Magnetic pole piece rotator, magnetic gear rotary machine, and method for manufacturing non-magnetic body for magnetic pole piece rotator

Abstract

To provide a magnetic pole piece rotator, a magnetic gear rotary machine, and a method for manufacturing a non-magnetic body for a magnetic pole piece rotator which can suppress generation of cracks in a non-magnetic body even when a temperature change has occurred.SOLUTION: A magnetic pole piece rotator includes: a plurality of magnetic pole pieces arranged at intervals in a circumferential direction; and a plurality of non-magnetic bodies arranged alternately with the magnetic pole pieces in the circumferential direction. At least one of the non-magnetic bodies is an FRP laminate body in which a plurality of FRP layers is laminated. The FRP laminate body includes: a radial-direction extension part in which a plurality of FRP layers is laminated in a circumferential direction between the FRP center as the center of the FRP laminate body and the magnetic pole pieces in an axial-directional view; and a circumferential-direction extension part in which the FRP layers are laminated on the radially inner and outer sides of the FRP center.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to a magnetic pole piece rotor, a magnetic gear rotating machine, and a method for manufacturing a non-magnetic body for a magnetic pole piece rotor.

Background Art

[0002] Conventionally, a magnetic pole piece rotor incorporated in a magnetic gear rotating machine is known. The magnetic pole piece rotor includes a plurality of magnetic pole pieces and a plurality of non-magnetic bodies arranged alternately in the circumferential direction (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Generally, a non-magnetic body has a property of being more likely to thermally deform than a magnetic pole piece. In the above patent document, a configuration in which two magnetic pole pieces sandwich one non-magnetic body in the circumferential direction is adopted, and the thermal deformation of the non-magnetic body is restricted by each of the two magnetic pole pieces. Therefore, when a temperature change occurs in the magnetic pole piece rotor, a large thermal strain occurs in the non-magnetic body, and there is a risk of cracks occurring in the non-magnetic body.

[0005] An object of the present disclosure is to provide a magnetic pole piece rotor, a magnetic gear rotating machine, and a method for manufacturing a non-magnetic body for a magnetic pole piece rotor that can suppress the occurrence of cracks in the non-magnetic body even when a temperature change occurs.

Means for Solving the Problems

[0006] The magnetic pole piece rotor according to at least one embodiment of the present disclosure is a plurality of magnetic pole pieces arranged at intervals in the circumferential direction, and the plurality of magnetic pole pieces and a plurality of non-magnetic bodies arranged alternately in the circumferential direction, comprising, at least one of the plurality of non-magnetic bodies is an FRP laminate in which a plurality of FRP layers are laminated, in an axial view, a radially extending portion in which the plurality of FRP layers are laminated along the circumferential direction between the FRP center, which is the center of the FRP laminate, and the magnetic pole piece, and circumferentially extending portions in which the plurality of FRP layers are laminated along the radial direction on each of the inner and outer sides in the radial direction from the FRP center.

[0007] A magnetic gear rotating machine according to at least one embodiment of the present disclosure includes, the above-described magnetic pole piece rotor, a magnet rotor located inside the radial direction with respect to the plurality of magnetic pole pieces and the plurality of non-magnetic bodies, and a stator located outside the radial direction with respect to the plurality of magnetic pole pieces and the plurality of non-magnetic bodies. comprising.

[0008] A method for manufacturing a non-magnetic body for a magnetic pole piece rotor according to at least one embodiment of the present disclosure is, the method for manufacturing a non-magnetic body for the above-described magnetic pole piece rotor, including a lamination step of laminating the plurality of FRP layers so that the radially extending portion and the circumferentially extending portion are formed.

Advantages of the Invention

[0009] According to the present disclosure, it is possible to provide a magnetic pole piece rotor, a magnetic gear rotating machine, and a method for manufacturing a non-magnetic body for a magnetic pole piece rotor that can suppress the occurrence of cracks in the non-magnetic body even when a temperature change occurs.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Best Mode for Carrying Out the Invention

[0011] Hereinafter, some embodiments of the present disclosure will be described with reference to the accompanying drawings. However, the dimensions, materials, shapes, relative arrangements, etc. of the components described as embodiments or shown in the drawings are not intended to limit the scope of the present disclosure, but are merely illustrative examples. For example, expressions representing relative or absolute arrangements such as "in a certain direction", "along a certain direction", "parallel", "orthogonal", "center", "concentric", or "coaxial" not only strictly represent such arrangements, but also represent a state of relative displacement with tolerances, or angles and distances that can obtain the same function. For example, expressions representing that things such as "identical", "equal", and "homogeneous" are in an equal state not only strictly represent an equal state, but also represent a state in which there are tolerances or differences that can obtain the same function. For example, expressions representing shapes such as a rectangular shape or a cylindrical shape shall represent not only the geometrically precise rectangular shape, cylindrical shape, etc., but also shapes including concavo-convex portions, chamfered portions, etc. within the range where the same effect can be obtained. On the other hand, the expressions "comprising", "including", or "having" for one component are not exclusive expressions that exclude the existence of other components. Note that the same reference numerals may be given to the same configurations and the description thereof may be omitted.

[0012] <Overview of the Magnetic Gear Rotating Machine 1> FIG. 1 is a schematic view of a magnetic gear rotating machine 1 according to an embodiment of the present disclosure. In the following description, the "axial direction" is the axial direction of the axis S of the magnetic gear rotating machine 1, the "circumferential direction" is the circumferential direction with respect to the axis S, and the "radial direction" is the radial direction with respect to the axis S. Further, the "outer side in the radial direction" is the side in the direction away from the axis S, and the "inner side in the radial direction" is the side in the direction approaching the axis S.

