Magnet arrangement method and method for manufacturing a rotor

Abstract

A magnet arrangement method is provided that facilitates the assembly of magnets. One aspect of the present invention is a magnet arrangement method for arranging multiple magnetized magnets in a Halebeck arrangement, wherein the magnet arrangement method comprises the following steps: combining magnets to form a first magnet group (11) such that the direction of the magnetic force applied to the magnets is oriented toward a first direction; combining magnets to form a second magnet group (12) such that the direction of the magnetic force applied to the magnets is oriented toward a second direction that is opposite to the first direction; and assembling multiple first magnet groups (11) and multiple second magnet groups (12).

Description

Technical Field

[0001] This invention relates to a method for arranging magnets and a method for manufacturing a rotor. Background Technology

[0002] An electric motor is known, comprising a stator with coils and a rotor with magnets. Patent Document 1 discloses a technology related to an external rotor motor that can more effectively utilize magnetic torque by increasing the magnetic flux generated by permanent magnets, thereby maximizing the torque generated under the same current. Furthermore, Patent Document 2 discloses a technology related to a periodic magnetic field generating device comprising a Halbach magnet arrangement having: a plurality of main permanent magnet poles magnetized in the direction of generating the magnetic field; secondary permanent magnet poles arranged between the main permanent magnet poles; and a back yoke for fixing these permanent magnets.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 11-308793

[0006] Patent Document 2: Japanese Patent Application Publication No. 2007-110822 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] During rotor manufacturing, multiple magnetized magnets need to be arranged in designated locations on the rotor. The Halebeck arrangement is a known method for arranging magnets. The Halebeck arrangement maximizes the magnetic field strength in a specific direction.

[0009] However, when assembling multiple magnetized magnets piece by piece to form a Helbeck arrangement, the direction in which the magnets are pressed changes depending on the orientation of the magnetic poles of the magnets to be assembled, resulting in a complicated assembly process.

[0010] In view of the above problems, the object of the present invention is to provide a magnet arrangement method and a rotor manufacturing method that facilitate the assembly of magnets.

[0011] Solution for solving the problem

[0012] One aspect of the present invention is a magnet arrangement method for arranging multiple magnetized magnets in a Halebeck arrangement, wherein the magnet arrangement method comprises the following steps: combining the magnets to form a first magnet group in such a way that the direction of the magnetic force applied to the magnets is oriented toward a first direction; combining the magnets to form a second magnet group in such a way that the direction of the magnetic force applied to the magnets is oriented toward a second direction that is opposite to the first direction; and assembling multiple first magnet groups and multiple second magnet groups.

[0013] In the above-described magnet arrangement method, magnets are combined such that the direction of the applied magnetic force is oriented towards a first direction to form a first magnet group, and magnets are combined such that the direction of the applied magnetic force is oriented towards a second direction to form a second magnet group. Multiple first magnet groups and multiple second magnet groups are assembled to form a Heilbeck arrangement. Here, the magnetic force directions of the first magnet group and the second magnet group are opposite to each other, so the direction of pressing the magnets does not change when assembling the first and second magnet groups, thus facilitating magnet assembly.

[0014] In the above-described magnet arrangement method, the number of magnets constituting the first magnet group can also be different from the number of magnets constituting the second magnet group. This makes the assembly of the magnets easier.

[0015] In the above-described magnet arrangement method, the plurality of magnetized magnets can also be arranged in a ring by a Helbeck array. When viewed from above, the first direction is the radially inward direction towards the magnets arranged in the ring, and the second direction is the radially outward direction towards the magnets arranged in the ring. Therefore, assembling the magnets is easier when the Helbeck array is formed into a ring.

[0016] In the above-described magnet arrangement method, when viewing the magnets arranged in a ring from above, the plurality of magnetized magnets are arranged such that the orientation of the magnetic poles of each magnet is rotated 45 degrees sequentially in the circumferential direction. With the first direction set to 0 degrees, the five magnets with magnetic pole orientations of 0 degrees, 45 degrees, 90 degrees, 135 degrees, and 180 degrees constitute the first magnet group, and the three magnets with magnetic pole orientations of 225 degrees, 270 degrees, and 315 degrees constitute the second magnet group. Therefore, when the Hellbeck magnets are arranged in a ring, the assembly of the magnets becomes easier.

