Pole piece module, magnetic geared electrical machine, manufacturing method for pole piece module and manufacturing method for magnetic geared electrical machine

Abstract

To provide a light-weight pole piece module, a magnetic geared electrical machine, a manufacturing method for a pole piece module, and a manufacturing method for a magnetic geared electrical machine.SOLUTION: A pole piece module comprises a plurality of pole pieces arranged at a distance from one another, and non-magnetic parts arranged between the pole pieces. The pole pieces are fixed by the molded non-magnetic parts, and gaps are formed in the non-magnetic parts.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to pole piece modules, magnetic-geared electric machines, methods of manufacturing pole piece modules, and methods of manufacturing magnetic-geared electric machines. [Background technology]

[0002] In recent years, magnetic gears (magnetic gears) with flux modulation that achieve high torque density have been developed. Magnetic-geared rotating machines have also been developed that integrate a magnetic gear with a wound stator. In these magnetic-geared rotating machines, a high-speed rotor is rotated by an internally placed stator coil, and the magnetic flux of a magnet placed on the high-speed rotor is modulated by magnetic pole pieces to rotate a low-speed rotor. This allows the low-speed rotor to obtain torque that is increased by the speed ratio (reduction ratio) of the high-speed rotor. Therefore, magnetic-geared rotating machines can achieve high torque density.

[0003] The low-speed rotor is composed of a pole piece module with multiple pole pieces arranged at equal intervals in a circular ring shape. The inner and outer diameter sides of this pole piece module face the high-speed rotor and stator, respectively, via gaps. If the radial and circumferential positioning accuracy of the pole pieces is low, it is necessary to increase the gap. However, increasing the gap poses the problem of reduced torque transmission efficiency. On the other hand, there is a demand for lighter motor systems, and there is also a demand for magnetic gear devices that are lighter and capable of transmitting higher torque. In conventional pole piece devices and magnetic gear devices, a method is described in which the space between the pole pieces is resin-molded to eliminate play between the pole pieces and the frame, thereby precisely positioning the pole pieces (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 7229909 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the magnetic pole piece device and magnetic gear device disclosed in the above-mentioned Patent Document 1, resin is filled into the gaps between the magnetic pole pieces and on the radial surfaces, and there is a problem in that the weight increases due to the resin portion.

[0006] The present disclosure discloses techniques for solving the above-mentioned problems, and aims to provide a lightweight pole piece module, a magnetic-geared electric machine, a method for manufacturing a pole piece module, and a method for manufacturing a magnetic-geared electric machine. [Means for solving the problem]

[0007] The pole piece module of the present disclosure comprises a plurality of pole pieces arranged at a distance from each other, and non-magnetic material portions arranged between the pole pieces, the pole pieces being fixed by the molded non-magnetic material portions, and gap portions being formed in the non-magnetic material portions. The magnetic-geared electric machine of the present disclosure also includes the above-mentioned pole piece module, a plurality of first magnets arranged in a row facing the pole piece module on one side of the pole piece module, and a plurality of second magnets arranged in a row facing the pole piece module on the other side of the pole piece module, with the pole piece module being arranged with air gaps between each of the plurality of first magnets and the plurality of second magnets. In addition, the manufacturing method of the pole piece module disclosed herein is the manufacturing method of the pole piece module described above, wherein the corners of the pole pieces have a right-angled shape for positioning with a molding machine that molds the non-magnetic material portion, and the method includes a step of positioning the pole pieces by bringing the corners of the pole pieces into contact with the right-angled portions of a molding jig provided on the molding machine, and fixing the pole pieces with the molded non-magnetic material portion. In addition, the manufacturing method of a magnetic-geared electric machine disclosed herein includes the steps of arranging a plurality of first magnets facing the pole piece module on one side of the pole piece module, arranging a plurality of second magnets facing the pole piece module on the other side of the pole piece module, and arranging a plurality of the first magnets and a plurality of the second magnets, each with a gap between them, in the pole piece module formed by the above-mentioned manufacturing method of the pole piece module. [Effects of the Invention]