[0013] The magnetic gear rotating machine 1 is connected to an external device 9 via a rotating shaft 18. The axis of the rotating shaft 18 substantially coincides with the above-described axis S. In FIG. 1, for the convenience of simplifying the drawing, the rotating shaft 18 is depicted as a single solid shaft member, but the present disclosure is not limited thereto. The rotating shaft 18 may be realized by a plurality of shaft members, and the plurality of shaft members may include shaft members formed in a cylindrical shape.

[0014] The magnetic gear rotating machine 1 includes a magnet rotor 10 connected to a rotating shaft 18 via a bearing B1. The magnet rotor 10 has a rotor core 15 configured to rotate relative to the rotating shaft 18, and a plurality of magnets 19 supported by the rotor core 15. The plurality of magnets 19 are arranged in the circumferential direction in the rotor core 15. Also, each magnet 19 extends in the axial direction. In the magnet rotor 10 illustrated in FIG. 1, a surface magnet type (SPM; Surface Permanent Magnet) configuration in which a plurality of magnets 19 are provided on the surface of the rotor core 15 is adopted, but the present disclosure is not limited thereto. For example, an interior permanent magnet type (IPM; Interior Permanent Magnet) configuration in which a plurality of magnets 19 are embedded in the rotor core 15 may be adopted (see FIG. 2).

[0015] The magnetic gear rotating machine 1 further includes a pole piece rotor 30 configured to rotate integrally with the rotating shaft 18. The pole piece rotor 30 includes a ring unit 33 disposed radially outside the magnet rotor 10, a first connecting portion 31 connecting one end portion of the ring unit 33 in the axial direction and the rotating shaft 18, and a second connecting portion 32 connecting the other end portion of the ring unit 33 and the rotating shaft 18. Details of the ring unit 33 will be described later.

[0016] The magnetic gear rotating machine 1 further includes a stator 20 disposed radially outside the ring unit 33. The stator 20 has a stator core 22 extending in the circumferential direction, a plurality of stator coils 27 disposed in the stator core 22, and a plurality of stator magnets 29 attached to the inner peripheral surface of the stator core 22. The stator coils 27 are electrically connected to an electrical system 16. The plurality of stator magnets 29 are arranged in the circumferential direction (see FIG. 2).

[0017] To attach the stator magnet 29 to the stator core 22, several methods can be adopted. As a first method, each stator magnet 29 may be attached to the inner peripheral surface of the stator core 22 by an adhesive. As a second method, each stator magnet 29 may be attached to two fingers (or two protrusions) protruding radially inward from the inner peripheral surface of the stator core 22. Also, an attachment method combining the first method and the second method may be adopted.

[0018] Referring to FIG. 2, the ring unit 33 of the pole piece rotor 30 is illustrated. The ring unit 33 faces the magnet rotor 10 in the radial direction with the inner air gap G1 therebetween, and faces the stator 20 in the radial direction with the outer air gap G2 therebetween.

[0019] The ring unit 33 includes a plurality of pole pieces 35 and a plurality of non-magnetic bodies 36 that are alternately arranged in the circumferential direction, and each pole piece 35 and each non-magnetic body 36 extend in the axial direction. Each pole piece 35 is realized by a plurality of electromagnetic steel sheets laminated in the axial direction, one or more powder cores extending in the axial direction, or a combination thereof. Also, at least one of the plurality of pole pieces 35 may be formed with a pole piece hole 56 that is open in the axial direction. The pole piece hole 56 may function as a ventilation path through which cooling air can pass, or may function as an insertion hole into which a support shaft for supporting the pole piece 35 is inserted. Similarly, at least one of the plurality of non-magnetic bodies 36 may be formed with a non-magnetic body hole 57 that is open in the axial direction. The non-magnetic body hole 57 may function as a ventilation path, or may function as an insertion hole into which a support rod for supporting the non-magnetic body 36 is inserted.

[0020] The non-magnetic body 36 is formed of fiber reinforced plastic (FRP). In other words, the non-magnetic body 36 is an FRP laminate 70 in which a plurality of FRP layers 60 are laminated (see FIG. 3). Details of the FRP laminate 70 will be described later. Note that the non-magnetic body 36 preferably has not only non-magnetic properties but also non-conductive properties.

[0021] The ring unit 33 illustrated in FIG. 2 may further include an inner cover 339 and an outer cover 332 that sandwich a plurality of magnetic pole pieces 35 and a plurality of non-magnetic bodies 36 in the radial direction. The inner cover 339 and the outer cover 332 are cylindrical members formed of a non-magnetic material such as FRP, for example. However, the present disclosure is not limited thereto, and the inner cover 339 and the outer cover 332 may not be provided. In this case, each of the magnetic pole pieces 35 and each of the non-magnetic bodies 36 are exposed to each of the inner air gap G1 and the outer air gap G2.

[0022] Returning to FIG. 1, the magnetic gear rotating machine 1 according to one embodiment is a magnetic gear generator configured to generate electricity by input of power from an external device 9 which may be a prime mover, for example. Its operating principle is as follows. When the external device 9 drives the rotating shaft 18, the magnetic pole piece rotor 30 rotates. The relative positional relationship between the plurality of magnets 19 and the plurality of magnetic pole pieces 35 with respect to the plurality of stator magnets 29 changes, and the magnetic flux between the magnet rotor 10 and the stator 20 is modulated. When the magnet rotor 10 rotates by receiving magnetic force from the modulated magnetic field by the magnets 19, an electric current is generated in the stator coil 27 by electromagnetic induction, and power is supplied from the stator coil 27 to the electrical system 16.

