Rotating electrical machine and method for manufacturing rotating electrical machine

Abstract

A rotor core (2) having a plurality of magnet insertion holes (29a, 29b) has a hole portion (8) between a fixing hole (23a) and outermost peripheral edge portions (29a1, 29b1) of the magnet insertion holes (29a, 29b), and the hole portion (8) is configured from a positioning function portion (8a) and a lightweight function portion (8b).

Description

Technical Field

[0001] This disclosure relates to a rotary electric machine and a method for manufacturing the rotary electric machine. Background Technology

[0002] Currently, a rotary electric motor is known, comprising a stator and a rotor. The stator has an annular stator core and stator coils mounted thereon. The rotor has a rotor core inserted into an inner space of the stator core and a plurality of permanent magnets embedded therein and forming excitation poles. In this type of rotary electric motor, the stator core typically has a plurality of pole teeth that protrude radially inward and are arranged at certain intervals in the circumferential direction. The rotor core has a plurality of magnet insertion holes and bridging portions. The magnet insertion holes are for inserting permanent magnets that form excitation poles near the outer circumferential surface. The bridging portions divide these magnet holes.

[0003] Currently, among rotary motors configured as described above, one rotary motor is disclosed that is configured such that, during the processing or assembly of the rotor core, a hole is formed in the rotor core for inserting a clamp for positioning the rotor core relative to the stator core (for example, see Patent Document 1).

[0004] Furthermore, a rotary motor is disclosed in which polygonal voids forming magnetic barriers are formed in the rotor core to restrict the flow of magnetic flux (see, for example, Patent Document 2). Also disclosed is a rotary motor in which a cavity for refrigerant flow is formed in the rotor core (see, for example, Patent Document 3). The voids in the rotor core disclosed in Patent Document 2 and the cavity in the rotor core disclosed in Patent Document 3 also contribute to the function of reducing rotor weight.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2000-4550

[0008] Patent Document 2: Japanese Patent Application Publication No. 2019-165592

[0009] Patent Document 3: Japanese Patent Application Publication No. 2005-184957 Summary of the Invention

[0010] The technical problem that the invention aims to solve

[0011] In the aforementioned conventional rotary motors, the rotor components include a rotor core formed by stacked electromagnetic steel plates, multiple permanent magnets inserted into multiple magnet insertion holes formed in the rotor core, and a rotor shaft with an axial length longer than that of the rotor core. The rotor shaft is supported by bearings for free rotation. However, due to the rotor's configuration as described above, it is relatively heavy. Consequently, the mechanical losses at the bearings supporting the rotor shaft are significant, leading to a decrease in the efficiency of the rotary motor. Furthermore, the greater the rotor's weight, the lower the efficiency of the rotary motor.

[0012] Forming holes within the rotor core is an effective way to reduce its weight. However, depending on the location of the holes, they can sometimes impede magnetic flux flow, leading to increased iron losses, or cause insufficient rotor strength due to stress from centrifugal force or the meshing of the rotor shaft and core. Therefore, the area where holes can be formed is limited.

[0013] Patent Document 1 discloses a conventional rotating electric motor with positioning holes in the rotor core. However, when additional holes for reducing rotor weight are provided in addition to the positioning holes, both types of holes need to be provided in a limited area of ​​the rotor core to prevent increased iron loss and reduced strength of the rotor. However, if weight-reducing holes and positioning holes are formed in the limited area, a bridging portion is formed between the two types of holes, causing stress to concentrate at the bridging portion, which becomes a cause of reduced strength of the rotor core.

[0014] Furthermore, the conventional rotary motor disclosed in Patent Document 2 includes a polygonal gap hole as a magnetic barrier, and the conventional rotary motor disclosed in Patent Document 3 includes a cavity for refrigerant flow. However, none of these conventional rotary motors include a positioning hole for the rotor core, and the aforementioned gap hole and cavity are not located in the region of the rotor core that takes into account preventing the increase of iron loss of the rotor and preventing the reduction of strength.

[0015] This disclosure discloses a technique for solving the aforementioned problems, with the aim of providing a rotary motor that can reduce costs and improve efficiency during its manufacture.

[0016] Furthermore, the purpose of this disclosure is to provide a method for manufacturing a rotary electric motor that can reduce costs and improve the efficiency of the rotary electric motor during its manufacture.

[0017] Technical solutions adopted to solve technical problems

[0018] The rotary electric motor disclosed herein includes: Stator core, wherein the stator core is formed in a ring shape; Stator coil, the stator coil being mounted on the stator core; The rotor core has multiple magnet insertion holes, and the outer peripheral surface of the rotor core is positioned opposite the inner peripheral surface of the stator core with a gap between them. Multiple permanent magnets are inserted into multiple magnet insertion holes to form multiple excitation poles in the rotor core; A rotor shaft, wherein a fixing hole located at the radial center of the rotor core is passed through the rotor core to support the rotor core; and The bearing, which supports the rotor shaft for free rotation, is characterized in that... The rotor core has a hole formed between the outermost periphery of the fixing hole and the magnet insertion hole. The hole is composed of a positioning function part and a lightweight function part. The positioning function unit helps in the positioning of the rotor core. The lightweight functional unit contributes to the lightweight design of the rotor core.

[0019] Furthermore, the method for manufacturing the rotary electric motor disclosed herein manufactures the aforementioned rotary electric motor, characterized by comprising: The stator core holding process involves holding the stator core by means of the stator core holding part of the axial alignment fixture; In the rotor core positioning process, multiple rod-shaped positioning members of the rotor core positioning part of the shaft alignment fixture are inserted into the positioning functional part of the hole in the rotor core to position the rotor core relative to the stator core; and In the assembly process, at least a portion of the rotating motor is assembled after the rotor core has been positioned relative to the stator core in the rotor core positioning process.

[0020] Furthermore, the method for manufacturing a rotary electric motor disclosed herein produces a rotary electric motor. The rotary motor has an end plate at at least one axial end of the rotor core that abuts against the rotor core axially. The end plate includes a hole with a positioning function that matches at least one positioning function formed in the hole of the rotor core. The manufacturing method comprises: The stator core holding process involves holding the stator core by means of the stator core holding part of the axial alignment fixture; In the rotor core positioning process, multiple rod-shaped positioning members of the rotor core positioning part of the shaft alignment fixture are inserted into the positioning functional part provided in the hole of the end plate and the positioning functional part provided in the hole of the rotor core to position the rotor core relative to the stator core; and In the assembly process, at least a portion of the rotating motor is assembled after the rotor core has been positioned relative to the stator core in the rotor core positioning process.

[0021] Furthermore, the method for manufacturing a rotary electric motor disclosed herein produces a rotary electric motor. The rotary electric motor has an end plate at at least one axial end of the rotor core that abuts against the rotor core axially. The end plate includes a hole with a positioning function that matches at least one positioning function formed in the hole of the rotor core. The manufacturing method is characterized in that... Positioning between the end plate and the rotor core is achieved by inserting multiple rod-shaped positioning parts provided in the clamp into both the positioning functional part provided in the hole of the end plate and the positioning functional part provided in the hole of the rotor core.