[0008] The pole piece modules, magnetic-geared electric machines, methods for manufacturing pole piece modules, and methods for manufacturing magnetic-geared electric machines disclosed herein provide lightweight pole piece modules, magnetic-geared electric machines, methods for manufacturing pole piece modules, and methods for manufacturing magnetic-geared electric machines. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a cross-sectional view showing a magnetic-geared rotating machine according to a first embodiment. [Figure 2] FIG. 2 is a cross-sectional view taken along line AA of FIG. 1, rotated 90 degrees. [Figure 3] FIG. 2 is an enlarged view of the stator according to the first embodiment. [Figure 4] FIG. 4 is a cross-sectional view taken along line BB in FIG. 3. [Figure 5] FIG. 4 is an enlarged view showing a modified example of the stator according to the first embodiment. [Figure 6] FIG. 6 is a cross-sectional view taken along the line CC of FIG. 5. [Figure 7] FIG. 4 is an enlarged view showing a modified example of the stator according to the first embodiment. [Figure 8] FIG. 4 is an enlarged view showing a modified example of the stator according to the first embodiment. [Figure 9] FIG. 10 is an enlarged view of a stator according to a second embodiment. [Figure 10] FIG. 10 is a cross-sectional view taken along line DD in FIG. 9. [Figure 11] FIG. 10 is an enlarged view showing a modified example of the stator according to the second embodiment. [Figure 12] FIG. 10 is an enlarged view showing a modified example of the stator according to the second embodiment. [Figure 13] 10A to 10C are diagrams illustrating a method for manufacturing a pole piece module according to a third embodiment. [Figure 14] FIG. 11 is an enlarged view of a pole piece module according to a third embodiment. [Figure 15] 10A to 10C are diagrams illustrating a method for manufacturing a pole piece module according to a third embodiment. [Figure 16] FIG. 11 is an enlarged view of a pole piece module according to a third embodiment. [Figure 17] 10A to 10C are diagrams illustrating a method for manufacturing a pole piece module according to a third embodiment. [Figure 18] FIG. 11 is an enlarged view of a pole piece module according to a third embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0010] A pole piece module, a magnetic-geared electric machine, a manufacturing method of a pole piece module, and a manufacturing method of a magnetic-geared electric machine according to embodiments of the present disclosure will be described in detail below with reference to the drawings. Note that the same reference numerals in the drawings indicate the same or equivalent parts. In the following description, the magnetic-geared rotating machine will be described as a magnetic reducer. However, the same applies if the magnetic-geared rotating machine is a magnetic speed increaser or a magnetic-geared rotating electric machine.

[0011] Embodiment 1 FIG. 1 is a cross-sectional view of a magnetic-geared rotating machine according to a first embodiment, taken along a plane perpendicular to the high-speed rotor shaft. The magnetic-geared rotating machine 10 of the first embodiment includes a high-speed rotor 1, a pole piece module 21, and a low-speed rotor 3. The high-speed rotor 1 includes a high-speed rotor shaft 11 serving as a rotation axis, a high-speed rotor core 12 fixed to the outer diameter side of the high-speed rotor shaft 11, and a plurality of high-speed rotor magnets 13 arranged at equal intervals on the outer circumferential surface of the high-speed rotor core 12. Hereinafter, the direction of the axis of rotation of the high-speed rotor shaft 11 will be referred to as the axial direction a, the direction from the center of rotation of the high-speed rotor shaft 11 toward the outer periphery as the radial direction b, and the direction of rotation around the high-speed rotor shaft 11 as the circumferential direction c. In the radial direction b, the direction away from the high-speed rotor shaft 11 will be referred to as the outer diameter side, and the opposite direction as the inner diameter side.

[0012] 1, the pole piece module 21 has a plurality of pole pieces 21a and a non-magnetic molded portion 21b for fixing the plurality of pole pieces 21a. The low-speed rotor 3 has a cylindrical low-speed rotor core 31 and a plurality of low-speed rotor magnets 32 arranged at equal intervals on the inner circumferential surface of the low-speed rotor core 31. In the magnetic-geared rotating machine 10 according to the first embodiment, the high-speed rotor 1, the pole piece module 21, and the low-speed rotor 3 are arranged in this order from the inner diameter side, with gaps between them. In the magnetic-geared rotating machine 10 according to the first embodiment, the high-speed rotor 1, the pole piece module 21, and the low-speed rotor 3 are arranged coaxially with the high-speed rotor shaft 11 as the central axis. In the magnetic-geared rotating machine 10 according to the first embodiment, the high-speed rotor core 12, the pole pieces 21a, and the low-speed rotor core 31 are formed by, for example, stacking electromagnetic steel sheets, which are magnetic materials, in the axial direction. The high-speed rotor magnets 13 and the low-speed rotor magnets 32 are permanent magnets.

[0013] FIG. 2 is a cross-sectional view of the cross section taken along line A-A in FIG. 1 , rotated 90 degrees. As shown in FIG. 2 , the stator 2 is formed of a pole piece module 21 and a stator frame 22. The pole piece module 21 is fixed at both ends in the axial direction a by a non-magnetic stator frame 22 made of resin, aluminum, or the like. This stator frame 22 is fixed to an external frame (not shown) of the low-speed rotor 3. The multiple pole pieces 21a of the pole piece module 21 transmit magnetic flux from the high-speed rotor 1 to the low-speed rotor 3, or from the low-speed rotor 3 to the high-speed rotor 1. As described above, the pole pieces 21a in the first embodiment are formed by stacking electromagnetic steel sheets in the axial direction a. As long as the pole pieces 21a are made of a magnetic material, the pole pieces 21a may be formed by stacking electromagnetic steel sheets in the radial direction b, or may be powder iron cores.

[0014] As shown in Figure 2, the high-speed rotor shaft 11 and the high-speed rotor core 12 are integrally formed. The high-speed rotor shaft 11 extends outward from one end in the axial direction a. The high-speed rotor 1 is disposed on the inner diameter side of the stator frame 22 via a bearing 41. The low-speed rotor shaft 33 is formed integrally with the low-speed rotor core 31 at the other end in the axial direction a of the low-speed rotor core 31. The center of rotation of the high-speed rotor shaft 11 and the center of rotation of the low-speed rotor shaft 33 are the same. The low-speed rotor 3 is disposed on the outer diameter side of the stator frame 22 via a bearing 41.

