ROTOR, ROTATING ELECTRIC MACHINE, AND METHOD FOR MANUFACTURING ROTOR AND ROTATING ELECTRIC MACHINE

Abstract

To provide a rotor that reduces gaps existing between an inside iron core, an outside iron core, and a magnet, and makes effective use of a magnetic flux of the magnet.SOLUTION: A rotor comprises: an inner diameter side iron core 42; a magnet 43 arranged on an outer diameter side of the inner diameter side iron core 42; an outer diameter side iron core 44 arranged on ann outer diameter side of the magnet 43; and a magnetic body 45 arranged between the inner diameter side iron core 42 and the magnet 43, or between the magnet 43 and the outer diameter side iron core 44, or between both of them. A structure 46 configured with the magnet 43, the magnetic body 45, and the outer diameter side iron core 44 is multiply arranged in a circumferential direction of a main shaft 41. A first resin part 52 is formed between end faces of the structures 46 in the circumferential direction.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present application relates to a rotor, a rotating electric machine, and a method for manufacturing the rotor and the rotating electric machine. [Background technology]

[0002] Conventionally, there is known a rotating electric machine with an interior permanent magnet (IPM) structure, which is composed of a stator made of an armature wound around a ring-shaped iron core, and a rotor with magnets arranged at a predetermined interval in the circumferential direction inside the iron core. Rotating electric machines with an IPM structure are excellent in that they can use rare earth magnets with high residual magnetic flux density and coercive force with good yield. However, in order to connect the iron cores arranged on the inner and outer diameters of the magnets, it is necessary to provide a bridge between adjacent magnets in the circumferential direction. This causes a problem in that part of the magnetic flux of the magnet leaks to the adjacent magnets, making it impossible to effectively utilize the magnetic flux.

[0003] In response to this problem, a bridgeless IPM rotor has been proposed that eliminates the bridge and separates the core radially inside and outside the magnet, fills the gaps between the magnets with resin, and fixes the resin part in a recess provided in the inner core, thereby reducing magnetic flux leakage (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2018 / 180692 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the rotor in Patent Document 1 has a problem in that dimensional variations between the inner diameter side iron core, the outer diameter side iron core, and the magnets cause gaps to form between the inner diameter side iron core and the magnets, reducing the magnetic flux.

[0006] The present application discloses technology for solving the problems described above, and aims to provide a rotor and a rotating electric machine that can effectively utilize the magnetic flux of the magnets by reducing the gaps that exist between the inner diameter side core and the outer diameter side core and the magnets, which are caused by the machining accuracy of the inner diameter side core, the outer diameter side core, and the magnets, and a method for manufacturing the rotor and the rotating electric machine. [Means for solving the problem]