[0022] Furthermore, the method for manufacturing a rotary electric motor disclosed herein produces a rotary electric motor. The rotary electric motor has an end plate at at least one end of the rotor core that abuts against the rotor core in the axial direction. The end plate includes a plurality of rod-shaped positioning members extending in the axial direction of the rotor core. The plurality of positioning members are inserted into at least the positioning functional portions formed in the plurality of holes in the rotor core. The manufacturing method is characterized in that... Positioning between the end plate and the rotor core is achieved by inserting the plurality of rod-shaped positioning members disposed on the end plate into the positioning functional part disposed on the hole of the rotor core.

[0023] Invention Effects

[0024] According to the rotary motor disclosed herein, a rotary motor can be obtained that reduces costs during the manufacture of the rotary motor and improves the efficiency of the rotary motor.

[0025] Furthermore, according to the method for manufacturing a rotary electric motor disclosed herein, a rotary electric motor can be obtained that reduces costs during manufacturing and improves the efficiency of the rotary electric motor. Attached Figure Description

[0026] Figure 1 This is a schematic longitudinal sectional view of the rotary electric motor according to Embodiment 1.

[0027] Figure 2 This is a cross-sectional view of the rotor of the rotary electric motor according to Embodiment 1.

[0028] Figure 3 This is an explanatory diagram of the rotor of the rotary electric motor according to Embodiment 1.

[0029] Figure 4 This is an explanatory diagram of the rotor of the rotary electric motor according to Embodiment 2.

[0030] Figure 5 This is an explanatory diagram of the rotor of the rotary electric motor according to Embodiment 3.

[0031] Figure 6 This is an explanatory diagram of the rotor of the rotary electric machine according to Embodiment 4.

[0032] Figure 7 This is an explanatory diagram of the rotor of the rotary electric machine according to Embodiment 5.

[0033] Figure 8 This is an explanatory diagram of the rotor of the rotary electric machine according to Embodiment Six.

[0034] Figure 9 This is an explanatory diagram of the rotor of the rotary electric machine according to Embodiment Seven. Detailed Implementation

[0035] The rotary motors of the various embodiments of this disclosure described below illustrate the case of permanent magnet type synchronous motors.

[0036] Implementation Method 1

[0037] Figure 1 This is a schematic longitudinal sectional view of the rotary motor according to Embodiment 1. Figure 1 In this rotating electric motor 100, there are a stator 1 and a rotor 2. The stator 1 includes a cylindrical metal frame 12, an annular stator core 13 fitted into the inner circumferential surface of the frame 12, and stator coils 14 mounted on the stator core 13. The stator coils 14 are, for example, composed of three-phase coils connected in a star configuration.

[0038] The frame 12 includes a flange 12a at one axial end for securing the rotary motor 100, for example, to other components of the vehicle (not shown). The stator core 13 is composed of a plurality of annular electromagnetic steel plates stacked axially, including a plurality of pole teeth (not shown) protruding from the inner circumferential surface and a plurality of slots (not shown) formed between adjacent pole teeth. Stator coils 14 are inserted into the slots.

[0039] The rotor 2 includes a rotor core 23, multiple permanent magnets 24, a first end plate 25a, a second end plate 25b, and a rotor shaft 26. The outer circumferential surface of the rotor core 23 is spaced apart from the inner circumferential surface of the stator core 13. The multiple permanent magnets 24 are embedded near the outer circumferential surface of the rotor core 23. The first end plate 25a abuts against one axial end of the rotor core 23, and the second end plate 25b abuts against the other axial end of the rotor core 23. The rotor shaft 26 passes through a fixing hole 23a located radially at the center of the rotor core 23, the first end plate 25a, and the second end plate 25b. The rotor core 23 is composed of multiple annular electromagnetic steel plates stacked axially.

[0040] The two ends of the rotor shaft 26 in the axial direction are supported by a first bearing 27a and a second bearing 27b for free rotation. The first bearing 27a and the second bearing 27b are respectively mounted on a pair of brackets (not shown) fixed to the frame 12. The axial position of the rotor core 23 relative to the rotor shaft 26 is limited by the second end plate 25b abutting against the stop member 28 provided on the rotor shaft 26.

[0041] The rotor core 23 is provided with eight first magnet insertion holes 29a and eight second magnet insertion holes 29b opposite to these first magnet insertion holes 29a. The permanent magnets 24 are respectively inserted into the first magnet insertion holes 29a and the second magnet insertion holes 29b. The permanent magnets 24 extend from one end of the rotor core 23 along the axial direction to the other end, and are divided into multiple, for example, six, segments along the axial direction of the rotor core 23.

[0042] The first end plate 25a and the second end plate 25b respectively abut against one end and the other end of the rotor core 23 in the axial direction to prevent the permanent magnet 24 from falling off or protruding from the first magnet insertion hole 29a and the second magnet insertion hole 29b. Alternatively, a hole for adjusting the rotational balance of the rotor 2 or a plate as a counterweight may be added to at least one of the first end plate 25a and the second end plate 25b.

[0043] Next, the structure of the rotor core 23 will be explained. Figure 2 This is a cross-sectional view of the rotor of the rotating electric machine according to Embodiment 1, viewed from the direction of the arrow along... Figure 1 A sectional view of the rotor along line A-A. Figure 2 In the rotor core 23, the rotor core 23 is supported on the rotor shaft 26, which is inserted into the fixing hole 23a provided in the center of the rotor core 23.

[0044] Rotor shaft 26 connects rotor core 23 and first end plate 25a (see reference). Figure 1 ) and the second end plate 25b (refer to Figure 2The rotor core 23 is fixed as a whole, transmitting the rotational force of the rotor core 23 to the outside of the rotary motor 100. In Embodiment 1, the rotor shaft 26 is a solid shaft. Furthermore, in Embodiment 1, the rotor core 23, the first end plate 25a, and the second end plate 25b are fitted onto the rotor shaft 26 via a press-fitting process or a heat-fitting process.

[0045] Alternatively, the rotor shaft 26 and the rotor core 23 can also be fitted together by a key mechanism provided on the periphery of the fixing hole 23a in the rotor core 23 and on the outer periphery of the rotor shaft 26. Furthermore, the rotor shaft 26 can also be a hollow cylindrical hub structure.

[0046] As described above, the rotor core 23 is constructed by stacking multiple electromagnetic steel plates axially. Eight pairs of magnet insertion holes 29, consisting of first magnet insertion holes 29a and second magnet insertion holes 29b, are arranged symmetrically around the axis O at 45-degree intervals. Furthermore, the virtual straight line X coincides with the d-axis described later.

[0047] In each of the eight magnet insertion hole pairs 29, the first magnet insertion hole 29a and the second magnet insertion hole 29b are arranged in a V-shape such that the interval between them facing each other on the radially outer side of the rotor core 23 is greater than the interval between them facing each other on the radially inner side of the rotor core 23. A permanent magnet 24 with a rectangular cross-section is inserted into each of the first magnet insertion hole 29a and the second magnet insertion hole 29b in the eight magnet insertion hole pairs 29. Each permanent magnet 24 is, for example, made of neodymium rare earth permanent magnets.

[0048] like Figure 2 As shown, in a pair of magnet insertion holes 29, the permanent magnet 24 inserted into the first magnet insertion hole 29a and the permanent magnet 24 inserted into the second magnet insertion hole 29b are magnetized so that their opposing long sides have the same magnetic polarity. The two permanent magnets 24 and the first part 231 of the rotor core sandwiched between the two permanent magnets 24 constitute an excitation pole. This excitation pole has a total of eight poles. The rotary motor 100 of Embodiment 1 is an eight-pole IPM motor with a total of sixteen permanent magnets 24.