[0023] The magnetic gear rotating machine 1 according to another embodiment is a magnetic gear motor configured to output power to an external device 9 by supply of power from the electrical system 16. Its operating principle is as follows. The magnet rotor 10 rotates by a rotating magnetic field generated with control of the current flowing through the stator coil 27. The relative positional relationship between the plurality of magnets 19 and the plurality of magnetic pole pieces 35 with respect to the plurality of stator magnets 29 changes, and the magnetic flux between the magnet rotor 10 and the stator 20 is modulated. When the magnetic pole pieces 35 receive magnetic force from the modulated magnetic field, the magnetic pole piece rotor 30 rotates, and power is output from the rotating shaft 18 to the external device 9. In this case, the external device 9 may be, for example, an electric vehicle, and the power output from the rotating shaft 18 may be transmitted to the drive shaft of the electric vehicle.

[0024] In FIG. 1, a structure in which the rotating shaft 18 rotates together with the pole piece rotor 30 is illustrated, but the present disclosure is not limited thereto. For example, a structure in which the rotating shaft 18 rotates together with the magnet rotor 10 may be adopted. In this case, the pole piece rotor 30 is connected to the rotating shaft 18 via a bearing. Further, the pole piece rotor 30 may be configured to rotate together with a shaft member different from the rotating shaft 18. When the other shaft member is connected to a device different from the external device 9, the magnetic gear rotating machine 1 can also transmit the power output from the other shaft member to the device.

[0025] <Overview of the non-magnetic body 36> FIG. 3 is a schematic view of the non-magnetic body 36 according to an embodiment of the present disclosure. As described above, each of the plurality of non-magnetic bodies 36 is an FRP laminate 70 in which a plurality of FRP layers 60 are laminated. The plurality of FRP layers 60 are formed by the prepreg 100. The number of prepregs 100 may be one, and in this case, a structure in which the prepreg 100 is wound multiple times is adopted. The present disclosure is not limited thereto, and the number of prepregs 100 may be two or more (details will be described later). In the following description, in an axial view, the center of the FRP laminate 70 in each of the circumferential direction and the radial direction may be referred to as the "FRP center C".

[0026] In an axial view, the FRP laminate 70 includes a radially extending portion 80 linearly extending along the radial direction, a circumferentially extending portion 90 linearly extending along the circumferential direction, and a corner portion 75 connecting to each of the radially extending portion 80 and the circumferentially extending portion 90.

[0027] The radially extending portion 80 has a structure in which a plurality of FRP layers 60 are laminated along the circumferential direction between the FRP center C and the pole piece 35. In FIG. 3, only the radially extending portion 80 located on one side in the circumferential direction with respect to the FRP center C is illustrated, but the radially extending portion 80 is also arranged on the other side in the circumferential direction (details will be described later). The circumferentially extending portion 90 is located on each of the inner and outer sides in the radial direction with respect to the FRP center C. The circumferentially extending portion 90 has a structure in which a plurality of FRP layers 60 are laminated along the radial direction.

[0028] In FIG. 3, two corner portions 75 are illustrated. Each corner portion 75 may be formed by the curved prepreg 100, may be formed by the resin material leaking from the prepreg 100, or may be formed by a combination thereof.

[0029] Explain the technical advantages of the non-magnetic body 36. The inventor obtained the following findings regarding the thermal stress generated in the non-magnetic body 36. That is, the direction of the principal stress at the circumferential end of the non-magnetic body 36 is along the radial direction (arrow P1), and the direction of the principal stress at the radial end of the non-magnetic body 36 is along the circumferential direction (arrow P2). Based on this finding, according to the above configuration, the former principal stress is generated in the radially extending portion 80 of the FRP laminate 70, and the direction of the principal stress (arrow P1) is in the in-plane direction of the FRP layer 60 included in the radially extending portion 80. Similarly, the latter principal stress is generated in the circumferentially extending portion 90 of the FRP laminate 70, and the direction of the principal stress (arrow P2) is in the in-plane direction of the FRP layer 60 included in the circumferentially extending portion 90. As described above, since the direction of the principal stress can be made to coincide with the in-plane direction of the plurality of FRP layers 60, a pole piece rotor 30 is realized in which cracks are suppressed from occurring in the non-magnetic body 36 due to temperature changes.

[0030] More specifically, for example, when the pole piece rotor 30 includes a thermoplastic adhesive between the end face of the non-magnetic body 36 in the circumferential direction and the end face of the pole piece 35 in the circumferential direction, a manufacturing process of heating the ring unit 33 using a device such as an autoclave is required. When the heated ring unit 33 is cooled, if the thermal contraction of the non-magnetic body 36 is inhibited by the pole piece 35, the thermal strain in the non-magnetic body 36 increases, and cracks may occur in the non-magnetic body 36. In this regard, according to the above configuration, the direction of the principal stress of the non-magnetic body 36 can be made to coincide with the in-plane direction of the FRP layer 60, and sufficient strength is ensured in the circumferentially extending portion 90 and the radially extending portion 80. Thereby, generation of cracks in the non-magnetic body 36 can be suppressed.

[0031] As another specific example, when the magnetic gear rotating machine 1 is in operation, the temperature of the ring unit 33 rises due to the generation of eddy currents in the magnetic pole pieces 35 or the like. If the thermal expansion of the non-magnetic body 36 accompanying the temperature rise is inhibited by the magnetic pole pieces 35, the thermal strain in the non-magnetic body 36 increases, and there is a possibility that the non-magnetic body 36 may be damaged (cracked). In this regard, according to the above configuration, the direction of the principal stress of the non-magnetic body 36 can be made to coincide with the in-plane direction of the FRP layer 60, and the occurrence of cracks in the non-magnetic body 36 can be suppressed.

[0032] Note that the present disclosure is not limited to each of the plurality of non-magnetic bodies 36 being the FRP laminate 70. The above technical advantages can be obtained as long as at least one of the plurality of non-magnetic bodies 36 shown in FIG. 2 is the FRP laminate 70. Further, the in-plane direction of the FRP layer 60 described above is a direction orthogonal to the thickness direction of the FRP layer 60 and is a direction along the prepreg 100.