[0015] Let Nh be the number of pole pairs of the high-speed rotor magnet 13 of the high-speed rotor 1, Np be the number of magnetic poles of the pole pieces of the pole piece module 21, and Nl be the number of pole pairs of the low-speed rotor magnet 32 ​​of the low-speed rotor 3. In the magnetic-geared rotating machine 10 of the first embodiment, the relationship Np = Nl + Nh holds. In this case, if the reduction ratio is Gr, then Gr = Nl / Nh. The rotational speed of the high-speed rotor 1 is multiplied by 1 / Gr and transmitted to the low-speed rotor 3, and the torque of the high-speed rotor 1 is multiplied by Gr and transmitted to the low-speed rotor 3. In the magnetic-geared rotating machine 10 of the first embodiment, for example, if Nh = 4, Np = 30, and Nl = 26, then Gr = 6.5. The equation for the reduction ratio also holds even if the relationship Np = Nl - Nh holds.

[0016] In the magnetic-geared rotating machine 10 of embodiment 1, the stator 2 is fixed and the high-speed rotor 1 and the low-speed rotor 3 are rotated, but the high-speed rotor 1 may be fixed and the stator 2 and the low-speed rotor 3 may be rotated, or the low-speed rotor 3 may be fixed and the high-speed rotor 1 and the stator 2 may be rotated. As shown in FIG. 1, the magnetic-geared rotating machine 10 according to the first embodiment is, for example, a cylindrical rotating type, but it can also be manufactured as a disk rotating type, a flat linear type, or a cylindrical linear type.

[0017] Next, the pole piece module 21 of the magnetic-geared rotating machine 10 according to the first embodiment will be described in detail. Fig. 3 is an enlarged view of the stator according to embodiment 1, and is a view from a radial perspective of a portion of the stator 2. For ease of explanation, Fig. 3 is a view in which the circumferential direction c (left-right direction on the paper) of the view as seen from the radial direction b is developed into a planar form. 3, pole piece module 21 according to embodiment 1 has pole pieces 21a, non-magnetic molded portions 21b, and mold gaps 21c alternately arranged in an annular shape in the center in the axial direction a. Stator frames 22 are disposed at both ends of pole piece module 21 in the axial direction a. Non-magnetic molded portions 21b may be present between pole pieces 21a and stator frame 22 in the axial direction a, or pole pieces 21a and stator frame 22 may be in contact with each other.

[0018] The non-magnetic molded portion 21b and the stator frame 22 may be fixed to each other by integral molding, or by using an adhesive. The non-magnetic molded portion 21b and the stator frame 22 may be fixed to each other by bolts, or by press-fitting the non-magnetic molded portion 21b into the stator frame 22. The stator 2 according to the first embodiment has a mold gap 21c in the non-magnetic molded portion 21b of the pole piece module 21. Providing the mold gap 21c in the pole piece module 21 enables the weight of the pole piece module 21 to be reduced. For reinforcement, the mold gap 21c may be filled with a non-magnetic material having a lower specific gravity than the material of the non-magnetic molded portion 21b. The non-magnetic molded portion 21b is made of a non-magnetic material such as resin, ceramic, or aluminum.

[0019] FIG. 4 is a cross-sectional view taken along line BB in FIG. 3, and is a cross-sectional view of pole piece module 21 taken along a plane perpendicular to the axial direction. The pole piece 21a shown in FIG. 4 is a simplified version of the pole piece 21a shown in FIG. 1. As shown in FIG. 4, the width of the pole piece 21a in the circumferential direction c decreases toward the outer diameter, and the width of the nonmagnetic molded portion 21b in the circumferential direction c that contacts the pole piece 21a increases toward the outer diameter. As shown in FIG. 4, the width of the mold gap portion 21c in the circumferential direction c may or may not change in the radial direction b. As shown in FIGS. 3 and 4, the inner diameter side surface and the outer diameter side surface of the pole piece 21a may or may not contact the nonmagnetic molded portion 21b.

[0020] Fig. 5 is an enlarged view showing a modified example of the stator according to embodiment 1, and is a view from a radial perspective of a part of the stator 2. Fig. 6 is a cross-sectional view taken along line CC in Fig. 5, showing a cross-sectional view of the pole piece module 21 in a plane perpendicular to the axial direction. As shown in FIGS. 5 and 6, pole pieces 21a, non-magnetic molded portions 21b, and mold gaps 21c are arranged in a circular ring shape in the center of the pole piece module 21 in the axial direction a according to the first embodiment. Furthermore, stator frames 22 are arranged at both ends of the pole pieces 21a in the axial direction a. As shown in FIGS. 5 and 6, one mold gap 21c is provided for each of two or more pole pieces 21a. The method of fixing the pole piece module 21 to the stator frame 22 is the same as that of the stator 2 in FIG. 3. Furthermore, as with the pole piece module 21 in FIG. 3, the mold gaps 21c may be filled with a non-magnetic material having a lower specific gravity than the material of the non-magnetic molded portions 21b for reinforcement. The strength and weight of the pole piece module 21 can be adjusted by adjusting the number of mold gaps 21c relative to the pole pieces 21a.