[0017] In the above-described magnet arrangement method, at least one first magnet group and at least one second magnet group can be combined to form a third magnet group. After arranging multiple third magnet groups with open intervals, multiple first magnet groups are respectively arranged between the multiple third magnet groups to form a ring-shaped Heilbeck arrangement. Therefore, when the Heilbeck arrangement is formed into a ring, the assembly of the magnets becomes easier.

[0018] In the above-described magnet arrangement method, when viewing the magnets arranged in a ring from above, the plurality of magnetized magnets are arranged such that the orientation of each magnet's magnetic poles is rotated 90 degrees sequentially in the circumferential direction. With the first direction set to 0 degrees, the magnets with their magnetic poles oriented at 0 degrees form the first magnet group, and the three magnets with their magnetic poles oriented at 90 degrees, 180 degrees, and 270 degrees form the second magnet group. This facilitates the assembly of the magnets when arranging the Helbeck magnets in a ring.

[0019] One aspect of the present invention is a rotor manufacturing method that uses the above-described magnet arrangement method to arrange multiple magnetized magnets in the circumferential direction of the rotor. This facilitates the assembly of the magnets during rotor manufacturing.

[0020] Invention Effects

[0021] According to the present invention, a magnet arrangement method and a rotor manufacturing method are provided that facilitate the assembly of magnets. Attached Figure Description

[0022] Figure 1 This is a top view used to illustrate an example of the magnet arrangement method of Embodiment 1.

[0023] Figure 2 This is a top view used to illustrate an example of the magnet arrangement method of Embodiment 1.

[0024] Figure 3 This is a top view used to illustrate an example of the magnet arrangement method of Embodiment 1.

[0025] Figure 4 This is a top view used to illustrate an example of the magnet arrangement method of Embodiment 1.

[0026] Figure 5 This is a top view used to illustrate an example of the magnet arrangement method of Embodiment 1.

[0027] Figure 6 This is a top view used to illustrate other examples of the magnet arrangement method of Embodiment 1.

[0028] Figure 7 This is a top view used to illustrate an example of a conventional method of arranging magnets.

[0029] Figure 8 This is a perspective view illustrating an example of the rotor manufacturing method of Embodiment 2.

[0030] Figure 9 This is a perspective view illustrating an example of the rotor manufacturing method of Embodiment 2.

[0031] Figure 10 This is a top view used to illustrate an example of the rotor manufacturing method of Embodiment 2.

[0032] Figure 11 This is a perspective view illustrating an example of the rotor manufacturing method of Embodiment 2.

[0033] Figure 12 This is a top view used to illustrate an example of the rotor manufacturing method of Embodiment 2. Detailed Implementation

[0034] <Implementation Method 1>

[0035] The embodiments of the present invention will be described below with reference to the accompanying drawings.

[0036] Figures 1-5 This is a top view used to illustrate an example of the magnet arrangement method of Embodiment 1. The magnet arrangement method of this embodiment is a method for arranging multiple magnetized magnets in a Helbeck arrangement. It should be noted that, as an example, the following description uses the magnet arrangement method of this embodiment to arrange the magnetized magnets in a ring shape. However, the magnet arrangement method of this embodiment can also be used to arrange the magnetized magnets in a shape other than a ring (e.g., a straight line).

[0037] Figure 1 The diagram shows a state in which multiple magnetized magnets are arranged in a Halebeck pattern, and is an illustration representing multiple magnetized magnets arranged in a ring shape in a Halebeck pattern. Figure 1 The Heilbeck array 1 shown is constructed using eight magnets a to h, each with a different orientation of its magnetic poles 10. In each magnet 10, the orientation of the magnetic poles is set from the S pole to the N pole. In this specification, the orientation of the magnetic poles is indicated by solid arrows.