[0033] Hereinafter, with reference to FIGS. 4 and 5, two more detailed configurations of the non-magnetic body 36 shown in FIG. 3 will be illustrated.

[0034] <Details of the non-magnetic body 36 (First Embodiment)> FIG. 4 is a schematic view of a non-magnetic body 36A (36) according to the first embodiment. The non-magnetic body 36A (36) is an FRP laminate 70A (70), and the plurality of FRP layers 60 of the FRP laminate 70A include at least one divided FRP layer 65A (65). The divided FRP layer 65A is a layer divided at a corner 75 within the same layer. In other words, the divided FRP layer 65A has a configuration in which two prepregs 100 are arranged side by side within the same layer, and a divided portion 45A (45) formed between the two prepregs 100 is located at the corner 75.

[0035] The divided portion 45A according to the first embodiment is a concave portion that is recessed from the innermost peripheral surface 76 of the corner 75 toward the outer peripheral side in the axial direction view. Here, the innermost peripheral surface 76 is the surface on the FRP center C side of the corner 75 in the axial direction view. A space Sp is formed inside the divided portion 45A, and the space Sp communicates with the inner space defined by the non-magnetic body hole 57.

[0036] As an example, the dividing portion 45A is formed over the entire axial length of the FRP laminate 70A. The dividing portion 45A is formed by cutting the innermost peripheral surface 76 of the corner portion 75 along the axial direction. Note that the inside of the dividing portion 45A may be filled with a non-magnetic material such as a resin material or a rubber material (not shown). Further, the dividing portions 45A may be formed at intervals in the axial direction. More specifically, between the two corner portions 75 shown in FIG. 4, the FRP laminate 70A may be configured such that a plurality of dividing portions 45A are alternately arranged in the axial direction.

[0037] According to the inventor's findings, relatively high thermal stress tends to occur even at the corner portion 75. In this regard, according to the configuration in which at least one layer of divided FRP layer 65A (65) is provided, since the FRP layer 60 is divided at the corner portion 75, the carbon fibers become discontinuous between the divided prepregs 100, and each prepreg 100 is liable to thermally deform. Therefore, the thermal strain at the corner portion 75 can be suppressed, and the occurrence of cracks at the corner portion 75 due to temperature change can be suppressed.

[0038] With reference to FIG. 4, the description of the FRP laminate 70A will be continued. In the example of FIG. 4, the FRP layer 60 closest to the FRP center C side in the axial view is divided at the corner portion 75. More specifically, the divided FRP layer 65A has a first FRP layer 61 that is located closest to the FRP center C side in the axial view among the plurality of FRP layers 60. According to the inventor's findings, relatively high thermal stress tends to occur at the inner peripheral side (FRP center C side) portion of the corner portion 75 of the FRP laminate 70. In this regard, according to the above configuration, since the first FRP layer 61 is divided at the corner portion 75, the occurrence of cracks at the inner peripheral side portion of the corner portion 75 can be suppressed.

[0039] In the example of FIG. 4, when viewed in the axial direction, all of the FRP layers 60 with two or more layers, counted in order from the one closest to the FRP center C, are each divided at the corner 75. More specifically, the divided FRP layer 65A further has at least one second FRP layer 62 continuously laminated from the first FRP layer 61 toward the outer peripheral side among the plurality of FRP layers 60. In the example of FIG. 4, a plurality of second FRP layers 62 are provided. According to the above configuration, since each of the continuously laminated first FRP layer 61 and second FRP layer 62 is divided at the corner 75, the occurrence of cracks at the inner peripheral side portion of the corner 75 can be more reliably suppressed.

[0040] In the example of FIG. 4, when viewed in the axial direction, the dividing portion 45A (45) extends linearly along the thickness direction of the plurality of FRP layers 60 (hereinafter, may be simply referred to as the "thickness direction"). According to the above configuration, since the dividing positions of the first FRP layer 61 and the second FRP layer 62 are aligned, the machining for forming the dividing portion 45A is facilitated. More specifically, by simply performing the step of cutting the inner side portion of the corner 75 along the axial direction once, it becomes possible to form the dividing portion 45A at a single corner 75.

[0041] Furthermore, in the example of FIG. 4, the outer peripheral end 45a of the dividing portion 45 is located closer to the FRP center C side than the center of the corner 75 (two-dot chain line N) in the thickness direction when viewed in the axial direction. According to the above configuration, the formation range of the dividing portion 45A at the corner 75 can be suppressed, and the strength of the FRP laminate 70 can be maintained.

[0042] <Details of the non-magnetic body 36 (Second Embodiment)> FIG. 5 is a schematic view of the non-magnetic body 36B (36) according to the second embodiment. Prior to the detailed description of the FRP laminate 70B (70) which is the non-magnetic body 36B according to the second embodiment, the radially extending portion 80, the circumferentially extending portion 90, and the corner 75 will be described in detail.

[0043] The radially extending portion 80 has a first radially extending portion 81 and a second radially extending portion 82 that are respectively located on one circumferential side and the other circumferential side with respect to the FRP center C. The circumferentially extending portion 90 has an outer circumferentially extending portion 91 and an inner circumferentially extending portion 92 that are respectively located on the outer side and the inner side in the radial direction with respect to the FRP center C.

[0044] Also, the corner portion 75 has a first corner portion 71, a second corner portion 72, a third corner portion 73, and a fourth corner portion 74. The configurations of these four corner portions 75 in the axial direction view are as follows. The first corner portion 71 is located on one circumferential side and the outer side in the radial direction with respect to the FRP center C, and the second corner portion 72 is located diagonally to the first corner portion 71. The third corner portion 73 is located on the other circumferential side and the outer side in the radial direction with respect to the FRP center C, and the fourth corner portion 74 is located diagonally to the third corner portion 73.