[0049] A hole 8 is provided at the second part 232 of the rotor core sandwiched between two adjacent excitation poles. The hole 8 is composed of a positioning function part 8a for positioning the rotor core 23 and a weight-reducing function part 8b for reducing the weight of the rotor core 23.

[0050] When machining or assembling the rotary motor 100, the rotor core 23 is positioned radially and circumferentially relative to the stator core 13 by inserting a fixture into the positioning function unit 8a. Additionally, the positioning function unit 8a is sometimes also used for positioning the first end plate 25a and the second end plate 25b.

[0051] Alternatively, as described later, a rod-shaped positioning member disposed on at least one of the end plates 25a and 25b can be inserted into the positioning function part 8a of the hole 8 of the rotor core 23 to position the rotor core 23.

[0052] Typically, at least two positioning holes are required in the rotor core 23 for positioning. If the fixing hole 23a for rotor shaft insertion in the rotor core 23 is used as one positioning hole, only one other positioning hole needs to be provided besides the fixing hole 23a. However, providing another positioning hole besides the fixing hole 23a will adversely affect the rotational balance of the rotor 2.

[0053] Therefore, from the viewpoints of adjusting the rotational balance of the rotor 2 and reducing weight, it is desirable to provide two or more holes 8 including positioning function parts 8a, and to arrange these holes 8 at equal intervals along the circumference of the rotor core 23. In the rotary electric machine of Embodiment 1, the holes 8, which are composed of positioning function parts 8a and weight-reducing function parts 8b, are formed in the second part 232 of the rotor core sandwiched between two adjacent excitation poles, and a total of eight holes are provided.

[0054] Figure 3 This is an explanatory diagram of the rotor of the rotary electric motor according to Embodiment 1. Figure 3 In this configuration, the radial center of the hole 8, which is composed of the positioning function part 8a and the lightweight function part 8b, is aligned with the q-axis of the rotor core, which is at an electrical angle of 90° relative to the d-axis. By configuring the hole 8 in this way, it is possible to place it at approximately the midpoint between two adjacent excitation poles, thereby preventing uneven magnetic flux flow between the two adjacent excitation poles.

[0055] Furthermore, the hole portion 8 is provided in the region of the rotor core 32 between the peripheral edge of the fixing hole 23a and the outermost peripheral edge 29a1 located on the outermost peripheral side of the first magnet insertion hole 29a and the outermost peripheral edge 29b1 located on the outermost peripheral side of the second magnet insertion hole 29b. The positioning function portion 8a of the hole portion 8 has a peripheral edge portion 8a1 that coincides with a portion of the arc of a virtual circle with a diameter of d1 [mm] and its center located on the q-axis.

[0056] Furthermore, in Embodiment 1, the lightweight functional portion 8b of the hole portion 8 has a pair of side edges 8b1 and 8b2 and an inner peripheral side edge 8b3. The pair of side edges 8b1 and 8b2 extend symmetrically and obliquely from both ends of the peripheral portion 8a1 of the positioning functional portion 8a towards both sides of the q-axis. The inner peripheral side edge 8b3 is connected to the pair of side edges 8b1 and 8b2. The inner peripheral side edge 8b3 of the lightweight functional portion 8b is formed in a straight line and is orthogonal to the q-axis.

[0057] The peripheral portion 8a1 of the positioning function unit 8a is biased towards the q-axis relative to the virtual straight line L1, which is parallel to the long side of the permanent magnet 24 inserted into the first magnet insertion hole 29a and coincides with the side edge 8b1 of the lightweight function unit 8b. Furthermore, the peripheral portion 8a1 of the positioning function unit 8a is biased towards the q-axis relative to a virtual straight line (not shown) that is parallel to the long side of the permanent magnet 24 inserted into the second magnet insertion hole 29b and coincides with the side edge 8b2 of the lightweight function unit 8b. In other words, the peripheral portion 8a1 of the positioning function unit 8a is not tangent to either of the aforementioned virtual straight lines.

[0058] The purpose of providing a positioning hole in the rotor core 23 is to insert a positioning jig into the positioning hole to position the rotor core 23 relative to the stator core 13. Therefore, in Embodiment 1, since the area of ​​the hole 8 through which the jig is inserted constitutes a positioning function section 8a, this positioning function section 8a essentially corresponds to a hole that helps position the rotor core 23. The area of ​​the hole 8 other than the positioning function section 8a constitutes a lightweight function section 8b that helps to reduce the weight of the rotor core 23.

[0059] The shape and size of the positioning function part 8a are adapted to the shape and size of the rod-shaped positioning part of the fixture used in the positioning process of the rotor core 23. Furthermore, since the lightweight function part 8b is provided for the purpose of reducing the weight of the rotor core 23, the area occupied by the lightweight function part 8b in the hole 8 is set to be larger than the area occupied by the positioning function part 8a. That is, if the area occupied by the positioning function part 8a is set to S1 and the area occupied by the lightweight function part 8b is set to S2, then the positioning function part 8a and the lightweight function part 8b are formed such that S2 > S1.

[0060] The second portion 232 of the rotor core 23, sandwiched between the first magnet insertion hole 29a and the second magnet insertion hole 29b, continuously narrows from the inner circumference to the outer circumference of the rotor core 23. Therefore, in Embodiment 1, a positioning function portion 8a is arranged on the outer circumference of the rotor core 23, and a lightweight function portion 8b is arranged on the inner circumference of the rotor core 23. As a result, it is easy to make the area S2 occupied by the lightweight function portion 8b larger than the area S1 occupied by the positioning function portion 8a.

[0061] Furthermore, the maximum circumferential width d2 [mm] of the lightweight functional section 8b is formed to be greater than the maximum circumferential width d1 [mm] of the positioning functional section 8a (i.e., the diameter d1 [mm] of the virtual circle) (d2>d1). By forming it in the above manner, the influence on the magnetic flux flowing in the rotor core 23 can be reduced. Furthermore, since the rotor core is lightweight through the hole 8 formed by the positioning functional section 8a and the lightweight functional section 8b, the mechanical losses of the first bearing 27a and the second bearing 27b, which support the rotor shaft 26 for free rotation, are reduced, and the efficiency of the rotor 2 is improved.

[0062] In Embodiment 1, the hole portion 8 has an external shape that integrates the positioning functional portion 8a and the lightweight functional portion 8b while making them independent regions. Furthermore, the positioning functional portion 8a and the lightweight functional portion 8b are connected by a smooth curve. This configuration can reduce stress concentration within the rotor core 23.

[0063] Furthermore, in Embodiment 1, it is assumed that a cylindrical rod-shaped clamp is used as the clamp for positioning the rotor core 23. Therefore, when the angle range θ of the arc-shaped peripheral portion 8a1 of the positioning function part 8a is set to a mechanical angle of 180° or more, the area occupied by the virtual circle shown by the dashed line that completes the peripheral portion 8a1 into a complete arc shape corresponds to the positioning function part 8a, and the remaining area in the hole 8 excluding the area of ​​the positioning function part 8a corresponds to the lightweight function part 8b.