[0038] In addition, Figure 1In this configuration, the outer side refers to the outer side of the magnets arranged in a ring, and the inner side refers to the inner side of the magnets arranged in a ring. Each magnet a to h is formed to extend vertically (through the plane of the paper). Furthermore, the orientation of the magnetic poles of each magnet a to h is arranged parallel to the horizontal plane (the plane parallel to the paper). It should be noted that in this embodiment, the Halebeck arrangement is configured to maximize the magnetic field strength on the inner side of the magnets arranged in a ring. The following description will use the case where the Halebeck arrangement is formed to maximize the magnetic field strength on the inner side of the magnets arranged in a ring as an example; however, in this embodiment, the Halebeck arrangement can also be formed to maximize the magnetic field strength on the outer side of the magnets arranged in a ring. For example, this can be achieved by making... Figure 1 The inner and outer sides of the Hellbeck arrangement shown are flipped to maximize the magnetic field strength on the outer side. Furthermore, this invention can be applied to both outer rotor and inner rotor types of rotors.

[0039] use Figure 2 This section provides a detailed explanation of the Heilbeck arrangement. For example... Figure 2 As shown, the Heilbeck arrangement is constructed using eight types of magnets, a to h, each with a different orientation of its magnetic poles. In this embodiment, with the radial inward direction of the magnets arranged in a ring set to 0 degrees, eight types of magnets are used: magnet a with a 0-degree orientation, magnet b with a 45-degree orientation, magnet c with a 90-degree orientation, magnet d with a 135-degree orientation, magnet e with a 180-degree orientation, magnet f with a 225-degree orientation, magnet g with a 270-degree orientation, and magnet h with a 315-degree orientation. It should be noted that... Figure 2 In the example configuration shown, the direction of magnetic pole rotation is set to clockwise. Furthermore, the orientation (angle) of the magnetic poles of magnets a through h can also be slightly (by a few degrees) offset depending on the design.

[0040] When viewed from above, the magnets arranged in a ring are arranged such that the magnetic poles of each magnet are rotated 45 degrees in turn circumferentially. Figure 1 The magnets a to h shown are Figure 2 The magnets shown correspond to magnets a through h.

[0041] like Figure 1 As shown, for each magnet a to h, a magnetic force acts in a specified direction due to the surrounding magnets. If an example is shown, then in... Figure 1In the example shown, magnet a experiences an inward magnetic force (indicated by a white hollow arrow; the same applies below), magnet b experiences a circumferential (clockwise) magnetic force, magnet c experiences an outward magnetic force, magnet d experiences a circumferential (counterclockwise) magnetic force, and magnet e experiences an inward magnetic force.

[0042] Here, the magnetic force acting on a magnet is the force generated by the orientation of the magnetic poles of each magnet. Specifically, the magnetic force acting on a magnet is the force generated by the orientation of the magnetic poles of a particular magnet and the orientation of the magnetic poles of the magnets adjacent to that particular magnet. For example, for magnet c, a magnetic force acting in the outward direction exists due to the orientation of the magnetic poles of magnet c and the orientation of the magnetic poles of adjacent magnets b and d.

[0043] This results in forces acting in different directions on each of the Hellbeck-arranged magnets a-h, leading to complex assembly. In other words, in situations like... Figure 7 When multiple magnetized magnets are assembled piece by piece to form a Helbeck arrangement, the direction in which the magnets are pressed will change depending on the orientation of the magnetic poles of the magnets to be assembled, thus causing the assembly to be complicated.

[0044] Specifically, such as Figure 7 As shown, when magnet c is placed next to magnet b, a force is exerted on magnet c towards the top of the paper. Furthermore, when magnet d is placed next to magnet c, a force is exerted on magnet d towards the left side of the paper. Additionally, when magnet e is placed next to magnet d, a force is exerted on magnet e towards the right side of the paper. Thus, when assembling multiple magnetized magnets piece by piece to form a Helbeck array, the direction in which the magnets are pressed changes depending on the orientation of the magnetic poles of the magnets being assembled, resulting in a complex assembly process.