[0045] The lamination structure of the FRP laminate 70B (70) will be described in detail. At least one layer of segmented FRP layer 65B (65) is arranged in the FRP laminate 70B, and the segmented FRP layer 65B includes a first segmented FRP layer 111 and a second segmented FRP layer 112.

[0046] A total of four types of prepregs 100 are applied to the first segmented FRP layer 111 and the second segmented FRP layer 112. Specifically, the first prepreg 101 and the second prepreg 102 are applied to the first segmented FRP layer 111, and the third prepreg 103 and the fourth prepreg 104 are applied to the second segmented FRP layer 112, respectively. Each type of prepreg 100 is bent at one of the four corner portions 75 described above.

[0047] More specifically, the first divided FRP layer 111 includes a first prepreg 101 having one-side radial extension portion 81 and inner circumferential extension portion 92, and a second prepreg 102 having the other-side radial extension portion 82 and outer circumferential extension portion 91. The first prepreg 101 is bent at the fourth corner portion 74, and the second prepreg 102 is bent at the third corner portion 73. Then, the first prepreg 101 and the second prepreg 102 are arranged side by side within the same layer with the first corner portion 71 and the second corner portion 72 therebetween. As a result, in the first divided FRP layer 111, a dividing portion 45B (45) is formed at each of the first corner portion 71 and the second corner portion 72. The dividing portion 45B according to the second embodiment is a resin material that leaked from the prepreg 100 during the molding process of the FRP laminate 70.

[0048] Furthermore, the second divided FRP layer 112 includes a third prepreg 103 having the other-side radial extension portion 82 and inner circumferential extension portion 92, and a fourth prepreg 104 having the one-side radial extension portion 81 and outer circumferential extension portion 91. The third prepreg 103 is bent at the second corner portion 72, and the fourth prepreg 104 is bent at the first corner portion 71. Then, the third prepreg 103 and the fourth prepreg 104 are arranged side by side within the same layer with the third corner portion 73 and the fourth corner portion 74 therebetween. As a result, in the second divided FRP layer 112, a dividing portion 45B (45) is formed at each of the third corner portion 73 and the fourth corner portion 74.

[0049] According to the configuration in which the divided FRP layer 65 includes the first divided FRP layer 111, the dividing portion 45B of the FRP layer 60 is formed at each of the first corner portion 71 and the second corner portion 72 that are diagonal to each other in the axial direction view. Thereby, the occurrence of cracks at each of the first corner portion 71 and the second corner portion 72 can be suppressed.

[0050] According to the configuration in which the divided FRP layer 65 includes the second divided FRP layer 112, the dividing portion 45B of the FRP layer 60 is formed at each of the third corner portion 73 and the fourth corner portion 74 that are diagonal to each other in the axial direction view. Thereby, the occurrence of cracks at each of the third corner portion 73 and the fourth corner portion 74 can be suppressed.

[0051] A plurality of first FRP layers 61 may be continuously laminated along the thickness direction. Similarly, a plurality of second FRP layers 62 may be continuously laminated along the thickness direction. Even in this case, the above-described technical advantages can be obtained. However, as illustrated in FIG. 5, it is preferable that the first FRP layer 61 and the second FRP layer 62 are alternately arranged in the thickness direction. According to this configuration, the dividing portions 45B are formed in a well-balanced manner at the first corner portion 71, the second corner portion 72, the third corner portion 73, and the fourth corner portion 74. More specifically, at any corner portion 75, the dividing portion 45B and the prepreg 100 are alternately arranged along the thickness direction. Thereby, the occurrence of cracks can be suppressed in a well-balanced manner at any corner portion 75.

[0052] <Method for manufacturing non-magnetic body 36 (First Embodiment)> With reference to FIGS. 4, 6, and 7, a method for manufacturing a non-magnetic body 36A (36) according to the first embodiment will be described. FIG. 6 is a flowchart showing a method for manufacturing the non-magnetic body 36A (i.e., the FRP laminate 70A). Hereinafter, the case where "step" is abbreviated as "S" will be described.

[0053] First, a lamination step (S11) of laminating a plurality of FRP layers 60 is executed so that the radially extending portion 80 and the circumferentially extending portion 90 are formed. For example, as shown in FIG. 7, the lamination step is executed by winding one prepreg 100 around the mold 99.

[0054] Next, a heating step of heating the plurality of FRP layers 60 is executed (S13). For example, the heating step is executed by pressurizing and heating the prepreg 100 wound around the mold 99 by a molding machine or the like. After molding, the mold 99 is pulled out.

[0055] Next, a cutting step is executed (S15) so that a dividing portion 45A is formed in the non-magnetic body 36A. For example, the FRP layers 60 are cut along the axial direction such that at least the first FRP layer 61, which is located closest to the FRP center C in the axial direction view among the plurality of FRP layers 60, is cut. In this example, the first FRP layer 61 and the plurality of second FRP layers 62 laminated on the first FRP layer 61 are collectively cut by a cutting process (see FIG. 4). More specifically, a water jet cutting process in which high-pressure water is jetted from a nozzle may be executed. Even more specifically, the nozzle may be disposed in the inner space of the non-magnetic body hole 57 (see FIG. 4), and the nozzle may be moved along the axial direction while jetting water toward the corner portion 75. As a result, a dividing portion 45A is formed at each of the four corner portions of the non-magnetic body 36A (see FIG. 4). As described above, the non-magnetic body 36A is completed. Note that S11 and S15 may be executed either by an operator or a robot arm.