[0064] Furthermore, in Embodiment 1, as the fixture used in the positioning process of the rotor core, it is assumed that a general cylindrical rod-shaped fixture is used as described above. In order to match the circular cross-sectional shape of the cylindrical fixture, the peripheral portion 8a1 of the positioning functional part 8a is set to an arc shape. Moreover, in order to make the peripheral portion 8a1 fit along most of the outer shape of the fixture, the angle range θ of the arc-shaped peripheral portion 8a1 of the positioning functional part 8a is set to a mechanical angle of 180° or more. However, the peripheral portion 8a1 of the positioning functional part 8a is not limited to such an arc shape, and can be set to the most suitable shape corresponding to the cross-sectional shape of the positioning fixture. For example, when a positioning fixture with an elliptical or rectangular cross-sectional shape is used, at least a portion of the shape of the peripheral portion 8a1 of the positioning functional part 8a can be set to a shape along the elliptical or rectangular outer shape.

[0065] Regarding the lightweight functional unit 8b, since its area S2 is set relatively large to achieve the lightweighting of the rotor core 23, if the lightweight functional unit 8b is entirely disposed in the area between adjacent magnet insertion holes, it will hinder the flow of magnetic flux in the rotor core 23, which is detrimental to the characteristics of the rotating electric machine. On the other hand, if the lightweight functional unit 8b is disposed near the inner diameter side of the fixing hole 23a of the rotor core 23, it will lead to a decrease in the strength of the rotor core 23. Therefore, it is desirable to minimize the area occupied by the lightweight functional unit 8b in the area between adjacent magnet insertion holes and to place it in a region as far away from the fixing hole 23a of the rotor core 23 as possible.

[0066] In the first portion 231 of the rotor core 23 constituting the excitation pole, the central axis between two permanent magnets 24, which are respectively inserted into the first magnet insertion hole 29a and the second magnet insertion hole 29b and are opposite to each other, is the d-axis (d-axis). The central axis between this d-axis and the adjacent d-axis is the q-axis (q-axis). This q-axis coincides with the central axis of the second portion 232 of the rotor core 23, which is sandwiched between the two adjacent magnet insertion holes 29.

[0067] The center of the hole 8 is positioned on the q-axis. By configuring it in this way, the hole 8 can be located at the basic midpoint between two adjacent excitation poles, thereby preventing uneven magnetic flux flow between the two adjacent excitation poles.

[0068] From the viewpoint of rotational balance of rotor 2, it is desirable to arrange the holes 8 symmetrically about the q-axis. When the distance from the first magnet insertion hole 29a of one excitation pole to the second magnet insertion hole 29b of the adjacent excitation pole, i.e., the shortest distance between magnetic poles, is set as d3 [mm], if there is a region in rotor core 23 through which the width of the magnetic flux is less than the shortest distance between magnetic poles d3 [mm], the magnetic loss of rotor core 23 will increase.

[0069] Therefore, as mentioned above, the shortest distance d4 [mm] between the magnet insertion hole and the hole portion, and more specifically, the shortest distance d4 [mm] between the first magnet insertion hole 29a and the hole portion 8 and the shortest distance d4 [mm] between the second magnet insertion hole 29b and the hole portion 8 (not shown), are set to be greater than or equal to the shortest pole distance d3 [mm] (d4 ≥ d3). With this configuration, the influence on the magnetic flux flowing in the rotor core 23 is reduced, and the efficiency decrease of the rotor 2 can be suppressed.

[0070] Furthermore, to further improve the weight reduction effect while suppressing magnetic loss, the shortest distance d4 [mm] between the magnet insertion hole and the hole portion 8 and the shortest distance between magnetic poles d3 [mm] can be set to be the same. In addition, stress generated by the engagement of the rotor core 23 and the rotor shaft 26, as well as stress generated by the centrifugal force due to the rotation of the rotor 2, will occur on the inner peripheral edge portion 8b3 of the lightweight functional section 8b. Therefore, it is ideal to pre-calculate the stress generated by the engagement of the rotor core 23 and the shaft 26, as well as the stress generated by the centrifugal force due to the rotation of the rotor 2, and based on the calculation results, determine the optimal distance from the periphery of the fixing hole 23a of the rotor core 23 to the inner peripheral edge portion 8b3 of the lightweight functional section 8b. By setting the above optimal distance, the influence of stress acting on the inner peripheral edge portion 8b3 of the lightweight functional section 8b can be suppressed.

[0071] According to the rotating motor of Embodiment 1, the mechanical losses of the bearing section can be reduced by the hole, which has a small impact on the magnetic flux, a positioning function, and a mass reduction function, thereby improving the efficiency of the rotor.

[0072] Implementation Method 2

[0073] Next, the rotary motor of Embodiment 2 will be described, mainly focusing on the structure of the hole. Figure 4 This is an explanatory diagram of the rotor of the rotary electric motor according to Embodiment 2. Figure 4 Similar to Embodiment 1, the hole 8, composed of the positioning function part 8a and the lightweight function part 8b, is configured such that its centerline aligns with the q-axis. By configuring it in this way, the hole 8 can be positioned approximately in the middle of two adjacent excitation poles, thereby preventing uneven magnetic flux flow between the two adjacent excitation poles.

[0074] Furthermore, the shortest distance d4 [mm] between the magnet insertion hole and the hole portion, more specifically, the shortest distance d4 [mm] between the first magnet insertion hole 29a and the hole portion 8 and the shortest distance d4 [mm] between the second magnet insertion hole 29b and the hole portion 8 (not shown) are formed to be greater than or equal to the shortest distance between magnetic poles d3 [mm] (d4≥d3).

[0075] The peripheral portion 8a1 of the positioning function unit 8a is configured to be biased towards the q-axis relative to the virtual straight line L1. The virtual straight line L1 is parallel to the long side of the permanent magnet 24 inserted into the first magnet insertion hole 29a and coincides with the side edge 8b1 of one side of the lightweight function unit 8b. Furthermore, the peripheral portion 8a1 of the positioning function unit 8a is configured to be biased towards the q-axis relative to the virtual straight line (not shown). This virtual straight line is parallel to the long side of the permanent magnet 24 inserted into the second magnet insertion hole 29b and coincides with the side edge 8b2 of the other side of the lightweight function unit 8b.

[0076] One side edge 8b1 of the lightweight functional unit 8b is connected to one end of the peripheral edge 8a1 of the positioning functional unit 8a via an outer peripheral edge 8b4 that is parallel to the inner peripheral edge 8b3. The other side edge 8b2 of the lightweight functional unit 8b is connected to the other end of the peripheral edge 8a1 of the positioning functional unit 8a via an outer peripheral edge 8b5 that is parallel to the inner peripheral edge 8b3.

[0077] One side edge 8b1 of the lightweight functional section 8b coincides with a virtual straight line L1 parallel to the long side of the permanent magnet 24 inserted into the first magnet insertion hole 29a, and the other side edge 8b2 of the lightweight functional section 8b coincides with a virtual straight line (not shown) parallel to the long side of the permanent magnet 24 inserted into the second magnet insertion hole 29b. By configuring it as described above, the magnetic loss of the rotor 2 can be suppressed, and the occupied area of ​​the hole 8 can be further increased.

[0078] The other components of the rotary motor in Embodiment 2 are the same as those of the rotary motor in Embodiment 1.