[0007] The rotor disclosed in the present application includes a main shaft that serves as a rotating shaft, an inner diameter side iron core arranged on the outer diameter side of the main shaft, magnets arranged on the outer diameter side of the inner diameter side iron core, an outer diameter side iron core arranged on the outer diameter side of the magnets, and a magnet core between the inner diameter side iron core and the magnets. The inner diameter side surface is placed in contact with the outer diameter side surface of the inner diameter side core. Or between the magnet and the outer diameter side iron core The outer diameter side of the core is placed in contact with the inner diameter side of the outer diameter side of the core. or a magnetic body arranged on the outer diameter side of the inner diameter side iron core, and a plurality of structures each composed of a magnet, a magnetic body, and an outer diameter side iron core arranged on the outer diameter side of the inner diameter side iron core are arranged circumferentially about the main shaft, and a first resin portion is formed between the circumferential end faces of adjacent structures. The rotor disclosed in the present application comprises a main shaft which serves as a rotating shaft, an inner diameter side core arranged on the outer diameter side of the main shaft, magnets arranged on the outer diameter side of the inner diameter side core with half the number of magnetic poles of the rotor and with the same polarity on the radially outer side, an outer diameter side core arranged on the outer diameter side of the magnets, a protrusion protruding from the inner diameter side of the inner diameter side core between the magnets and the outer diameter side core, and a magnet between the inner diameter side core and the magnets. The inner diameter side surface is placed in contact with the outer diameter side surface of the inner diameter side core. Or between the magnet and the outer diameter side iron core The outer diameter side of the core is placed in contact with the inner diameter side of the outer diameter side of the core. or a magnetic body arranged on both the inner diameter side core and the outer diameter side core, the outermost end face of the protrusion of the inner diameter side core has an arc of the same radius as the outermost end face of the outer diameter side core to form a magnetic pole portion, the circumferential end face of the protrusion is separated from the circumferential end face of a structure composed of the magnet, magnetic body, and outer diameter side core arranged on the outer diameter side of the inner diameter side core, and a first resin portion is formed between the circumferential end face of the protrusion and the circumferential end face of the structure. The rotor disclosed in the present application comprises a main shaft which serves as a rotating shaft, an inner diameter side core arranged on the outer diameter side of the main shaft, magnets arranged on the outer diameter side of the inner diameter side core with half the number of magnetic poles of the rotor and the same polarity on the radially outward side, an outer diameter side core arranged on the outer diameter side of the magnets, a protrusion protruding from the inner diameter side of the inner diameter side core between the magnets and the outer diameter side core, and a magnetic body arranged between the inner diameter side core and the magnet, or between the magnet and the outer diameter side core, or both, wherein the outer diameter end face of the protrusion of the inner diameter side core has an arc of the same radius as the outer diameter side end face of the outer diameter side core to form a magnetic pole portion, the circumferential end face of the protrusion is separated from the circumferential end face of a structure composed of the magnets, magnetic body, and outer diameter side core arranged on the outer diameter side of the inner diameter side core, a first resin portion is formed between the circumferential end face of the protrusion and the circumferential end face of the structure, and the protrusion is provided with a flux barrier. The rotor disclosed in the present application comprises a main shaft which serves as a rotating shaft, an inner diameter side core arranged on the outer diameter side of the main shaft, a magnet arranged on the outer diameter side of the inner diameter side core, an outer diameter side core arranged on the outer diameter side of the magnet, and a magnetic body arranged between the inner diameter side core and the magnet, or between the magnet and the outer diameter side core, or both, and a plurality of structures formed from the magnet arranged on the outer diameter side of the inner diameter side core, the magnetic body, and the outer diameter side core are arranged circumferentially about the main shaft, a first resin part is formed between the circumferential end faces of adjacent structures, and the magnetic body is one or more thin plates. The rotor disclosed in the present application comprises a main shaft which serves as a rotating shaft, an inner diameter side core arranged on the outer diameter side of the main shaft, magnets arranged on the outer diameter side of the inner diameter side core with half the number of magnetic poles of the rotor and with the same polarity on the radially outward side, an outer diameter side core arranged on the outer diameter side of the magnets, a protrusion protruding from the inner diameter side of the inner diameter side core between the magnet and the outer diameter side core, and a magnetic body arranged between the inner diameter side core and the magnet, or between the magnet and the outer diameter side core, or both, wherein the outer diameter end face of the protrusion of the inner diameter side core has an arc of the same radius as the outer diameter side end face of the outer diameter side core to form a magnetic pole portion, the circumferential end face of the protrusion is separated from the circumferential end face of a structure composed of the magnet, magnetic body, and outer diameter side core arranged on the outer diameter side of the inner diameter side core, a first resin portion is formed between the circumferential end face of the protrusion and the circumferential end face of the structure, and the magnetic body is one or more thin plates. The rotor disclosed in the present application comprises a main shaft which serves as a rotating shaft, an inner diameter side iron core arranged on the outer diameter side of the main shaft, a magnet arranged on the outer