[0056] <Manufacturing method of non-magnetic body 36 (Second Embodiment)> With reference to FIGS. 4 and 8 to 10, a manufacturing method of a non-magnetic body 36B (36) according to the second embodiment will be described. FIGS. 8 and 9 are flowcharts showing a manufacturing method of the non-magnetic body 36B (that is, the FRP laminate 70B).

[0057] First, a lamination step (S21) is executed to laminate a plurality of FRP layers 60 so that a radially extending portion 80 and a circumferentially extending portion 90 are formed. More specifically, as shown in FIG. 9, a step (S31) of disposing the first divided FRP layer 111 and a step (S33) of disposing the second divided FRP layer 112 are executed in order. In S31, the first prepreg 101 and the second prepreg 102 are disposed on the mold 99 with gaps M1 and M2 therebetween (see FIG. 10). Also, in S33, the third prepreg 103 and the fourth prepreg 104 are disposed with gaps M3 and M4 therebetween on each of the first prepreg 101 and the second prepreg 102 (see FIG. 10). S31 and S33 may be executed either by an operator or a robot arm.

[0058] After S33, it is determined whether to finish the lamination, for example, by an operator (S35). If it is determined to continue the lamination (S35: NO), S31 and S33 are executed again. As a result, as shown in FIG. 10, the first divided FRP layer 111 and the second divided FRP layer 112 are alternately arranged. If it is determined to finish the lamination (S35: YES), the lamination step ends.

[0059] Returning to FIG. 8, then, a heating step of heating a plurality of FRP layers 60 including the first divided FRP layer 111 and the second divided FRP layer 112 is executed (S23). S23 is the same step as S13 (see FIG. 6). During heating, the resin material impregnated in the prepreg 100 leaks out. This resin material penetrates into the gaps M1, M2 between the first prepreg 101 and the second prepreg 102 in the same layer, and the gaps M3, M4 in the third prepreg 103 and the fourth prepreg 104 in the same layer and solidifies. As a result, the divided portion 45B is formed. Thus, the non-magnetic body 36B is completed.

[0060] <Summary> The content described in several of the above-described embodiments is understood as follows, for example.

[0061] 1) The pole piece rotor (30) according to at least one embodiment of the present invention includes a plurality of pole pieces (35) arranged at intervals in the circumferential direction, a plurality of non-magnetic bodies (36) alternately arranged with the plurality of pole pieces in the circumferential direction, and at least one of the plurality of non-magnetic bodies is an FRP laminate (70) in which a plurality of FRP layers are laminated, in an axial view, the FRP laminate includes a radially extending portion (80) in which the plurality of FRP layers are laminated along the circumferential direction between an FRP center (C) that is the center of the FRP laminate and the pole piece, and circumferentially extending portions (90) in which the plurality of FRP layers are laminated along the radial direction on each of the inner and outer sides in the radial direction from the FRP center. ​

[0062] The inventors have obtained the following findings regarding the thermal stress generated in a non-magnetic body. That is, the direction of the principal stress at the circumferential end of the non-magnetic body is along the radial direction, and the direction of the principal stress at the radial end of the non-magnetic body is along the circumferential direction. Based on this finding, according to the configuration of 1) above, the former principal stress is generated in the radially extending portion of the FRP laminate, and the direction of the principal stress is in the in-plane direction of the FRP layers included in the radially extending portion. Therefore, cracks in the radially extending portion can be suppressed. Similarly, the latter principal stress is generated in the circumferentially extending portion of the FRP laminate, and the direction of the principal stress is in the in-plane direction of the FRP layers included in the circumferentially extending portion. Therefore, cracks in the circumferentially extending portion can be suppressed. As described above, since the direction of the principal stress can be made to coincide with the in-plane direction of the plurality of FRP layers, a magnetic pole piece rotor is realized in which cracks are suppressed from occurring in the non-magnetic body due to temperature changes.

[0063] 2) In some embodiments, the magnetic pole piece rotor according to 1) above, the FRP laminate further includes a corner portion (75) connecting to each of the radially extending portion and the circumferentially extending portion, the plurality of FRP layers includes at least one layer of divided FRP layer (65) that is divided at the corner portion within the same layer.

[0064] According to the inventors' findings, relatively high thermal stress tends to occur at the corner portion as well. In this regard, according to the configuration of 2) above, since at least one layer of FRP layer is divided at the corner portion of the FRP laminate, thermal strain at the corner portion can be suppressed. Thereby, the occurrence of cracks at the corner portion due to temperature changes can be suppressed.

[0065] 3) In some embodiments, the magnetic pole piece rotor according to 2) above, the at least one layer of divided FRP layer has a first FRP layer (61) that is located closest to the FRP center side in the axial view among the plurality of FRP layers.

[0066] According to the inventor's findings, relatively high thermal stress tends to occur in the inner peripheral side portion of the corner of the FRP laminate. In this regard, according to the configuration of 3) above, since the first FRP layer is divided at the corner, the generation of cracks in the inner peripheral side portion of the corner can be suppressed.

[0067] 4) In some embodiments, the pole piece rotor described in 3) above, The at least one divided FRP layer further has at least one second FRP layer (62) continuously laminated from the first FRP layer toward the outer peripheral side among the plurality of FRP layers.

[0068] According to the configuration of 4) above, since each of the continuously laminated first FRP layer and second FRP layer is divided at the corner, the generation of cracks in the inner peripheral side portion of the corner can be more reliably suppressed.

[0069] 5) In some embodiments, the pole piece rotor described in 4) above, At the corner, a divided portion (45) defined by the first FRP layer and the at least one second FRP layer extends linearly along the thickness direction of the FRP layer.

[0070] According to the configuration of 5) above, since the division positions of the first FRP layer and the at least one second FRP layer are aligned, the processing for forming the divided portion is facilitated.