[0079] According to the rotating electric motor of Embodiment 2, the mechanical losses of the bearing section can be reduced by the hole, which has a small impact on the magnetic flux, a positioning function, and a mass reduction function, thereby improving the efficiency of the rotor.

[0080] Implementation Method 3

[0081] Next, the rotary motor of Embodiment 3 will be described, mainly focusing on the structure of the hole. Figure 5 This is an explanatory diagram of the rotor of the rotary electric motor according to Embodiment 3. Figure 5 Similar to Embodiment 1, the hole 8, composed of the positioning function part 8a and the lightweight function part 8b, is configured such that its centerline aligns with the q-axis. By configuring it in this way, the hole 8 can be positioned approximately in the middle of two adjacent excitation poles, thereby preventing uneven magnetic flux flow between the two adjacent excitation poles.

[0082] The shortest distance d4 [mm] between the magnet insertion hole and the hole portion, that is, the shortest distance d4 [mm] between the first magnet insertion hole 29a and the hole portion 8 and the shortest distance d4 [mm] between the second magnet insertion hole 29b and the hole portion 8 (not shown), is configured to be greater than or equal to the shortest distance between magnetic poles d3 [mm] (d4≥d3).

[0083] The peripheral portion 8a1 of the positioning function unit 8a is tangent to a virtual straight line L1, which is parallel to the long side of the permanent magnet 24 inserted into the first magnet insertion hole 29a and coincides with one side edge 8b1 of the lightweight function unit 8b. Furthermore, the peripheral portion 8a1 of the positioning function unit 8a is tangent to a virtual straight line (not shown), which is parallel to the long side of the permanent magnet 24 inserted into the second magnet insertion hole 29b and coincides with the other side edge 8b2 of the lightweight function unit 8b.

[0084] One side edge 8b1 of the lightweight functional unit 8b is connected to one end of the peripheral edge 8a1 of the positioning functional unit 8a via an outer peripheral edge 8b4 that is parallel to the inner peripheral edge 8b3. The other side edge 8b2 of the lightweight functional unit 8b is connected to the other end of the peripheral edge 8a1 of the positioning functional unit 8a via an outer peripheral edge 8b5 that is parallel to the inner peripheral edge 8b3.

[0085] One side edge 8b1 of the lightweight functional section 8b coincides with the virtual straight line L1, and the other side edge 8b2 of the lightweight functional section 8b coincides with the virtual straight line parallel to the long side of the permanent magnet 24 inserted into the second magnet insertion hole 29b. By configuring it as described above, the magnetic loss of the rotor 2 can be suppressed, and the occupied area of ​​the hole 8 can be further increased.

[0086] The other components of the rotary motor in Embodiment 3 are the same as those of the rotary motor in Embodiment 1.

[0087] According to the rotating motor of Embodiment 3, the mechanical losses of the bearing section can be reduced by using holes that have little impact on magnetic flux, have positioning function and reduce mass, thereby improving the efficiency of the rotor.

[0088] Implementation Method 4

[0089] Next, the rotary motor of Embodiment 4 will be described, mainly focusing on the structure of the hole. Figure 6 This is an explanatory diagram of the rotor of the rotary electric machine according to Embodiment 4. Figure 6In this configuration, the hole portion 8, which is composed of the positioning function portion 8a and the lightweight function portion 8b, is arranged such that its centerline aligns with the d-axis. Furthermore, the hole portion 8 is positioned on the inner circumferential side of the first portion 231 of the rotor core 23 that constitutes the excitation pole, specifically, between the inner circumferential edge portion 29a2 of the first magnet insertion hole 29a and the inner circumferential edge portion 29b2 of the second magnet insertion hole 29b.

[0090] One side edge 8b1 of the lightweight functional unit 8b is connected to one end of the peripheral edge 8a1 of the positioning functional unit 8a via an outer peripheral edge 8b4 that is parallel to the inner peripheral edge 8b3. The other side edge 8b2 of the lightweight functional unit 8b is connected to the other end of the peripheral edge 8a1 of the positioning functional unit 8a via an outer peripheral edge 8b5 that is parallel to the inner peripheral edge 8b3.

[0091] One side edge 8b1 of the lightweight functional unit 8b faces the inner peripheral side edge 29b2 of the second magnet insertion hole 29b at a predetermined interval, and the other side edge 8b2 of the lightweight functional unit 8b faces the inner peripheral side edge 29a2 of the first magnet insertion hole 29a at a predetermined interval. The predetermined interval is set to suppress the influence of magnetic flux flow on the excitation poles and to maintain the minimum strength required for the rotor core 23.

[0092] The other components of the rotary motor in Embodiment 4 are the same as those of the rotary motor in Embodiment 1.

[0093] According to the rotary motor of embodiment four, the mechanical losses of the bearing section can be reduced by using holes that have little impact on magnetic flux, have positioning function and mass reduction function, thereby improving the efficiency of the rotor.

[0094] Implementation Method 5

[0095] Next, the rotary motor of Embodiment 5 will be described. Figure 7 This is an explanatory diagram of the rotor of the rotary electric machine according to Embodiment 5. According to the rotary electric machine of Embodiment 5, at the first portion 231 of the rotor core 23 constituting one excitation pole, a first magnet insertion hole section 291 and a second magnet insertion hole section 292 are arranged symmetrically about the d-axis and radially from the inner circumference to the outer circumference of the rotor core 23 in a stepped manner. The first magnet insertion hole section 291 is located on the inner circumference of the rotor core 23 relative to the second magnet insertion hole section 292.

[0096] The first magnet insertion hole section 291 is composed of a first magnet insertion hole 29a and a second magnet insertion hole 29b, and the second magnet insertion hole section 292 is composed of a third magnet insertion hole 29c and a fourth magnet insertion hole 29d. A first permanent magnet 241 is inserted into the first magnet insertion hole 29a and the second magnet insertion hole 29b, and a second permanent magnet 242 is inserted into the third magnet insertion hole 29c and the fourth magnet insertion hole 29d.

[0097] The hole portion 8, which is composed of the positioning function portion 8a and the lightweight function portion 8b, is configured such that its centerline is aligned with the d-axis. Furthermore, the hole portion 8 is provided on the rotor core 23 at the position where the inner peripheral edge portion 29a2 of the first magnet insertion hole 29a and the inner peripheral edge portion 29b2 of the second magnet insertion hole 29b are opposite each other.

[0098] One side edge 8b1 of the lightweight functional unit 8b is connected to one end of the peripheral edge 8a1 of the positioning functional unit 8a via an outer peripheral edge 8b4 that is parallel to the inner peripheral edge 8b3. The other side edge 8b2 of the lightweight functional unit 8b is connected to the other end of the peripheral edge 8a1 of the positioning functional unit 8a via an outer peripheral edge 8b5 that is parallel to the inner peripheral edge 8b3.

[0099] One side edge 8b1 of the lightweight functional unit 8b is positioned opposite the inner peripheral side edge 29b2 of the second magnet insertion hole 29b at a predetermined interval, and the other side edge 8b2 of the lightweight functional unit 8b is positioned opposite the inner peripheral side edge 29a2 of the first magnet insertion hole 29a at a predetermined interval. The predetermined interval is set to suppress the influence of magnetic flux flow on the excitation poles and to maintain the minimum strength required for the rotor core 23.