diameter side of the inner diameter side iron core, an outer diameter side iron core arranged on the outer diameter side of the magnet, and a magnetic body arranged between the inner diameter side iron core and the magnet, or between the magnet and the outer diameter side iron core, or both, and a plurality of structures formed from the magnets, magnetic bodies, and outer diameter side iron core arranged on the outer diameter side of the inner diameter side iron core are arranged circumferentially about the main shaft, and a first resin part is formed between the circumferential end faces of adjacent structures, and the first resin part is connected to a second resin part and a third resin part formed of resin on both axial end faces of the structure. The rotor disclosed in the present application comprises a main shaft which serves as a rotating shaft, an inner diameter side core arranged on the outer diameter side of the main shaft, magnets arranged on the outer diameter side of the inner diameter side core with half the number of magnetic poles of the rotor and with the same polarity on the radially outer side, an outer diameter side core arranged on the outer diameter side of the magnets, a protrusion protruding from the inner diameter side of the inner diameter side core between the magnet and the outer diameter side core, and a magnetic body arranged between the inner diameter side core and the magnet, or between the magnet and the outer diameter side core, or both, and The radial end face has an arc of the same radius as the outermost end face of the outer diameter side iron core, forming a magnetic pole portion, and the circumferential end face of the protrusion is separated from the circumferential end face of a structure composed of the magnet, magnetic material, and outer diameter side iron core arranged on the outer diameter side of the inner diameter side iron core, and a first resin part is formed between the circumferential end face of the protrusion and the circumferential end face of the structure, and the first resin part is connected to a second resin part and a third resin part formed of resin on both axial end faces of the structure. The rotor disclosed in the present application comprises a main shaft which serves as a rotating shaft, an inner diameter side core arranged on the outer diameter side of the main shaft, a magnet arranged on the outer diameter side of the inner diameter side core, an outer diameter side core arranged on the outer diameter side of the magnet, and a magnetic body arranged between the inner diameter side core and the magnet, or between the magnet and the outer diameter side core, or both, and a plurality of structures formed from the magnet, the magnetic body, and the outer diameter side core arranged on the outer diameter side of the inner diameter side core are arranged circumferentially about the main shaft, a first resin portion is formed between the circumferential end faces of adjacent structures, and the magnetic body has a folded shape, with the magnet sandwiched on both sides. The rotor disclosed in the present application comprises a main shaft which serves as a rotating shaft, an inner diameter side core arranged on the outer diameter side of the main shaft, magnets arranged on the outer diameter side of the inner diameter side core with half the number of magnetic poles of the rotor and with the same polarity on the radially outward side, an outer diameter side core arranged on the outer diameter side of the magnets, a protrusion protruding from the inner diameter side of the inner diameter side core between the magnets and the outer diameter side core, and a magnetic body arranged between the inner diameter side core and the magnets, or between the magnets and the outer diameter side core, or both, and the inner diameter side core The outermost end face of the protrusion of the core has an arc of the same radius as the outermost end face of the outer diameter side iron core, forming a magnetic pole portion, and the circumferential end face of the protrusion is spaced apart from the circumferential end face of a structure composed of the magnet, magnetic material, and outer diameter side iron core arranged on the outer diameter side of the inner diameter side iron core, a first resin portion is formed between the circumferential end face of the protrusion and the circumferential end face of the structure, the magnetic material has a folded shape, and the magnet is sandwiched from both sides. The rotating electric machine disclosed in the present application includes the rotor and a stator disposed radially opposite to the rotor. The method of manufacturing a rotor disclosed in the present application uses a main shaft that serves as the rotating shaft of the rotor, an inner diameter side core arranged on the outer diameter side of the main shaft, a magnet arranged on the outer diameter side of the inner diameter side core, an outer diameter side core arranged on the outer diameter side of the magnet, and a magnetic body arranged between the inner diameter side core, the magnet, and the outer diameter side core, and arranges magnets on the outer diameter side of the inner diameter side core inside a molding die, and further arranges the outer diameter side core on the outer diameter side of the magnet, and arranges a set of magnets and the outer diameter side core on the outer diameter side of the inner diameter side core, and sequentially arranges magnets for the number of poles of the rotor. The method includes a rotor member arrangement process in which the outer diameter side core is arranged on the outer diameter side of the inner diameter side core; a magnetic material insertion process in which a structure is formed from the magnets, the outer diameter side core, and the magnetic material by inserting the magnetic material between the inner diameter side core and the magnets, or between the magnets and the outer diameter side core, or both, and in which the outer diameter side core is pressed against the inner wall surface of the molding die; and a resin injection process in which resin is injected through a resin injection hole in the molding die to form resin portions between the circumferential end faces of adjacent structures and on both axial end faces of the structure. The method for manufacturing a rotating electric machine disclosed in the present application includes a stator arrangement process in which a stator is arranged on the outer diameter side of the rotor via an air gap, using a rotor manufactured using the above-mentioned rotor manufacturing method. Effect of the Invention