[0071] 6) In some embodiments, the pole piece rotor described in 5) above, The outer peripheral end (45a) of the divided portion is located closer to the FRP center side than the center (two-dot chain line N) of the corner in the thickness direction in the axial view.

[0072] According to the configuration of 6) above, the formation range of the divided portion at the corner can be suppressed, and the strength of the FRP laminate can be maintained.

[0073] 7) In some embodiments, it is the pole piece rotor described in any one of 2) to 4) above, The radially extending portion has a first radially extending portion (81) and a second radially extending portion (82) respectively located on one side and the other side in the circumferential direction with respect to the center of the FRP. The circumferentially extending portion has an outer circumferentially extending portion (91) and an inner circumferentially extending portion (92) respectively located on the outer side and the inner side in the radial direction with respect to the center of the FRP. The at least one layer of segmented FRP layer includes a first segmented FRP layer (111) having a first prepreg (101) having the one - side radially extending portion and the inner circumferentially extending portion, and a second prepreg (102) having the other - side radially extending portion and the outer circumferentially extending portion.

[0074] According to the configuration of 7) above, in each of the first corner portion and the second corner portion that are diagonal to each other in the axial view, a segmented portion of the FRP layer is formed. Thereby, the generation of cracks in each of the first corner portion and the second corner portion can be suppressed.

[0075] 8) In some embodiments, it is the pole piece rotor described in 7) above, The at least one layer of segmented FRP layer further includes a second segmented FRP layer (112) having a third prepreg (103) having the other - side radially extending portion and the inner circumferentially extending portion, and a fourth prepreg (104) having the one - side radially extending portion and the outer circumferentially extending portion.

[0076] According to the configuration of 8) above, in each of the third corner portion and the fourth corner portion that are diagonal to each other in the axial view, a segmented portion of the FRP layer is formed. Thereby, the generation of cracks in each of the third corner portion and the fourth corner portion can be suppressed.

[0077] 9) In some embodiments, it is the pole piece rotor described in 8) above, In the thickness direction of the FRP layer, the first segmented FRP layer and the second segmented FRP layer are laminated alternately.

[0078] According to the configuration of 9) above, the dividing portions are formed in a well-balanced manner at the first corner portion, the second corner portion, the third corner portion, and the fourth corner portion. Thereby, the occurrence of cracks can be suppressed in a well-balanced manner at any corner portion.

[0079] 10) The magnetic gear rotating machine (1) according to at least one embodiment of the present disclosure is the magnetic pole piece rotor (30) described in any one of 1) to 9) above, a magnet rotor (10) located inside in the radial direction with respect to the plurality of magnetic pole pieces and the plurality of non-magnetic bodies, and a stator (20) located outside in the radial direction with respect to the plurality of magnetic pole pieces and the plurality of non-magnetic bodies and includes.

[0080] According to the configuration of 10) above, the same technical advantages as those of 1) above can be obtained.

[0081] 11) A method for manufacturing a non-magnetic body (36) for a magnetic pole piece rotor (30) according to at least one embodiment of the present invention is the method for manufacturing a non-magnetic body for a magnetic pole piece rotor described in 1) above, and includes a lamination step (S11, S21) of laminating the plurality of FRP layers so that the radially extending portion and the circumferentially extending portion are formed.

[0082] According to the configuration of 11) above, the same technical advantages as those of 1) above can be obtained.

[0083] 12) In some embodiments, it is a method for manufacturing a non-magnetic body for a magnetic pole piece rotor described in 11) above, wherein in the lamination step, the plurality of FRP layers are laminated by winding at least one prepreg (100), the FRP laminate includes a corner portion (75) connecting to each of the radially extending portion and the circumferentially extending portion, After the laminating step, a cutting step (S15) is further provided, in which at least a first FRP layer (61) located closest to the FRP center in the axial direction among the plurality of FRP layers at the corner is cut along the axial direction of the pole piece rotor.

[0084] According to the configuration of the above 12), the same technical advantages as those of the above 3) can be obtained.

[0085] 13) In some embodiments, there is a method for manufacturing a non-magnetic body for a pole piece rotor described in the above 11), The radially extending portion has a first radially extending portion (81) and a second radially extending portion (82) respectively located on one side and the other side in the circumferential direction with respect to the FRP center, The circumferentially extending portion has an outer circumferentially extending portion (91) and an inner circumferentially extending portion (92) respectively located on the outer side and the inner side in the radial direction with respect to the FRP center, In the laminating step, a first divided FRP layer (111) having a first prepreg (101) for forming the first radially extending portion and the outer circumferentially extending portion and a second prepreg (102) for forming the second radially extending portion and the inner circumferentially extending portion is arranged (S31), Before or after arranging the first divided FRP layer, a second divided FRP layer (112) having a third prepreg (103) for forming the second radially extending portion and the outer circumferentially extending portion and a fourth prepreg (104) for forming the first radially extending portion and the inner circumferentially extending portion is arranged (S33).

[0086] According to the configuration of the above 13), the same technical advantages as those of the above 7) and the above 8) can be obtained.

[0087] 14) In some embodiments, there is a method for manufacturing a non-magnetic body for a pole piece rotor described in the above 13), In the laminating step, the arrangement of the first divided FRP layer and the arrangement of the second divided FRP layer are alternately executed.

[0088] According to the configuration of the above (14), the same technical advantages as those of the above (9) can be obtained.