[0100] The distance d5 [mm] between the outermost peripheral edge 29a1 of the first magnet insertion hole 29a and the outermost peripheral edge 29c1 of the third magnet insertion hole 29c, and the distance d5 [mm] between the outermost peripheral edge 29b1 of the second magnet insertion hole 29b and the outermost peripheral edge 29d1 of the fourth magnet insertion hole 29d, are formed as the shortest distance between the first magnet insertion hole segment 291 and the second magnet insertion hole segment 292 within the magnetic pole, i.e., the shortest distance between magnet insertion hole segments.

[0101] Here, a virtual circle CX is defined as the circle tangent to the inner peripheral edge 29c2 of the third magnet insertion hole 29c and the inner peripheral edge 29d2 of the fourth magnet insertion hole 29d, located in the second magnet insertion hole section 292 on the outer periphery of the rotor core 23. The shortest distance d6 [mm] between the arc of the virtual circle CX and the periphery 8a1 of the positioning function section 8a of the hole section 8 is set to be greater than or equal to the shortest magnet insertion section distance d5 (d6≥d5). With this configuration, a region of the rotor core 23 with a width smaller than the shortest magnet insertion hole section distance d5 is eliminated in the first part 231 of the rotor core 23, thus preventing an increase in magnetic loss.

[0102] In addition, Figure 7 In the fifth embodiment shown, the magnet insertion hole segment is set as two segments: the first magnet insertion hole 291 and the second magnet insertion hole 292. However, it can also be configured as three or more segments.

[0103] Alternatively, holes consisting of positioning and lightweighting functional parts can be provided on the d-axis of all magnet insertion hole sections in two or more magnet insertion hole sections. In this case, the configuration of the magnet insertion hole section located on the outermost periphery of the rotor core 23 is the same as described above. Figure 6 The magnet insertion hole and the hole portion in Embodiment 4 shown have the same structure.

[0104] The other components of the rotary electric motor in Embodiment 5 are the same as those in Embodiment 1. However, in Embodiment 5, Figure 1 The longitudinal section view is not applicable.

[0105] According to the rotating electric motor of Embodiment 5, the mechanical losses of the bearing section can be reduced by using holes that have little impact on magnetic flux, have positioning function and reduce mass, thereby improving the efficiency of the rotor.

[0106] Implementation Method Six

[0107] Next, the rotary motor of Embodiment Six will be described. Figure 8 This is an explanatory diagram of the rotor of the rotary electric machine according to Embodiment Six. In the rotary electric machine according to Embodiment Six, the positioning function part 8a of the hole 8 is disposed on the inner diameter side of the rotor core 23 compared with the lightweight function part 8b, and is opposite to the fixing hole 23a of the rotor core 23.

[0108] Although stresses generated by the engagement of the rotor core 23 and the rotor shaft 26, as well as stresses generated by the centrifugal force of the rotor 2, will occur on the inner circumferential side of the rotor core in the hole, the positioning function part 8a can be arranged on the inner circumferential side of the rotor core 23 when the calculation results show that these stress values ​​are relatively small.

[0109] The hole portion 8, which consists of the positioning function part 8a and the lightweight function part 8b, is configured such that its centerline is aligned with the q-axis. By configuring it in this way, the hole portion 8 can be located at the basic middle of two adjacent excitation poles, thereby preventing uneven magnetic flux flow between the two adjacent excitation poles.

[0110] One side edge 8b6 of the lightweight functional unit 8b is connected to one end of the peripheral edge 8a1 of the positioning functional unit 8a via an outer peripheral side edge 8b9 parallel to the outer peripheral side edge 8b8. The other side edge 8b7 of the lightweight functional unit 8b is connected to the other end of the peripheral edge 8a1 of the positioning functional unit 8a via an outer peripheral side edge 8b10 parallel to the outer peripheral side edge 8b8.

[0111] One side edge 8b6 of the lightweight functional part 8b extends parallel to the long side of the permanent magnet 24 inserted into the second magnet insertion hole 29b, and the other side edge 8b7 of the lightweight functional part 8b extends parallel to the long side of the permanent magnet 24 inserted into the first magnet insertion hole 29a. The shortest distance d4 [mm] between the magnet insertion hole and the hole portion, that is, the shortest distance d4 [mm] between the first magnet insertion hole 29a and the hole portion 8 and the shortest distance d4 [mm] between the second magnet insertion hole 29b and the hole portion 8 (not shown), is configured to be at least the shortest pole distance d3 [mm] (d4≥d3).

[0112] By configuring it as described above, the magnetic loss of the rotor 2 can be suppressed, and the area occupied by the hole 8 can be further increased.

[0113] The other components of the rotary motor in Embodiment Six are the same as those of the rotary motor in Embodiment One.

[0114] According to the rotating electric motor of Embodiment Six, the mechanical losses of the bearing section can be reduced by using holes that have little impact on magnetic flux, have positioning function and reduce mass, thereby improving the efficiency of the rotor.

[0115] Implementation Method Seven

[0116] Next, the rotary motor of Embodiment Seven will be described. Figure 9 This is an explanatory diagram of the rotor of the rotary electric machine according to Embodiment Seven. Figure 9 As shown, in the rotary motor of Embodiment Seven, the inner peripheral edge 8b3 of the lightweight functional part 8b of the hole 8 is configured as an arc shape bulging radially inward toward the rotor core 23. Other configurations are similar to... Figure 5 The rotary motor described in Embodiment 3 is the same.

[0117] As mentioned above, although the inner peripheral edge 8b3 of the lightweight functional part 8b in the hole 8 is subjected to stress generated by the engagement of the rotor core 23 and the rotor shaft 26, as well as stress generated by the centrifugal force caused by the rotation of the rotor 2, the aforementioned stress acting on the inner peripheral edge 8b3 formed in the rotating motor according to Embodiment 7 is reduced because the inner peripheral edge 8b3 of the lightweight functional part 8b is configured as an arc shape bulging toward the radially inner side of the rotor core 23.

[0118] According to the rotating electric motor of embodiment seven, the mechanical losses of the bearing section can be reduced by using holes that have little impact on magnetic flux, have positioning function and reduce mass, thereby improving the efficiency of the rotor.

[0119] Implementation Method Eight

[0120] Next, the rotary motor of Embodiment 8 will be described. The rotary motor of Embodiment 8 has at least one of the end plates, namely a first end plate 25a that abuts against one axial end of the rotor core 23 and a second end plate 25b that abuts against the other axial end of the rotor core 23, which has multiple rod-shaped positioning members (not shown) extending along the axial direction of the rotor core 23. The positioning members are configured to be inserted into the positioning functional part 8a formed in the hole 8 of the rotor core 23.

[0121] The multiple rod-shaped positioning members disposed on the end plate have a cross-sectional shape that matches the shape of the positioning functional part 8a of the hole portion 8 of the rotor core 23. Furthermore, the multiple rod-shaped positioning members are arranged at circumferential intervals corresponding to the circumferential intervals of the multiple positioning functional parts 8a to be inserted in the rotor core 23.

[0122] Here, the multiple rod-shaped positioning members are pre-set to specify which of the multiple positioning function parts 8a to be inserted into the multiple holes of the rotor core 23, and the spacing between the multiple rod-shaped positioning members is set to match the spacing between the multiple positioning function parts 8a to be inserted. Alternatively, the end plate can be configured to adjust the spacing between the multiple rod-shaped positioning members to match the spacing between the multiple positioning function parts 8a to be inserted.