[0045] To address this problem, the magnet arrangement method of this embodiment uses the following method to form a Hellbeck arrangement. Specifically, in this embodiment, magnets are combined to form a first magnet group such that the direction of the magnetic force applied to the magnets is towards a first direction. Furthermore, magnets are combined to form a second magnet group such that the direction of the magnetic force applied to the magnets is towards a second direction, which is opposite to the first direction. Then, a Hellbeck arrangement is formed by assembling multiple first magnet groups and multiple second magnet groups. Here, it is also possible that the number of magnets constituting the first magnet group is different from the number of magnets constituting the second magnet group. Furthermore, when the Hellbeck arrangement is in a ring shape, the first direction is the direction towards the radially inward side of the ring-shaped magnets, and the second direction is the direction towards the radially outward side of the ring-shaped magnets.

[0046] The following uses Figures 1-5 The magnet arrangement method of this embodiment will now be described in detail. In the magnet arrangement method of this embodiment, firstly, as follows... Figure 3 As shown, five magnets, a through e, are combined to form the first magnet group 11. That is, with the inward direction set to 0 degrees, the first magnet group 11 is formed using magnet a with a magnetic pole orientation of 0 degrees, magnet b with a magnetic pole orientation of 45 degrees, magnet c with a magnetic pole orientation of 90 degrees, magnet d with a magnetic pole orientation of 135 degrees, and magnet e with a magnetic pole orientation of 180 degrees.

[0047] At this time, the direction of the magnetic force applied to the magnets of the first magnet group 11 is inward direction 21 (first direction). The direction of the magnetic force applied to the magnets of the first magnet group 11 is the direction 21 after combining the vectors of the magnetic forces acting on each magnet a to e (shown by white hollow arrows respectively).

[0048] Next, as Figure 4 As shown, magnets f to h are combined to form a second magnet group 12. That is, with the inward direction set to 0 degrees, magnet f with a magnetic pole orientation of 225 degrees, magnet g with a magnetic pole orientation of 270 degrees, and magnet h with a magnetic pole orientation of 315 degrees are used to form the second magnet group 12.

[0049] At this time, the magnetic force applied to the magnets of the second magnet group 12 is directed outward in direction 22 (second direction). The magnetic force applied to the magnets of the second magnet group 12 is the direction 22 resulting from the synthesis of the vectors acting on each magnet f to h (shown by white hollow arrows respectively).

[0050] Next, as Figure 5 As shown, a plurality of first magnet groups 11 and a plurality of second magnet groups 12 are assembled to form a Hellbeck arrangement. That is, the Hellbeck arrangement is formed by alternately arranging the first magnet groups 11 and the second magnet groups 12 and joining them together. It should be noted that an adhesive can be used to join the magnets.

[0051] As explained above, in this embodiment of the magnet arrangement method, magnets are combined such that the direction of the applied magnetic force is towards a first direction (inner side) to form a first magnet group 11, and magnets are combined such that the direction of the applied magnetic force is towards a second direction (outer side) to form a second magnet group 12. Multiple first magnet groups 11 and multiple second magnet groups 12 are assembled to form a Heilbeck arrangement. Here, the magnetic force directions of the first magnet group 11 and the second magnet group 12 are opposite to each other, so the direction of pressing the magnets does not change when assembling the first magnet group 11 and the second magnet group 12, thus making magnet assembly easy.

[0052] Specifically, the magnetic force applied to the magnets in the first magnet group 11 and the magnetic force applied to the magnets in the second magnet group 12 are radially opposite to each other (see reference). Figure 5 This reduces the force required to assemble the first magnet group 11 and the second magnet group 12 into a ring. It should be noted that the order in which the first magnet group 11 and the second magnet group 12 are formed is not particularly limited.

[0053] Figure 6 This is a top view used to illustrate other examples of the magnet arrangement method of this embodiment. Figure 6 The image shows an example of a Helbeck arrangement using four magnets α to δ, each with its poles facing in different directions. Figure 6 In the illustrated configuration example, with the radial inward direction of the ring-shaped magnets set to 0 degrees, four types of magnets are used: magnet α with its poles oriented at 0 degrees, magnet β with its poles oriented at 90 degrees, magnet γ with its poles oriented at 180 degrees, and magnet δ with its poles oriented at 270 degrees. When viewing the ring-shaped magnets from above, these magnets α to δ are arranged such that the orientation of each magnet's poles is rotated 90 degrees sequentially circumferentially. It should be noted that... Figure 6 In the example configuration shown, the direction of magnetic pole rotation is set to counterclockwise. Furthermore, the orientation (angle) of the magnetic poles α to δ of each magnet can be slightly (by a few degrees) offset depending on the design.