Explanation of Signs

[0089] 1: Magnetic gear rotating machine 9: External device 10: Magnet rotor 15: Rotor core 16: Electrical system 18: Rotating shaft 19: Magnet 20: Stator 22: Stator core 27: Stator coil 29: Stator magnet 30: Pole piece rotor 31: First connecting part 32: Second connecting part 33: Ring unit 35: Pole piece 36: Non-magnetic body 45: Disconnecting part 45a: Outer peripheral end 56: Pole piece hole 57: Non-magnetic body hole 60: FRP layer 61: First FRP layer 62: Second FRP layer 65: Disconnecting FRP layer 70: FRP laminate 71: First corner 72: Second corner 73: Third corner 74: Fourth corner 75: Corner 76: Innermost peripheral surface 80: Radially extending part 81: One-side radially extending part 82: The other-side radially extending part 90: Circumferentially extending part 91: Outer circumferentially extending part 92: Inner circumferentially extending part 99: Mold 100: Prepreg 101: First prepreg 102: Second prepreg 103: Third prepreg 104: Fourth prepreg 111: First segmented FRP layer 112: Second segmented FRP layer 332: Outer cover 339: Inner cover B1: Bearing C: FRP center G1: Inner air gap G2: Outer air gap M1~M4: Gap N: Dashed double-dot line S: Axis Sp: Space

Claims

1. A plurality of magnetic pole pieces arranged at intervals in the circumferential direction, A plurality of non-magnetic bodies alternately arranged with the plurality of magnetic pole pieces in the circumferential direction, Comprising, At least one of the plurality of non-magnetic bodies is an FRP laminate in which a plurality of FRP layers are laminated, The FRP laminate, in an axial view, A radially extending portion in which the plurality of FRP layers are laminated along the circumferential direction between the FRP center, which is the center of the FRP laminate, and the magnetic pole piece, Circumferentially extending portions in which the plurality of FRP layers are laminated along the radial direction on each of the inner and outer sides in the radial direction from the FRP center, Including A magnetic pole piece rotor.

2. The FRP laminate further includes corner portions connecting to each of the radially extending portion and the circumferentially extending portion, The plurality of FRP layers include at least one layer of divided FRP layer divided at the corner portions within the same layer. The magnetic pole piece rotor according to Claim 1.

3. The at least one layer of divided FRP layer has a first FRP layer located closest to the FRP center side in the axial view among the plurality of FRP layers. The magnetic pole piece rotor according to Claim 2.

4. The at least one layer of divided FRP layer further has at least one layer of second FRP layer continuously laminated from the first FRP layer toward the outer peripheral side among the plurality of FRP layers. The magnetic pole piece rotor according to Claim 3.

5. At the corner portion, a divided portion defined by the first FRP layer and the at least one layer of second FRP layer extends linearly along the thickness direction of the FRP layer. The magnetic pole piece rotor according to Claim 4.

6. The outer peripheral end of the divided portion is located closer to the FRP center side than the center of the corner portion in the thickness direction in the axial view. The magnetic pole piece rotor according to Claim 5.

7. The radially extending portion has a one-side radially extending portion and an other-side radially extending portion respectively located on one side and the other side in the circumferential direction with respect to the FRP center, The circumferentially extending portion has an outer-side circumferentially extending portion and an inner-side circumferentially extending portion respectively located on the outer side and the inner side in the radial direction with respect to the FRP center, The at least one layer of divided FRP layer, Includes a first divided FRP layer having a first prepreg having the one-side radially extending portion and the inner-side circumferentially extending portion, and a second prepreg having the other-side radially extending portion and the outer-side circumferentially extending portion. The pole piece rotor according to any one of claims 2 to 4.

8. The at least one divided FRP layer includes a second divided FRP layer having a third prepreg having the other-side radially extending portion and the inner circumferentially extending portion, and a fourth prepreg having the one-side radially extending portion and the outer circumferentially extending portion. The pole piece rotor according to claim 7.

9. In the thickness direction of the FRP layer, the first divided FRP layer and the second divided FRP layer are alternately laminated. The pole piece rotor according to claim 8.

10. The pole piece rotor according to any one of claims 1 to 6, a magnet rotor located inside in the radial direction with respect to the plurality of pole pieces and the plurality of non-magnetic bodies, and a stator located outside in the radial direction with respect to the plurality of pole pieces and the plurality of non-magnetic bodies A magnetic gear rotating machine comprising.

11. A method for manufacturing a non-magnetic body for a pole piece rotor according to claim 1, comprising a lamination step of laminating the plurality of FRP layers so that the radially extending portion and the circumferentially extending portion are formed. A method for manufacturing a non-magnetic body for a pole piece rotor.

12. In the lamination step, the plurality of FRP layers are laminated by winding at least one prepreg, the FRP laminate includes corner portions connecting to each of the radially extending portion and the circumferentially extending portion, after the lamination step, a cutting step of cutting at least a first FRP layer located closest to the FRP center in the axial direction view among the plurality of FRP layers at the corner portion along the axial direction of the pole piece rotor is further provided. The method for manufacturing a non-magnetic body for a pole piece rotor according to claim 11.

13. The radially extending portion has a one-side radially extending portion and an other-side radially extending portion respectively located on one side and the other side in the circumferential direction with respect to the FRP center, the circumferentially extending portion has an outer circumferentially extending portion and an inner circumferentially extending portion respectively located on the outer side and the inner side in the radial direction with respect to the FRP center, In the lamination step, a first divided FRP layer having a first prepreg for forming the one-side radially extending portion and the outer circumferentially extending portion, and a second prepreg for forming the other-side radially extending portion and the inner circumferentially extending portion is arranged. Before or after disposing the first segmented FRP layer, a second segmented FRP layer having a third prepreg for forming the other-side radially extending portion and the outer circumferentially extending portion, and a fourth prepreg for forming the one-side radially extending portion and the inner circumferentially extending portion is disposed. The method for manufacturing a non-magnetic body for a pole-piece rotor according to claim 11.

14. In the laminating step, the disposition of the first segmented FRP layer and the disposition of the second segmented FRP layer are alternately executed. The method for manufacturing a non-magnetic body for a pole-piece rotor according to claim 13.

Images