[0008] The rotor disclosed in the present application reduces leakage flux around the magnet of the IPM rotor and reduces gaps that exist between the inner diameter side iron core and the outer diameter side iron core and the magnet due to machining accuracy, thereby making effective use of the magnetic flux of the magnet. The rotating electric machine disclosed in this application reduces leakage flux around the magnet of the IPM rotor and reduces gaps that exist between the inner diameter side iron core and the outer diameter side iron core and the magnet due to machining accuracy, thereby making effective use of the magnetic flux of the magnet. The rotor manufacturing method disclosed in the present application reduces leakage magnetic flux around the magnet of the IPM rotor and reduces gaps that exist between the inner diameter side iron core and the outer diameter side iron core and the magnet due to machining accuracy, thereby making effective use of the magnetic flux of the magnet. The manufacturing method for a rotating electric machine disclosed in the present application reduces leakage flux around the magnet of the IPM rotor and reduces gaps that exist between the inner diameter side iron core and the outer diameter side iron core and the magnet due to machining accuracy, thereby making effective use of the magnetic flux of the magnet. [Brief description of the drawings]

[0009] [Figure 1] 1 is a plan view of a rotating electric machine according to a first embodiment. [Diagram 2] FIG. 2 is a side view of the rotor according to the first embodiment. [Diagram 3] 1 is a cross-sectional view of a rotor according to a first embodiment. [Figure 4] 1 is a cross-sectional view of a rotor according to a first embodiment. [Diagram 5] FIG. 3 is an explanatory diagram of the arrangement of the rotor in the molding die according to the first embodiment. [Figure 6] 3 is a cross-sectional view for explaining the arrangement of the rotor in the molding die according to the first embodiment. FIG. [Figure 7] 6 is an explanatory diagram of another example of arrangement of the rotor in the molding die according to the first embodiment. FIG. [Figure 8] 3A to 3C are explanatory diagrams of examples of inserting magnets and magnetic bodies into the rotor according to the first embodiment. [Figure 9] 4 is a flowchart of a method for manufacturing a rotor according to the first embodiment. [Figure 10] FIG. 11 is a cross-sectional view of a rotor according to a second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Embodiment 1 The first embodiment includes an inner diameter side core arranged on the outer diameter side of a main shaft that serves as a rotating shaft, a magnet arranged on the outer diameter side of the inner diameter side core, an outer diameter side core arranged on the outer diameter side of the magnet, and a magnetic body arranged between the inner diameter side core, the magnet, and the outer diameter side core, and structures formed of the magnet, the magnetic body, and the outer diameter side core are arranged in the circumferential direction of the main shaft by the number of poles of the rotor, and a resin part is formed between the circumferential end faces of adjacent structures. The first embodiment also relates to a rotating electric machine using this rotor. The first embodiment also relates to a manufacturing method of the rotor and the rotating electric machine.

[0011] The rotor, rotating electric machine, and manufacturing method of the rotor and the manufacturing method of the rotating electric machine in accordance with embodiment 1 will be described below with reference to Figure 1, which is a plan view of the rotating electric machine, Figure 2, which is a side view of the rotor, Figures 3 and 4, which are cross-sectional views of the rotor, Figure 5, which is an explanatory view of the arrangement of the rotor in the molding die, Figure 6, which is a cross-sectional view for explaining the arrangement of the rotor in the molding die, Figure 7, which is an explanatory view of another example of arrangement of the rotor in the molding die, Figure 8, which is an explanatory view of an example of inserting the magnets and magnetic material of the rotor, and Figure 9, which is a flowchart of the manufacturing method of the rotor. In each drawing, the same or corresponding parts are indicated by the same reference numerals, and duplicated explanations will be omitted. In addition, in the following description, when axis (direction), diameter (direction), inner diameter (side, direction), outer diameter (side, direction), and circumference (direction) are used, unless otherwise specified, they refer to the rotation axis (direction), radius (direction), relative radial direction toward the center (side, direction), relative radial direction toward the outside (side, direction), and circumference (direction) of the rotation axis in a cylindrical coordinate system centered on the rotation axis of the rotor.

[0012] First, the overall structure of a rotating electric machine 1 according to the first embodiment will be described with reference to FIG. 1, which is a plan view of the rotating electric machine 1 as viewed from an axial end face thereof. In FIG. 1, in order to clarify the directions described above, the direction toward the center of the rotation axis (the vertical direction in FIG. 1) is described as the radial direction (R), and the direction along the rotation direction centered on the rotation axis is described as the circumferential direction (P).

[0013] The rotating electric machine 1 includes a stator 2 and a rotor 4 . The stator 2 includes teeth 21 that protrude in the radial direction from a yoke that is connected to form a circle at its outermost diameter, by the number of slots, and stator windings 22 made of copper wire wound around the teeth 21 with an insulating layer (not shown) sandwiched therebetween. The rotor 4 is integrated with the main shaft 41, and each component of the rotor 4 will be described with reference to Figs. 2 to 4. The stator 2 and the rotor 4 exchange magnetic flux through the air gap 3 , and the rotating magnetic field of the stator winding 22 generates torque, thereby functioning as a rotating electric machine 1 .