[0021] FIG. 7 is an enlarged view showing a modified example of the stator according to the first embodiment, showing a portion of the stator 2 as viewed from a radial direction. As shown in FIG. 7, the pole piece module 21 includes a pole piece 21a and a nonmagnetic molded portion 21b, with each pole piece 21a molded with a nonmagnetic material. Because the size of each pole piece module 21 can be reduced, a molding machine for molding the nonmagnetic material can be made more compact than the pole piece modules 21 shown in FIGS. 3 to 6. Stator frames 22 are disposed at both ends of the pole piece module 21 in the axial direction a. A nonmagnetic molded portion 21b may be present between the pole piece 21a and the stator frame 22, or the pole piece 21a and the stator frame 22 may be in contact with each other. The method of fixing the nonmagnetic molded portion 21b to the stator frame 22 is the same as that of the stator 2 shown in FIG. 3. The pole piece modules 21 are arranged in a circular ring shape with gaps 21f between adjacent pole piece modules 21. As with the pole piece module 21 in Fig. 3, the gaps 21f may be filled with a non-magnetic material having a lower specific gravity than the material of the non-magnetic molded portion 21b. Furthermore, mold gaps 21c may or may not be provided inside the non-magnetic molded portion 21b for the purpose of reducing weight.

[0022] FIG. 8 is an enlarged view showing a modified example of the stator according to the first embodiment, showing a portion of the stator 2 as viewed from a radial direction. As shown in FIG. 8, the pole piece module 21 is formed of a pole piece 21a, a non-magnetic molded portion 21b, and a mold gap 21c. The pole piece module 21 may or may not have the mold gap 21c. The pole piece module 21 of FIG. 7 has one pole piece 21a molded from a non-magnetic material, whereas the pole piece module 21 of FIG. 8 has two or more pole pieces 21a molded from a non-magnetic material. The pole piece module 21 of FIG. 8 allows for the downsizing of the molding machine used to mold the non-magnetic material and the adjustment of the number of parts of the stator 2 by adjusting the number of pole pieces 21a to be molded.

[0023] Stator frames 22 are disposed at both ends of the pole pieces 21a in the axial direction a. A non-magnetic molded portion 21b may be present between the pole pieces 21a and the stator frame 22, or the pole pieces 21a and the stator frame 22 may be in contact with each other. The method of fixing the non-magnetic molded portion 21b to the stator frame 22 is the same as that of the stator 2 in FIG. 3. The pole piece modules 21 are disposed in a circular ring shape, and gaps 21f exist between adjacent pole piece modules 21. The gaps 21f and the mold gaps 21c may be filled with a non-magnetic material having a smaller specific gravity than the material of the non-magnetic molded portion 21b, as in the pole piece module 21 in FIG. 3.

[0024] As described above, the pole piece module 21 according to embodiment 1 comprises a plurality of pole pieces 21a arranged at a distance from each other, and non-magnetic molded portions 21b, which are non-magnetic material portions arranged between the pole pieces 21a, and the pole pieces 21a are fixed by molded non-magnetic material portions, and mold gap portions 21c, which are gap portions, are formed in the non-magnetic material portions. As a result, the pole piece module 21 according to the first embodiment can improve the positioning accuracy of the pole pieces 21a and can be made lighter. In addition, in the pole piece module 21 according to embodiment 1, the non-magnetic molded portion 21b, which is a non-magnetic material portion, is fixed to the stator frame 22, which is a non-magnetic frame, at both ends in a direction perpendicular to the direction in which the multiple pole pieces 21a and non-magnetic material portions are arranged.

[0025] In addition, in embodiment 1, a magnetic-geared rotating machine 10 having a pole piece module 21 is used as an example, but the pole piece module 21 can be applied to magnetic-geared electric machines including direct-acting motors used in linear motors, for example.

[0026] The magnetic-geared rotating machine 10, which is a magnetic-geared electric machine according to embodiment 1, comprises the above-mentioned pole piece module 21, a plurality of first magnets, for example, high-speed rotor magnets 13, arranged in a row facing the pole piece module 21 on one side of the pole piece module 21, and a plurality of second magnets, for example, low-speed rotor magnets 32, arranged in a row facing the pole piece module 21 on the other side of the pole piece module 21, with the pole piece module 21 being arranged with gaps between each of the plurality of first magnets and the plurality of second magnets. Furthermore, the magnetic-geared rotating machine 10, which is a magnetic-geared electric machine according to embodiment 1, has a pole piece module 21 that is annular in shape, with pole pieces 21a and non-magnetic molded portions 21b, which are non-magnetic material portions, arranged in a ring shape, and multiple first magnets that are arranged inside the pole piece module 21, and is equipped with a first rotor, for example, a high-speed rotor 1, that has multiple first magnets and a first core, for example, a high-speed rotor core 12, that supports the multiple first magnets.

[0027] Furthermore, the magnetic-geared rotating machine 10, which is a magnetic-geared electric machine according to embodiment 1, has a plurality of second magnets arranged outside the pole piece module 21, and is equipped with a second rotor, for example, a low-speed rotor 3, having a plurality of second magnets and a second core, for example, a low-speed rotor core 31, which supports the plurality of second magnets. This allows the magnetic-geared rotating machine 10, which is the magnetic-geared electric machine according to the first embodiment, to be lightweight.

