magnet holder that fixes the plurality of magnets to the outer periphery of the rotor core; The magnet holder has: a base portion provided on one axial surface side of the rotor core portion and through which the output shaft is inserted; and an arm portion, one end of which is connected to the base portion and extends axially, The base portion has: The inner circumference of the ring; an annular outer peripheral beam, the outer peripheral beam being provided on the outer peripheral side of the inner peripheral portion and connected to the one end of the arm portion; and a connecting beam connecting the inner peripheral portion and the outer peripheral beam, The rotor core is provided with a protrusion at an end portion of the outer peripheral portion opposite to the side where the base portion is provided. An axial retaining portion is provided on a surface of at least one of the outer peripheral beam and the connecting beam on a side opposite to the magnet, and the axial retaining portion retains the axial side surface of the magnet. The protrusion is arranged opposite to the axial retaining portion.

20. The rotating electrical machine according to claim 19, wherein The connecting beam has a folded portion.

21. The rotating electrical machine according to claim 19 or 20, wherein: A plurality of rotor cores are arranged and fixed on the output shaft along the axial direction. In each of the plurality of rotor cores, the magnets of the same polarity are fixed at positions shifted by a predetermined angle in the circumferential direction.

22. A method for manufacturing a rotating electrical machine, comprising: a step of arranging a plurality of magnets along a circumferential direction and disposing them on the outer periphery of a rotor core; a step of arranging a base portion of a magnet holder having an annular inner peripheral portion, an annular outer peripheral beam provided on an outer peripheral side of the inner peripheral portion, and a connecting beam connecting the inner peripheral portion to a portion of the peripheral beam other than a portion connected to one end of the arm portion, on one axial surface side of the rotor core; as well as The process of arranging the arm portion of the magnet holder, one end of which is connected to a part of the outer peripheral beam and extending axially, on the outer peripheral surface of the magnet, and pressing the magnet from the arm portion through the outer peripheral beam to fix the magnet between the arm portion and the outer peripheral portion of the rotor core.

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