[0014] Next, the configuration and function of the rotor 4 of the rotating electric machine 1 will be described with reference to Fig. 2 to Fig. 4. Fig. 2 is a side view showing the rotor 4 of the rotating electric machine 1. Fig. 3 is a cross-sectional view taken along line A-A in Fig. 2, and Fig. 4 is a cross-sectional view taken along line B-B in Fig. 2. In addition, in order to clarify the directions described above, the axial direction (X), radial direction (R), and circumferential direction (P) are described in Figures 2 to 4. The axial direction (X) is the up-down direction in Figures 2 and 4. The upper end face side of the rotor 4 into which the magnetic body 45 described in Figures 5 and 7 is inserted is the + side, and the opposite side is the - side. In addition, in FIG. 5 and subsequent figures, the axial direction (X), radial direction (R), and circumferential direction (P) are indicated as appropriate to clarify the directions.

[0015] The rotor 4 has a main shaft 41 that coincides with the rotation axis of the rotating electric machine 1 penetrating through the center, and an inner diameter side iron core 42 is disposed on the outer diameter side of the main shaft 41. A magnet 43 is disposed on the outer diameter side of the inner diameter side iron core 42, and an outer diameter side iron core 44 is disposed on the outer diameter side of the magnet 43. Furthermore, a magnetic body 45 is disposed between the inner diameter side iron core 42 and the magnet 43, or between the magnet 43 and the outer diameter side iron core 44, or both. In Fig. 3, thick magnetic material 45 is disposed (inserted) only between inner diameter side iron core 42, outer diameter side iron core 44 and magnet 43, but this is for the purpose of making the drawing easier to understand. In reality, magnetic material 45 is disposed either between inner diameter side iron core 42 and magnet 43, or between magnet 43 and outer diameter side iron core 44 and 3, or both. The magnetic material 45 is arranged to eliminate gaps that inevitably occur between the inner diameter side iron core 42, the magnet 43, and the outer diameter side iron core 44 due to processing accuracy, and is therefore thinner than the magnet 43 and the outer diameter side iron core 44 and cannot be shown in the figure.

[0016] Magnets 43, magnetic material 45, and structure 46 of outer diameter side iron core 44, arranged on the outer diameter side of inner diameter side iron core 42, are arranged circumferentially around main shaft 41, which is the central axis of rotation, at predetermined intervals equal to the number of poles of rotor 4. In addition, in the rotor 4, a first resin portion 51 is formed by filling a circumferential gap of a structure 46 formed of the magnets 43, the outer diameter side iron core 44, and the magnetic body 45 with a resin.

[0017] The main shaft 41 is usually connected to the inner diameter side iron core 42 by, for example, welding. However, it is possible to omit the process of joining main shaft 41 and inner diameter side core 42 by welding. In this case, the inner diameter of inner diameter side core 42 is expanded, a gap is provided between main shaft 41 and inner diameter side core 42, and main shaft 41 and inner diameter side core 42 are joined with resin when first resin portion 51 is molded. In this case, the radial thickness of inner diameter side core 42 is set to a minimum length that can ensure a magnetic path that is not saturated with the magnetic flux emitted by magnet 43. The procedure for joining main shaft 41 and inner diameter side iron core 42 when first resin portion 51 is molded with resin will be described with reference to FIG.

[0018] The outer diameter side iron core 44 has an inner diameter end surface 44a on the magnet side that contacts the magnet 43 or a magnetic body 45 that contacts the magnet 43. As shown in FIG. 1, the outer diameter side iron core 44 serves as a magnetic path between the stator 2 and the magnet 43, with a tiny air layer (air gap 3) sandwiched in the outer diameter direction.

[0019] In Fig. 3, the inner core 42 contacts the magnet 43 at its magnet-side outer end surface 42a. However, when a magnetic body 45 is inserted between the inner core 42 and the magnet 43, the inner core 42 contacts the magnetic body 45 which is in contact with the magnet 43. The inner core 42 provides a magnetic path between the magnets 43 adjacent in the circumferential direction. In order to determine the relative position with respect to the magnet 43 in the circumferential direction, for example, a circumferential protrusion may be provided on the inner core 42 as a contact surface that contacts the circumferential side surface of the magnet 43, if necessary.

[0020] The magnetic body 45 is disposed between the inner diameter side iron core 42 and the magnet 43, or between the magnet 43 and the outer diameter side iron core 44, or in close contact with both, and passes the magnetic flux of the magnet 43. The magnetic body 45 is assumed to be, for example, iron, but the material is not particularly limited as long as it has a higher magnetic permeability than air and resin. The magnetic body 45 has a shape that allows it to come into close contact in the radial direction with the inner diameter side iron core 42, the outer diameter side iron core 44, and the magnet 43. For example, when the contact surfaces of the inner diameter side iron core 42, the outer diameter side iron core 44, and the magnet 43 are flat, the magnetic body 45 is a plate-like body having a similar flat shape.