[0028] Embodiment 2 Fig. 9 is an enlarged view of a stator according to embodiment 2, and is a cross-sectional view of the radial center of stator 2. Fig. 10 is a cross-sectional view taken along line DD in Fig. 9, and is a cross-sectional view of pole piece module 21 taken along a plane perpendicular to the axial direction. In embodiment 2, an increase in the strength of pole piece module 21 will be described. 9 and 10, the stator 2 according to the second embodiment is formed of a pole piece module 21 and a stator frame 22. The pole piece module 21 is formed of a pole piece 21a, a non-magnetic molded portion 21b, and a reinforcing member 21d. In the second embodiment, the reinforcing member 21d, which is made of a non-magnetic metal such as SUS (Steel Use Stainless) or carbon, can improve the strength of the pole piece module 21. A stator frame 22 is disposed at both axial ends of the pole piece module 21. A non-magnetic molded portion 21b may be present between the pole piece 21a and the stator frame 22 in the axial direction, or the pole piece 21a and the stator frame 22 may be in contact with each other. As shown in FIG. 10, the inner and outer surfaces of the pole piece 21a may or may not be in contact with the non-magnetic molded portion 21b.

[0029] As shown in FIG. 9, the reinforcing members 21d are arranged on both circumferential sides of the pole piece 21a and penetrate the nonmagnetic molded portion 21b in the axial direction a. The number of reinforcing members 21d may be two or more. The reinforcing members 21d may be divided in the axial direction a, or may not be divided. The pole piece modules 21 in FIG. 9 are arranged at intervals, similar to the pole piece modules 21 in FIG. 7. Reinforcing members 21d are provided between the multiple pole pieces 21a and fixed in a state where they penetrate the nonmagnetic molded portion 21b, which is a nonmagnetic portion, and the stator frame 22, which is a frame. The reinforcing members 21d may be press-fitted into the stator frame 22 or fixed with bolts.

[0030] FIG. 11 is an enlarged view showing a modified example of the stator according to the second embodiment, and is a cross-sectional view of the radial center of the stator 2. As shown in FIG. 11, the stator 2 according to the second embodiment is formed of a pole piece module 21, a stator frame 22, a screw 23 having a fixing bolt 23a and a nut 23b, a washer 24, and an insulating washer 25. The pole piece module 21 is formed of a pole piece 21a, a non-magnetic molded portion 21b, and a reinforcing member 21d. The stator frame 22 is disposed at both ends of the pole piece module 21 in the axial direction a. The reinforcing member 21d is fixed to the stator frame 22 by a fixing bolt 23a via a nut 23b, for example. Note that the hatched portion of the fixing bolt 23a indicates the helical portion of the thread, and the reinforcing member 21d and the stator frame 22, which is a frame, are fastened together by the screw 23. A non-magnetic molded portion 21b may be present between the pole piece 21a and the stator frame 22 in the axial direction a, or the pole piece 21a may be in contact with the stator frame 22. As in Figures 9 and 10, the inner diameter side surface and the outer diameter side surface of the pole piece 21a may or may not be in contact with the non-magnetic molded portion 21b.

[0031] When the reinforcing member 21d and the stator frame 22 are made of a conductor such as metal, a portion of the reinforcing member 21d is covered with a non-magnetic molded portion 21b made of an insulating material to prevent a current loop caused by induced electromotive force from being formed between the reinforcing member 21d and the stator frame 22. To prevent the current loop, a non-magnetic molded portion 21b is provided between the reinforcing member 21d and the stator frame 22 at the location where the reinforcing member 21d is inserted into the stator frame 22. The non-magnetic molded portion 21b may be provided at both ends in the axial direction a or on only one side in the axial direction a. In FIG. 11, a portion where the non-magnetic molded portion 21b is provided is formed between the reinforcing member 21d and the stator frame 22 at the lower part in the axial direction a.

[0032] When the pole piece module 21 is fixed to the stator frame 22 with the metal fixing bolt 23a, in order to prevent the above-mentioned current loop, an insulating washer 25 made of an insulating material such as resin is provided between the stator frame 22 and the fixing bolt 23a of the screw 23 on the side where the non-magnetic molded portion 21b exists between the reinforcing member 21d and the stator frame 22. The washer 24 used on the side where the non-magnetic molded portion 21b does not exist between the reinforcing member 21d and the stator frame 22 may be made of an insulator such as resin, or may be made of a conductor such as metal. From the above, in the modified example of the stator 2 according to the embodiment 2, the stator frame 22, which is the frame, and the reinforcing member 21d are conductors, the non-magnetic molded portion 21b, which is the non-magnetic portion, is made of an insulating material, and the portion of the reinforcing member 21d that comes into contact with the frame is covered by the non-magnetic molded portion 21b, which is a non-magnetic insulating material.