[0123] The cross-sectional shape of the multiple rod-shaped positioning members provided on the end plate is formed to match the cross-sectional shape of the positioning functional part 8a to be inserted. In addition, the positioning members are configured to be inserted into the positioning functional part 8a of the hole 8 of the rotor core 23 with a looseness within an allowable range.

[0124] By engaging the rod-shaped positioning member of the end plate with the positioning function part 8a of the hole 8 in the rotor core 23, a two-dimensional radial arrangement of the rotor 2 relative to the stator 1 can be achieved, ensuring that the axes of the stator 1 and the rotor 2 are aligned. Furthermore, as long as the engagement accuracy between the rod-shaped positioning member of the end plate and the positioning function part 8a of the hole 8 in the rotor core 23 is within the allowable range, a relatively coarse positioning of the rotor 2 relative to the stator 1 can be achieved within the allowable range.

[0125] Implementation Method Nine

[0126] Next, the manufacturing method of the rotary electric motor according to Embodiment Nine will be described. The manufacturing method of the rotary electric motor according to Embodiment Nine is a method for manufacturing the rotary electric motors described in Embodiments One to Seven above by using the positioning function of the hole portion of the rotor core 23 and the axis alignment fixture to align the axis of the stator core and the rotor core.

[0127] The axial alignment fixture includes a rotor core positioning part and a stator core holding part. The rotor core positioning part positions the rotor core relative to the stator core, and the stator core holding part holds the stator core. The stator core holding part is disposed around the rotor core positioning part. For example, the stator core holding part is composed of a clamping mechanism or the like, and holds the stator core 13 in a predetermined position.

[0128] The rotor core positioning section consists of multiple rod-shaped positioning members. These members are inserted into the positioning functional section 8a located in the hole 8 of the rotor core 23 to hold the rotor core 23 in place, ensuring that the axis of the stator core 13 is aligned with the axis of the rotor core 23, thus performing radial positioning of the rotor core 23 relative to the stator core 13. The alignment fixture is designed to ensure that the axis of the stator core and the axis of the rotor core remain within a predetermined error range.

[0129] The multiple rod-shaped positioning members constituting the rotor core positioning section have a cross-sectional shape that matches the shape of the positioning functional section 8a of the hole portion 8 of the rotor core 23. Furthermore, the multiple rod-shaped positioning members are arranged at circumferential intervals corresponding to the circumferential intervals of the multiple positioning functional sections 8a to be inserted in the rotor core 23.

[0130] Here, the distance between the multiple rod-shaped positioning members is set to match the distance between the positioning function parts 8a of the multiple holes 8 of the rotor 23 into which the multiple rod-shaped positioning members will be inserted, as predetermined. Alternatively, the rotor core positioning part can be configured to adjust the spacing between the multiple rod-shaped positioning members to match the spacing between the multiple positioning function parts 8a to be inserted.

[0131] The method for manufacturing a rotary electric motor according to Embodiment Nine is a method for manufacturing a rotary electric motor according to any one of Embodiments One to Seven, comprising: a stator core holding step, in which the stator core is held by a stator holding part of an axial alignment fixture; a rotor core positioning step, in which multiple rod-shaped positioning members of the rotor core positioning part of the axial alignment fixture are inserted into a positioning functional part of a hole in the rotor core to position the rotor relative to the stator; and an assembly step, in which at least a portion of the rotary electric motor is assembled while the rotor core is positioned relative to the stator by the rotor core positioning step.

[0132] In addition, from the perspective of preventing interference between the stator core 13 and the rotor core 23, it is advantageous to perform the stator core holding process before the rotor core positioning process. However, if there is no particular problem with interference between the stator core 13 and the rotor core 23, either the stator core holding process or the rotor core positioning process can be performed first.

[0133] According to the method for manufacturing a rotary electric motor described in Embodiment 9, by utilizing the positioning function of the hole in the rotor core and the shaft alignment fixture, a rotary electric motor can be obtained, which can reduce costs and improve the efficiency of the rotary electric motor during manufacturing.

[0134] Implementation Method Ten

[0135] Next, the manufacturing method of the rotary electric motor according to Embodiment 10 will be described. The manufacturing method of the rotary electric motor according to Embodiment 10 relates to the manufacturing methods of the rotary electric motors according to Embodiments 1 to 7, wherein, when at least one of the first end plate and the second end plate is provided with a hole having a positioning function portion that is the same as the positioning function portion provided in the hole portion of the rotor core, the rotary electric motor is manufactured using the positioning function portion of the end plate and the positioning function portion of the rotor core.

[0136] In the method for manufacturing a rotary electric motor according to Embodiment 10, the end plate is positioned relative to the rotor core 23 by inserting multiple rod-shaped positioning parts provided in the fixture into the positioning function part provided in the hole of the end plate and the positioning function part 8a provided in the hole 8 of the rotor core.

[0137] According to the method for manufacturing a rotary electric motor as described in Embodiment 10, a rotary electric motor can be obtained by utilizing the positioning function of the holes in the end plate and the rotor core, as well as the positioning fixture. This method can reduce costs and improve the efficiency of the rotary electric motor during manufacturing.

[0138] Implementation Method Eleven

[0139] Next, the manufacturing method of the rotary electric machine according to Embodiment Eleven will be described. In the manufacturing method of the rotary electric machine according to Embodiment Eleven, for the rotary electric machine described in Embodiment Eight above, the positioning function of the hole in the rotor core and the end plate installed at the axial end of the rotor core are used to align the end plate with the rotor core.

[0140] In the method for manufacturing a rotary electric machine according to Embodiment 11, the end plate and the rotor core are positioned by inserting multiple rod-shaped positioning members provided on the end plate into the positioning function part 8a provided in the hole 8 of the rotor core 23.

[0141] According to the method for manufacturing a rotary motor described in Embodiment 11 above, by utilizing the positioning function of the hole in the rotor core and the end plate having multiple columnar protrusions, a rotary motor can be obtained, which can reduce costs and improve the efficiency of the rotary motor during manufacturing.

[0142] Furthermore, in the rotary electric machines described in Embodiments 1 to 8 above, the positioning function of the hole is configured to be used primarily for axial alignment between the rotor and the stator, or for alignment between the rotor core and the end plate. However, for example, due to reasons such as the commonality of rotor component design, a rotor core having the above-described positioning function may be used as a common component between rotary electric machines not manufactured according to Embodiments 9 to 11 above.

[0143] While this disclosure describes various exemplary embodiments, the various features, methods, and functions described in one or more embodiments are not limited to specific embodiments, but can also be applied individually or in various combinations to embodiments. Therefore, numerous modifications not illustrated are contemplated within the scope of the technology disclosed in this application. For example, these include modifications, additions, or omissions of at least one constituent element, as well as extraction of at least one constituent element and combination with constituent elements of other embodiments.