[0021] The resin part 50 is composed of a first resin part 51, a second resin part 52, and a third resin part 53. The first resin portion 51 is formed by filling circumferential gaps between the structure 46 (the magnet 43, the magnetic body 45, and the outer diameter side iron core 44) with resin. As shown in FIG. 4, the second resin portion 52 is formed on an upper end surface of the rotor 4 in the axial direction, and the third resin portion 53 is formed on a lower end surface of the rotor 4 in the axial direction. The first resin part 51, the second resin part 52, and the third resin part 53 are connected to each other.

[0022] The first resin portion 51 reduces the magnetic flux that shorts out in the circumferential direction of the magnet 43, and positions the magnet 43, the outer diameter side iron core 44, and the magnetic body 45 in the circumferential direction. Furthermore, the second resin portion 52 and the third resin portion 53 can restrict the magnet 43, the outer diameter side iron core 44, the magnetic body 45, and the first resin portion 51 from moving axially and radially outward. The first resin portion 51 is a structural member equivalent to the bridge in a conventional IPM structure, but since resin has a relative magnetic permeability equivalent to that of air, it does not allow magnetic flux to leak in the circumferential direction.

[0023] Next, a manufacturing procedure for rotor 4 will be described with reference to Fig. 5 and Fig. 6. Specifically, a procedure for arranging each component member of rotor 4 in molding die 60 and integrally molding with resin portion 50 will be described.

[0024] Fig. 5 is an explanatory diagram of the arrangement of the rotor 4 in the molding die 60, and is a plan view showing the state in which each component of the rotor 4 is placed in the molding die 60 before the resin part 50 is molded. Fig. 6 is an explanatory diagram of the arrangement of the rotor in the molding die, and is an example of a cross-sectional view of the plan view in Fig. 5 cut along line CC and viewed from the direction of the arrows.

[0025] A molding die 60 for integrally molding the rotor 4 of the rotating electric machine 1 according to the first embodiment from resin includes a lower die 61 and an upper die 62. The lower die 61 is a die for fixing the rotor members before molding, that is, the main shaft 41, the inner diameter side iron core 42, the magnets 43, the outer diameter side iron core 44, and the magnetic body 45. The lower die 61 also serves as the bottom of the lid of the molding die 60, and the second resin part 52 is formed between the lower die 61 and the lower end surface of the structure 46. The upper die 62 serves as a lid for closing the molding die 60, and the third resin portion 53 is formed between the upper die 62 and the upper end surface of the structure .

[0026] A positioning pin 66a for positioning the inner diameter side core 42 in the radial and circumferential directions is disposed on the outer diameter side of the inner diameter side core 42 at a position that does not interfere with the magnet 43 and the magnetic body 45 on the bottom surface 61a of the lower die 61. Furthermore, a positioning pin 66b for determining the circumferential position of the magnet 43 and a positioning pin 66c for determining the circumferential position of the outer diameter side core 44 are provided on the bottom surface 61a of the lower die 61.

[0027] The positioning pins 66a-66c do not have to be cylindrical as long as they can properly position the inner diameter side iron core 42, the magnet 43, and the outer diameter side iron core 44. If necessary, they may be tapered, shaped to fit the outer diameter of the inner diameter side iron core 42, the magnet 43, and the outer diameter side iron core 44, or shaped like a polygonal column. In addition, the number of positioning pins 66a-66c may be appropriately added or deleted other than the example shown in Fig. 5. The axial height of each of the positioning pins 66a-66c may be freely set within a range in which they contact the outer end faces of the inner diameter side iron core 42, the magnet 43, and the outer diameter side iron core 44. As long as the functions of the positioning pins 66a-66c are satisfied, protrusions or the like for fixing the outer diameter side iron core 44 to the lower die inner diameter end surface 61c of the lower die 61 may be used instead.

[0028] In FIG. 6, gravity is acting downward on the paper surface. The main shaft 41 of the rotor 4 is inserted into a fitting portion 61b provided in the center of the bottom surface 61a of the lower die 61. When the components of the rotor 4 are inserted into the lower die 61, if they are placed directly on the bottom surface 61a of the lower die 61, the third resin portion 53 cannot be molded. For this reason, the axial bottom surfaces 61a of the inner diameter side iron core 42, magnets 43, magnetic body 45, and outer diameter side iron core 44 are supported by the spacer 63, floating them by the axial thickness of the third resin portion 53. As long as the first resin portion 51 and the third resin portion 53 are not separated, the spacer 63 may be in the shape of a polygonal column or a pin. The spacer 63 for determining the axial direction of the outer diameter side iron core 44, the magnet 43, the magnetic body 45, and the inner diameter side iron core 42 may be integrated or may be independent. Since the plate thickness of the magnetic body 45 is usually considered to be thinner than that of the magnet 43, it is preferable that the spacer 63 for determining the axial direction of the magnet 43 and the magnetic body 45 is integrated. The spacer 63 may be made of the same material as the resin used for molding, and may be formed to become a part of the third resin portion 53 after molding.