[0054] In formation Figure 6 In the Hellbeck arrangement shown, with the inward direction set to 0 degrees, a magnet α with its poles oriented at 0 degrees is used to form the first magnet group 31. At this time, the magnetic force applied to the first magnet group 31 is in the inward direction (first direction). It should be noted that in this invention, it is assumed that a single magnet can also be used to form the first magnet group 31. That is, it is assumed that the "magnet group" also includes a single magnet.

[0055] Furthermore, with the inward direction set to 0 degrees, a second magnet group 32 is formed using three magnets: magnet β with its poles oriented at 90 degrees, magnet γ with its poles oriented at 180 degrees, and magnet δ with its poles oriented at 270 degrees. At this time, the magnetic force applied to the magnets in the second magnet group 32 is directed outwards (the second direction).

[0056] Then, a Hellbeck arrangement is formed by assembling multiple first magnet groups 31 and multiple second magnet groups 32. That is, the Hellbeck arrangement is formed by alternately arranging the first magnet groups 31 and the second magnet groups 32 and joining them together. It should be noted that an adhesive can be used in joining the magnets.

[0057] exist Figure 6 In the case of the configuration example shown, the assembly of the magnets can also be made easier for the same reason.

[0058] <Implementation Method 2>

[0059] Next, Embodiment 2 of the present invention will be described. In Embodiment 2, a method for manufacturing a rotor using the magnet arrangement method of Embodiment 1 will be described.

[0060] Figure 8 This is a perspective view illustrating an example of the rotor manufacturing method of this embodiment, and a diagram illustrating the case where three magnets f to h are combined to form a second magnet group 12. Figure 8 As shown, when magnet f (with its poles oriented at 225 degrees), magnet g (with its poles oriented at 270 degrees), and magnet h (with its poles oriented at 315 degrees) are arranged, a force is exerted on magnet g in the outward direction. Therefore, when arranging the three magnets f to h, after pushing magnet g inward using a prescribed clamp, the three magnets f to h are fixed with an adhesive. By using this method, a second magnet group 12 can be formed.

[0061] Figure 9 This is a perspective view illustrating an example of the rotor manufacturing method of this embodiment, specifically illustrating the case where five magnets a to e are combined to form a first magnet assembly 11. When forming the first magnet assembly 11, firstly, magnet b with its poles oriented at 45 degrees, magnet c with its poles oriented at 90 degrees, and magnet d with its poles oriented at 135 degrees are arranged and fixed. In this case, a force is applied to magnet c in the inward direction; therefore, after magnet c is pushed outward using a prescribed clamp, the three magnets b to d are fixed using an adhesive.

[0062] Next, magnet a, with its magnetic poles oriented at 0 degrees, and magnet e, with its magnetic poles oriented at 180 degrees, are brought close to the three magnets b to d along the circumference and fixed with adhesive. By using this method, the first magnet group 11 can be formed.

[0063] After that, as Figure 10 As shown, the first magnet assembly 11 and the second magnet assembly 12 are brought close together circumferentially and secured with adhesive. This method is used to secure one first magnet assembly 11 and two second magnet assemblies 12, thereby forming... Figure 10 The third magnet group 13 is shown.

[0064] It should be noted that, in Figure 10 As an example, the diagram illustrates the use of a first magnet group 11 and two second magnet groups 12 to form a third magnet group 13 with a total of 11 magnets. However, the number of magnets constituting the third magnet group 13 can be arbitrarily determined. In other words, as long as the number of first magnet groups 11 and second magnet groups 12 used is at least one, the number of first magnet groups 11 and second magnet groups 12 can be arbitrarily determined.