[0033] FIG. 12 is an enlarged view showing a modified example of the stator according to the second embodiment, and is a cross-sectional view of the radial center of the stator 2. As shown in FIG. 12, the stator 2 is formed of a pole piece module 21 and a stator frame 22. The pole piece module 21 is formed of a pole piece 21a, a non-magnetic molded portion 21b, and a strength member 21e. As in FIGS. 9 and 10, the inner and outer surfaces of the pole piece 21a may or may not be in contact with the non-magnetic molded portion 21b. The strength member 21e, made of a high-strength material such as metal, is in contact with both axial ends of the pole piece 21a and is molded with the non-magnetic molded portion 21b. The non-magnetic molded portion 21b does not contact the surfaces of both axial ends of the strength member 21e. As described above, in the modified example of the stator 2 according to the second embodiment, a strength member 21e is provided between the pole piece 21a and the stator frame 22, which is a frame, and is arranged in contact with the pole piece 21a and the frame, respectively, and the strength member 21e is molded so that a gap 26 is formed between the pole piece 21a and the frame.

[0034] Therefore, when the pole piece module 21 and the stator frame 22 are fixed together, the compressive load is applied to the pole pieces 21a and the strength member 21e, not to the nonmagnetic molded portion 21b. As a result, the load applied to the nonmagnetic molded portion 21b is alleviated, and creep that occurs in the nonmagnetic molded portion 21b can be suppressed. If the strength member 21e is an elastic body such as a metal spring or rubber, the strength member 21e can absorb variations in the stack thickness of the pole pieces 21a for each pole piece module 21. As a result, rattle of the pole piece module 21 relative to the stator frame 22 can be reduced. As described above, the pole piece module 21 in the second embodiment can improve its strength even if its strength is reduced by, for example, the formation of the mold gap 21c or the void 21f.

[0035] Embodiment 3 Fig. 13 is a diagram illustrating a method for manufacturing a pole piece module according to embodiment 3, and more specifically, a cross-sectional view of a pole piece module 21 and a portion of a forming jig 5 for molding the pole piece module 21, taken out in a plane perpendicular to the axial direction. Fig. 14 is an enlarged view of the pole piece module according to embodiment 3, and is a cross-sectional view of a pole piece module 21 molded using the forming jig 5 shown in Fig. 13, taken in a plane perpendicular to the axial direction. The method for manufacturing the pole piece module 21 according to embodiment 3 will now be described. The forming jig 5 is a mechanism for positioning and fixing the pole piece 21a in the molding machine. As can be seen from Fig. 13, the pole piece 21a has four right-angled corners, and the forming jig 5 has a right-angle positioning mechanism that aligns with the four corners of the pole piece 21a.

[0036] Meanwhile, in a conventional rotating electric machine, for example, disclosed in International Publication No. 2021-210118, a spacer having a hollow portion is disposed between the pole pieces, and a method for reducing weight is described. However, the conventional technology disclosed above has a problem of reduced positioning accuracy of the pole pieces due to backlash caused by tolerances between the pole pieces and the spacer.

[0037] In the manufacturing method of the pole piece module according to the third embodiment, as shown in FIG. 13, the corners of the pole piece 21a, which have four right-angled corners, are abutted against the right-angled inner surfaces of the molding jig 5, thereby positioning and fixing the pole piece 21a in the circumferential and radial directions within the molding machine. The corners of the pole piece 21a and the molding jig 5 improve the positioning accuracy of the pole piece 21a within the pole piece module 21. Furthermore, because the surfaces of the corners of the pole piece 21a contact the surfaces of the inner corners of the molding jig 5, leakage of the molding material to the inner and outer diameter sides of the pole piece 21a during molding of the pole piece module 21 is prevented. Therefore, as shown in FIG. 14, a structure is possible in which the inner and outer diameter sides of the pole piece 21a do not come into contact with the non-magnetic molded portion 21b.

[0038] FIG. 15 is a diagram illustrating a method for manufacturing a pole piece module according to the third embodiment, specifically a cross-sectional view of a pole piece module 21 and a portion of a molding jig 5 used to mold the pole piece module 21, taken along a plane perpendicular to the axial direction. FIG. 16 is an enlarged view of the pole piece module according to the third embodiment, taken along a plane perpendicular to the axial direction of the pole piece module 21 molded using the molding jig 5 shown in FIG. 15. As shown in FIG. 15, the molding jig 5 is a mechanism for positioning and fixing the pole piece 21a within the molding machine. As shown in FIG. 15, the pole piece 21a has a right-angled corner on the outer diameter side, and the molding jig 5 has a right-angled positioning mechanism on the outer diameter side to match the corner on the outer diameter side of the pole piece 21a.

[0039] As shown in Figure 15, the pole piece 21a is positioned circumferentially and radially within the molding machine by abutting the right-angled portion on the outer diameter side of the molding jig 5. The inner diameter side of the molding jig 5 is in contact with the inner diameter side surface of the pole piece 21a, thereby fixing the pole piece 21a within the molding machine. As in Figure 13, leakage of the molded material can be prevented during molding of the pole piece module 21, and as shown in Figure 16, a structure can be achieved in which the inner diameter side surface and outer diameter side surface of the pole piece 21a do not come into contact with the non-magnetic molded portion 21b.