[0029] Here, a procedure for omitting the previously described step of joining main shaft 41 and inner diameter side iron core 42, i.e., for joining main shaft 41 and inner diameter side iron core 42 with resin when molding first resin portion 51, will be described with reference to Fig. 7. Fig. 7 is an explanatory diagram of another example of arrangement of rotor 4 in molding die 60. 6, the main shaft 41 of the rotor 4 is inserted into the fitting portion 61b provided in the center of the bottom surface 61a of the lower die 61. 7, the radial thickness of the inner diameter side core 42 is reduced to provide a gap between the inner diameter side core 42 and the main shaft 41. A positioning pin 66d for determining the radial and circumferential positions of the inner diameter side core 42 is disposed on the inner diameter side of the inner diameter side core 42. The shape, number, height, and other conditions of the positioning pins 66d are the same as those of the positioning pins 66a-66c described above.

[0030] When the inner diameter side core 42, the magnets 43, and the outer diameter side core 44 are arranged in the molding die 60, gaps are formed between the inner diameter side core 42 and the outer diameter side core 44 and the magnets 43 due to the machining accuracy of the inner diameter side core 42, the outer diameter side core 44, and the magnets 43. In order to reduce (preferably eliminate) these gaps, a magnetic body 45 is arranged (inserted) along the axial direction from the upper die side of the axial end face of the rotor 4 between the inner diameter side core 42 and the magnets 43, or between the magnets 43 and the outer diameter side core 44, or both.

[0031] Before placing the magnetic body 45, the gaps generated between the inner diameter side iron core 42 and the outer diameter side iron core 44 and the magnet 43 are measured in advance, and magnetic body 45 having a plate thickness of the same dimension as those gaps is prepared, thereby reducing the number of magnetic bodies 45 used. Alternatively, by preparing magnetic material 45 in multiple thicknesses, including one that is thinner than the expected gap, it becomes unnecessary to measure the gap and prepare magnetic material 45 with the gap width, thereby making it possible to efficiently place magnetic material 45. In other words, after the inner diameter side iron core 42, magnet 43, and outer diameter side iron core 44 are positioned, the thin plate magnetic material 45 prepared is inserted into the gaps between the inner diameter side iron core 42, the outer diameter side iron core 44, and the magnet 43 until the gaps are filled, thereby making the work more efficient.

[0032] Furthermore, a procedure for improving the efficiency of the arrangement (insertion) of the magnetic body 45 will be described with reference to Fig. 8. Fig. 8 is an explanatory diagram of an example of inserting the magnets and magnetic body of the rotor. In FIG. 8, the magnetic body is designated as magnetic body 45A in order to distinguish it from magnetic body 45, which has approximately the same axial length as magnet 43 described with reference to FIGS. As shown in Fig. 8, magnetic body 45A is prepared with a length at least twice the axial length of magnet 43. Magnetic body 45A is folded so as to be in close contact with both sides of magnet 43, and magnet 43 is sandwiched between the folded magnetic body 45A. Magnet 43 is pushed together with magnetic body 45A, and inserted between inner diameter side iron core 42 and outer diameter side iron core 44 from the + side to the - side in the axial direction (X). By inserting magnet 43 and magnetic body 45A as a single unit in this way, work efficiency can be improved.

[0033] After magnet 43 and magnetic body 45A are inserted integrally between inner diameter side iron core 42 and outer diameter side iron core 44, it is assumed that gaps will exist between inner diameter side iron core 42 and magnetic body 45A, and between magnetic body 45A and outer diameter side iron core 44. In this case, a thin magnetic body 45 prepared in advance is placed (inserted) in this gap to reduce the gap as much as possible.