[0065] After that, as Figure 11 , Figure 12 As shown, clamps 41 and 42 are used to arrange the magnets to create the rotor 2. Specifically, after arranging multiple third magnet groups 13 with open intervals (gap 15), multiple first magnet groups 11 are arranged between the multiple third magnet groups 13 (gap 15) to form a ring-shaped Heilbeck arrangement.

[0066] In other words, clamp 41 is used to fix the third magnet assembly 13. Then, with the first magnet assembly 11 fixed to clamp 42, clamp 42 is moved vertically to position the first magnet assembly 11 in the gap 15 of the third magnet assembly 13. At this time, an inward force is applied to the first magnet assembly 11, so it is not necessary to press the clamp on the outside of the first magnet assembly 11. It should be noted that in Figure 11 , Figure 12 In order to explain the arrangement of each magnet 10, the diagram of the rotor body that constitutes the rotor 2 is omitted.

[0067] By using the magnet arrangement method described above, multiple magnetized magnets can be arranged circumferentially on the rotor. Furthermore, the method of this embodiment simplifies magnet assembly. It should be noted that the rotor manufacturing method described above is an example; in this embodiment, rotors with other configurations (e.g., rotors with different numbers of magnets arranged in a ring) can also be manufactured.

[0068] The present invention has been described above according to the above embodiments, but the present invention is not limited to the above embodiments, and naturally includes various modifications, alterations and combinations that can be made by those skilled in the art within the scope of the invention as described in the claims of this application.

[0069] This application claims priority based on Japanese Application Special Purpose 2021-44585, filed on March 18, 2021, all of which are hereby incorporated.

[0070] Explanation of reference numerals in the attached figures

[0071] 1: Heilbeck arrangement;

[0072] 2: Rotor;

[0073] 11, 31: First magnet group;

[0074] 12, 32: Second magnet group;

[0075] 13: The third magnet group;

[0076] 15: Gap;

[0077] 41, 42: Fixtures.

Claims

1. A method for arranging magnets, wherein multiple magnetized magnets are arranged in a Halebeck pattern, wherein, The magnet arrangement method includes the following steps: The magnets are combined in such a way that the direction of the magnetic force applied to the magnets is oriented toward a first direction to form a first magnet group; To form a second magnet group, magnets are combined such that the direction of the magnetic force applied to the magnets is oriented in a second direction that is opposite to the first direction. as well as Assemble multiple first magnet groups and multiple second magnet groups. The direction of the magnetic force applied to a magnet is the direction of the vector summation of the magnetic forces acting on each magnet. The multiple magnetized magnets are arranged in a ring by Helbeck. When viewing the magnets arranged in a ring from above, the first direction is the radially inward direction towards the magnets arranged in the ring, and the second direction is the radially outward direction towards the magnets arranged in the ring. At least one first magnet group is combined with at least one second magnet group to form a third magnet group. After arranging a plurality of the third magnet groups in an open-spaced manner, a plurality of the first magnet groups are respectively arranged between the plurality of the third magnet groups to form a ring-shaped Heilbeck arrangement.

2. The magnet arrangement method according to claim 1, wherein, The number of magnets constituting the first magnet group is different from the number of magnets constituting the second magnet group.

3. The magnet arrangement method according to claim 1, wherein, When viewed from above, the magnets arranged in the ring shape are positioned such that the magnetic poles of each magnet are rotated 45 degrees circumferentially. With the first direction set to 0 degrees, the five magnets with poles oriented at 0 degrees, 45 degrees, 90 degrees, 135 degrees, and 180 degrees constitute the first magnet group. The three magnets with their poles oriented at 225 degrees, 270 degrees, and 315 degrees constitute the second magnet group.

4. The magnet arrangement method according to claim 1, wherein, When viewed from above, the magnets arranged in the ring shape are positioned such that the magnetic poles of each magnet are rotated 90 degrees circumferentially. With the first direction set to 0 degrees, the magnet with its poles pointing at 0 degrees is the first magnet group. The three magnets with their poles oriented at 90 degrees, 180 degrees, and 270 degrees constitute the second magnet group.

5. A method for manufacturing a rotor, comprising arranging a plurality of magnetized magnets in the circumferential direction of the rotor using the magnet arrangement method as described in any one of claims 1 to 4.

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