[0040] FIG. 17 is a diagram illustrating a method for manufacturing a pole piece module according to the third embodiment, specifically a cross-sectional view of a pole piece module 21 and a portion of a molding jig 5 used to mold the pole piece module 21, taken along a plane perpendicular to the axial direction. FIG. 18 is an enlarged view of the pole piece module according to the third embodiment, taken along a plane perpendicular to the axial direction of the pole piece module 21 molded using the molding jig 5 shown in FIG. 17. As shown in FIG. 17, the molding jig 5 is a mechanism for positioning and fixing the pole piece 21a within the molding machine. As shown in FIG. 17, the pole piece 21a has a right-angled corner on its inner diameter side, and the molding jig 5 has a right-angled positioning mechanism on its inner diameter side to match the corner on its inner diameter side of the pole piece 21a. 15, the pole piece 21a is positioned in the circumferential and radial directions by the right-angled portion on the inner diameter side of the pole piece 21a and the right-angled portion on the inner diameter side of the forming jig 5, and the outer diameter side of the forming jig 5 is in contact with the outer diameter side surface of the pole piece 21a, so the pole piece 21a is fixed in place within the molding machine. As in FIG. 13, leakage of the molded material can be prevented when molding the pole piece module 21, and a structure can be achieved in which the inner diameter side surface and outer diameter side surface of the pole piece 21a do not come into contact with the non-magnetic molded portion 21b, as shown in FIG.

[0041] As described above, the manufacturing method of the pole piece module in embodiment 3 is a manufacturing method of the above-mentioned pole piece module 21, in which the corners of the pole piece 21a have a right-angled shape for positioning with a molding machine that molds the non-magnetic molded portion 21b, which is a non-magnetic part, and includes a process of positioning the pole piece 21a by bringing the corners of the pole piece 21a into contact with the right-angled portion of a molding jig 5 provided on the molding machine, and fixing the pole piece 21a with the molded non-magnetic molded portion 21b. In the conventional rotating electric machines described above, it was difficult to achieve both weight reduction and improved positioning accuracy of the pole pieces, but the manufacturing method of the pole piece module 21 in embodiment 3 makes it possible to achieve both weight reduction and improved positioning accuracy of the pole pieces 21a. In addition, a manufacturing method for the magnetic-geared rotating machine 10, which is a magnetic-geared electric machine, includes the steps of arranging a plurality of first magnets, for example, high-speed rotor magnets 13, facing the pole piece module 21 on one side of the pole piece module 21, arranging a plurality of second magnets, for example, low-speed rotor magnets 32, facing the pole piece module 21 on the other side of the pole piece module, and arranging a plurality of first magnets and a plurality of second magnets, each with an air gap between them, in the pole piece module 21 formed by the above-mentioned manufacturing method for the pole piece module.

[0042] Although the preferred embodiments have been described in detail above, the present invention is not limited to the above-described embodiments, and various modifications and substitutions can be made to the above-described embodiments without departing from the scope of the claims.

[0043] Various aspects of the present disclosure are summarized below as appendices.

[0044] (Appendix 1) a plurality of magnetic pole pieces arranged in a spaced relation to one another; a non-magnetic portion arranged between the magnetic pole pieces; The pole piece is fixed by the molded non-magnetic portion, and a gap is formed in the non-magnetic portion. (Appendix 2) A pole piece module as described in Appendix 1, wherein the non-magnetic material portion is fixed to a non-magnetic frame at both ends in a direction perpendicular to the direction in which the plurality of pole pieces and the non-magnetic material portion are arranged. (Appendix 3) A pole piece module as described in Appendix 2, wherein a reinforcing member is provided between the plurality of pole pieces and fixed in a state that penetrates the non-magnetic portion and the frame. (Appendix 4) When the frame and the reinforcing member are conductors, the non-magnetic portion is made of an insulating material, 4. The pole piece module according to claim 3, wherein the portion of the reinforcing member that comes into contact with the frame is covered with the non-magnetic insulating member. (Appendix 5) The reinforcing member and the frame are fastened together with screws, 5. The pole piece module of claim 4, wherein an insulating washer is provided between the frame and the screw. (Appendix 6) Strength members are provided between the pole pieces and the frame, the strength members being in contact with the pole pieces and the frame, respectively; 6. The pole piece module of claim 2, wherein the strength member is molded to form a gap between the pole piece and the frame. (Appendix 7) 7. The pole piece module of claim 6, wherein the strength member is an elastic body. (Appendix 8) 8. The pole piece module according to claim 1, wherein the gap is filled with a non-magnetic material having a specific gravity smaller than that of the material of the non-magnetic material portion. (Appendix 9) 9. The pole piece module of any one of claims 1 to 8. a plurality of first magnets arranged side by side on one side of the pole piece module facing the pole piece module; a plurality of second magnets arranged side by side facing the pole piece module on the other side of the pole piece module, The magnetic-geared electric machine includes a plurality of pole piece modules disposed between the first magnets and the second magnets, each with an air gap therebetween. (Appendix 10) the pole piece module has an annular shape in which the pole pieces and the non-magnetic material portions are arranged in an annular shape, a plurality of the first magnets are disposed inside the pole piece module; 10. The magnetic-geared electric machine of claim 9, comprising: a first rotor having a plurality of the first magnets and a first core supporting the plurality of first magnets. (Appendix 11) a plurality of the second magnets are disposed outside the pole piece module; 11. The magnetic-geared electric machine of claim 10, further comprising: a second rotor having a plurality of the second magnets and a second core supporting the plurality of second magnets. (Appendix 12) 9. A method of manufacturing a pole piece module according to any one of claims 1 to 8, comprising: the corners of the magnetic pole pieces have right-angled shapes for positioning with a molding machine that molds the non-magnetic material portion, A method for manufacturing a pole piece module, comprising the steps of positioning the pole piece by placing the corner of the pole piece against a right-angled portion of a molding jig provided in the molding machine, and fixing the pole piece with the molded non-magnetic portion. (Appendix 13) arranging a plurality of first magnets facing the pole piece module on one side of the pole piece module; arranging a plurality of second magnets facing the pole piece module on the other side of the pole piece module; and arranging a plurality of the first magnets and a plurality of the second magnets, each with an air gap, in the pole piece module formed by the pole piece module manufacturing method described in Appendix 12.