[0144] Symbol Explanation

[0145] 100 rotary motors, 1 stator, 12 frames, 12a flanges, 13 Stator core, 14 Stator coil, 2 Rotor, 23 Rotor core, 23a Fixing hole, 231 First part of rotor core, 232 Second part of rotor core, 24 Permanent magnet, 241 First permanent magnet, 242 Second permanent magnet, 25a First end plate, 25b Second end plate, 26 Rotor shaft, 27a First bearing, 27b Second bearing, 28 Stop component, 29 Magnet insertion hole pair, 291 First magnet insertion hole segment, 292 Second magnet insertion hole section, 29a First magnet insertion hole, 29b Second magnet insertion hole, 29c Third magnet insertion hole, 29d Fourth magnet insertion hole 29a1, 29b1 outermost peripheral edge portion, 29a2, 29b2 inner peripheral side edge portion, 8-hole section, 8a positioning functional section, 8a1 peripheral section, 8b lightweight functional section, 8b1, 8b2, 8b6, 8b7 side edge, 8b3, 8b9, 8b10 inner side edge, 8b4, 8b5, 8b8 peripheral lateral margins

Claims

1. A rotary electric machine comprising: a stator core formed in a ring shape; a stator coil mounted to the stator core; a rotor core having a plurality of magnet insertion holes, an outer peripheral surface portion of the rotor core opposing an inner peripheral surface portion of the stator core with a gap therebetween; a plurality of permanent magnets respectively inserted into the plurality of magnet insertion holes to form a plurality of magnet poles in the rotor core; a rotor shaft penetrating a fixing hole provided in a radially central portion of the rotor core to support the rotor core; and a bearing supporting the rotor shaft so as to be free to rotate, characterized in that: the rotor core has a hole portion formed between the fixing hole and an outermost peripheral edge portion of the magnet insertion hole, the hole portion is composed of a positioning function portion and a lightweight function portion, the positioning function portion contributes to positioning of the rotor core, and the lightweight function portion contributes to lightweight of the rotor core.

2. The rotary electric machine according to claim 1, characterized in that: when an occupied area of the positioning function portion is set as SI and an occupied area of the lightweight function portion is set as S2, the hole portion is formed in such a manner that S2 > SI is satisfied.

3. The rotary electric machine according to claim 1 or 2, characterized in that: the positioning function portion has a circular arc-shaped peripheral edge portion.

4. The rotary electric machine according to claim 3, characterized in that: the circular arc-shaped peripheral edge portion of the positioning function portion is composed of a circular arc portion having an angle range of 180° or more in mechanical angle.

5. The rotary electric machine according to claim 3 or 4, characterized in that: when a diameter of the circular arc-shaped peripheral edge portion of the positioning function portion is set as dl and a maximum width of the lightweight function portion in a circumferential direction of the rotor core is set as d2, the hole portion is formed in such a manner that d2 > dl is satisfied.

6. The rotary electric machine according to any one of claims 1 to 5, characterized in that: the hole portion is disposed on a q-axis of the magnet pole, when a shortest magnet pole distance between two adjacent magnet poles is set as d3 and a shortest distance between the magnet insertion hole and the hole portion is set as d4, the rotor core is composed in such a manner that d4 > d3 is satisfied.

7. The rotary electric machine according to claim 6, characterized in that: the lightweight function portion of the hole portion has a side edge portion extending in parallel with a long side of the permanent magnet, the side edge portion of the lightweight function portion is formed so as to coincide with a virtual straight line LI extending in parallel with the long side of the permanent magnet with the d4 therebetween.

8. The rotary electric machine according to claim 7, characterized in that: the positioning function portion of the hole portion has a circular arc-shaped peripheral edge portion, the circular arc-shaped peripheral edge portion is formed so as to be tangent to the virtual straight line LI.

9. The rotary electric machine according to any one of claims 1 to 5, characterized in that: the hole portion is disposed on a d-axis of the magnet pole, and the hole portion is formed at a portion of the rotor core where two magnet insertion holes of the magnet pole opposing each other on an inner side in a radial direction of the rotor core. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ 10. The rotary electric motor as described in claim 9, characterized in that, The rotor core includes: First magnet insertion hole section; and The second magnet insertion hole section is disposed on the outer peripheral side of the rotor core relative to the first magnet insertion hole section. The first magnet insertion hole segment is composed of a first magnet insertion hole and a second magnet insertion hole, which are symmetrically arranged about a virtual straight line extending radially in the rotor core. The second magnet insertion hole segment is composed of a third magnet insertion hole and a fourth magnet insertion hole arranged symmetrically about the virtual straight line. The plurality of excitation poles are respectively formed by permanent magnets inserted into the first magnet insertion hole and the second magnet insertion hole, and by permanent magnets inserted into the third magnet insertion hole and the fourth magnet insertion hole. The hole is formed between the outermost periphery of the fixing hole and the third magnet insertion hole and the fourth magnet insertion hole.

11. The rotary electric motor as described in any one of claims 1 to 8, characterized in that, The positioning function unit is located on the outer periphery of the rotor core, compared to the lightweight function unit.

12. The rotary electric motor as described in any one of claims 3 to 5 and 8, characterized in that, The lightweight functional unit is located on the outer periphery of the rotor core, unlike the positioning functional unit. The arc-shaped peripheral portion of the positioning function part is configured to face the fixing hole of the rotor core.

13. The rotary electric motor as described in any one of claims 1 to 12, characterized in that, The rotor core has an end plate at at least one end in the axial direction that abuts against the rotor core in the axial direction. The end plate includes a hole with a positioning function that matches at least one of the positioning functions formed in the hole of the rotor core.

14. The rotary electric motor as claimed in any one of claims 1 to 12, characterized in that, The rotor core has an end plate at at least one end in the axial direction that abuts against the rotor core in the axial direction. The end plate includes a plurality of rod-shaped positioning members extending axially from the rotor core. The plurality of positioning members are inserted into at least the positioning functional portion formed in the plurality of holes in the rotor core.

15. A manufacturing method of a rotating electric machine, the rotating electric machine according to any one of claims 1 to 12 is manufactured, characterized by, The manufacturing method includes: The stator core holding process involves holding the stator core by means of the stator core holding part of the axial alignment fixture; In the rotor core positioning process, multiple rod-shaped positioning members of the rotor core positioning part of the shaft alignment fixture are inserted into the positioning functional part of the hole in the rotor core to position the rotor core relative to the stator core; and In the assembly process, at least a portion of the rotating motor is assembled after the rotor core has been positioned relative to the stator core in the rotor core positioning process.

16. A method of manufacturing a rotating electric machine, the rotating electric machine of claim 13 being manufactured, characterized by The manufacturing method includes: The stator core holding process involves holding the stator core by means of the stator core holding part of the axial alignment fixture; The rotor core positioning process positions the rotor core with respect to the stator core by inserting a plurality of rod-shaped positioning members of a rotor core positioning portion of the shaft center alignment jig into the positioning function portions provided to the hole portions of the end plate and the hole portions provided to the rotor core. The assembly process assembles at least a portion of the rotary electric machine in a state in which the rotor core is positioned with respect to the stator core by the rotor core positioning process.

17. A manufacturing method of a rotary electric machine, wherein the rotary electric machine according to claim 13 is manufactured, characterized in that, The end plate and the rotor core are positioned by inserting a plurality of rod-shaped positioning members provided to the end plate into both the positioning function portions provided to the hole portions of the end plate and the hole portions provided to the rotor core.

18. A manufacturing method of a rotary electric machine, wherein the rotary electric machine according to claim 14 is manufactured, characterized in that, The end plate and the rotor core are positioned by inserting a plurality of rod-shaped positioning members provided to the end plate into both the positioning function portions provided to the hole portions of the end plate and the hole portions provided to the rotor core.

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