[0045] Although the present disclosure describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to application to a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless variations not exemplified are conceivable within the scope of the technology disclosed in this specification, including, for example, cases where at least one component is modified, added, or omitted, and cases where at least one component is extracted and combined with components of another embodiment. [Explanation of symbols]

[0046] 1 high-speed rotor, 11 high-speed rotor shaft, 12 high-speed rotor core, 13 high-speed rotor magnet, 2 stator, 21 pole piece module, 21a pole piece, 21b non-magnetic molded portion, 21c mold gap portion, 21d reinforcing member, 21e strength member, 21f air gap portion, 22 stator frame, 23a fixing bolt, 23b nut, 23 screw, 24 washer, 25 insulating washer, 26 gap, 3 low-speed rotor, 31 low-speed rotor core, 32 low-speed rotor magnet, 33 low-speed rotor shaft, 41 bearing, 5 molding jig, 10 magnetic-geared rotating machine

Claims

1. a plurality of magnetic pole pieces arranged in a spaced relation to one another; a non-magnetic portion arranged between the magnetic pole pieces; The pole piece is fixed by the molded non-magnetic portion, and a gap is formed in the non-magnetic portion.

2. The pole piece module according to claim 1 , wherein the non-magnetic material portion is fixed to a non-magnetic frame at both ends in a direction perpendicular to the direction in which the plurality of pole pieces and the non-magnetic material portion are arranged.

3. 3. The pole piece module according to claim 2, wherein a reinforcing member is provided between the plurality of pole pieces and is fixed in a state of penetrating the non-magnetic portion and the frame.

4. When the frame and the reinforcing member are conductors, the non-magnetic portion is made of an insulating material, 4. The pole piece module according to claim 3, wherein the reinforcing member has a portion that contacts the frame covered with the non-magnetic insulating member.

5. The reinforcing member and the frame are fastened together with screws, 5. The pole piece module of claim 4, wherein an insulating washer is provided between the frame and the screw.

6. Strength members are provided between the pole pieces and the frame, the strength members being in contact with the pole pieces and the frame, respectively; 6. The pole piece module of claim 2, wherein the strength members are molded to form a gap between the pole piece and the frame.

7. 7. The pole piece module of claim 6, wherein said strength members are elastic.

8. 6. The pole piece module according to claim 1, wherein the gap is filled with a non-magnetic material having a specific gravity smaller than that of the material of the non-magnetic portion.

9. A pole piece module according to any one of claims 1 to 5, a plurality of first magnets arranged side by side on one side of the pole piece module facing the pole piece module; a plurality of second magnets arranged side by side facing the pole piece module on the other side of the pole piece module; The magnetic-geared electric machine, wherein the pole piece modules are disposed between a plurality of the first magnets and a plurality of the second magnets, with air gaps therebetween.

10. the pole piece module has an annular shape in which the pole pieces and the non-magnetic material portions are arranged in an annular shape, a plurality of the first magnets are disposed inside the pole piece module; The magnetic-geared electric machine of claim 9 , comprising a first rotor having a plurality of the first magnets and a first core supporting the plurality of first magnets.

11. a plurality of the second magnets are disposed outside the pole piece module; The magnetic-geared electric machine of claim 10 , further comprising a second rotor having a plurality of the second magnets and a second core supporting the plurality of second magnets.

12. A method for manufacturing a pole piece module according to any one of claims 1 to 5, comprising the steps of: the corners of the magnetic pole pieces have right-angled shapes for positioning with a molding machine that molds the non-magnetic material portion, A method for manufacturing a pole piece module, comprising the steps of positioning the pole piece by placing the corner of the pole piece against a right-angled portion of a molding jig provided in the molding machine, and fixing the pole piece with the molded non-magnetic portion.

13. arranging a plurality of first magnets facing the pole piece module on one side of the pole piece module; arranging a plurality of second magnets facing the pole piece module on the other side of the pole piece module; and arranging a plurality of the first magnets and a plurality of the second magnets, each with an air gap therebetween, in the pole piece module formed by the pole piece module manufacturing method according to claim 12.

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