[0034] An injection port for injecting resin is provided at a desired position inside the molding die 60, and the resin is filled into the resin portion 50. By arranging the magnetic material 45 so that it is in close contact between the inner diameter side iron core 42 and the magnet 43, or between the magnet 43 and the outer diameter side iron core 44, or both, the outermost end face 44b on the outer periphery of the outer diameter side iron core 44 is pressed against the lower mold inner diameter end face 61c of the lower mold 61. In this way, the resin is filled while the outer diameter side core 44 is pressed against the molding die 60, so that the inner diameter side core 42, magnet 43, magnetic material 45, and outer diameter side core 44 are closely attached to each other, and the outer diameter of the rotor 4 also has good roundness. Although the resin filled in the rotor 4 is assumed to be a thermosetting resin, there are no particular limitations on the material as long as the material has a lower magnetic permeability than the iron core. For example, cement or a vitreous material may be used.

[0035] Even when the step of joining the main shaft 41 and the inner diameter side iron core 42 described in FIG. 7 is omitted, the main shaft 41 is inserted into the fitting portion 61b provided in the center of the bottom surface 61a of the lower die 61 during molding, so that the main shaft 41 can be molded integrally while ensuring coaxiality within the molding die 60.

[0036] Here, the above-described manufacturing method for the rotor 4 will be collectively described with reference to the flow chart of FIG. In this embodiment, the main shaft 41 and the inner diameter side iron core 42 are connected by welding. The manufacturing process of rotor 4 in FIG. 9 is composed of step 01 (S01) to step 03 (S03) which will be described below.

[0037] In the rotor component arrangement process of step 01 (S01), a magnet 43 is arranged on the outer diameter side of an inner diameter side core 42 inside a molding die 60, and an outer diameter side core 44 is further arranged on the outer diameter side of the magnet 43, so that a set of magnets 43 and outer diameter side core 44 is arranged on the outer diameter side of the inner diameter side core 42, and successively, the pole number sets of magnets 43 and outer diameter side core 44 of rotor 4 are arranged on the outer diameter side of the inner diameter side core 42.

[0038] The specific steps of the rotor member arrangement process will be described. Positioning pins 66a-66c for positioning the inner diameter side iron core 42, the magnet 43, and the outer diameter side iron core 44 are arranged on the bottom surface 61a of the lower mold 61 of the molding die 60. Next, the inner diameter side iron core 42, the magnet 43, and the outer diameter side iron core 44 are floated on the bottom surface 61a of the lower mold 61, and a spacer 63 for forming the third resin portion 53 is installed.

[0039] Next, the inner diameter side iron core 42 is disposed in the lower die 61 by inserting the main shaft 41 of the rotor 4 into the fitting portion 61 b ​​provided in the center of the bottom surface 61 a of the lower die 61 . Next, the magnets 43 and the outer diameter side core 44 are sequentially arranged on the lower die 61. The magnets 43 and the outer diameter side core 44 are sequentially arranged as a set on the outer diameter side of the inner diameter side core 42. That is, the magnets 43 are placed on the outer diameter side of the inner diameter side core 42, and the outer diameter side core 44 is placed on the outer diameter side of the magnets 43.

[0040] Next, magnet 43 is placed on the outer diameter side of inner core 42 next to the set of magnets 43 and outer diameter core 44 that have already been placed on the outer diameter side of inner core 42, and outer diameter core 44 is placed on the outer diameter side of that. In this manner, sets of magnets 43 and outer diameter side iron cores 44 corresponding to the number of poles of the rotor 4 are sequentially arranged on the outer diameter side of the inner diameter side iron core 42 .

[0041] As a method for arranging the magnets 43 and the outer diameter side cores 44 on the outer diameter side of the inner diameter side core 42, there is also a method in which magnets 43 are first arranged in the number of poles of the rotor 4, and then the outer diameter side cores 44 are arranged in the number of poles of the rotor 4.

[0042] In the magnetic material insertion process of step 02 (S02), a magnetic material 45 is inserted between the inner diameter side iron core 42 and the magnet 43, or between the magnet 43 and the outer diameter side iron core 44, or both, so that the magnet 43, the outer diameter side iron core 44, and the magnetic material 45 form a structure 46, and the outer diameter end face 44b of the outer diameter side iron core 44 is pressed against the inner wall surface (lower mold inner diameter end face 61c) of the molding die 60.

[0043] At this time, in order to reduce the gap (preferably eliminate the gap), one magnetic body 45 may be inserted or multiple magnetic bodies 45 may be inserted. When inserting one magnetic body 45, the width of the gap is measured, and a magnetic body 45 having a thickness equal to the gap width is prepared and inserted. Furthermore, when a plurality of magnetic bodies 45 are inserted, a plurality of thin magnetic bodies 45 are prepared and the plurality of magnetic bodies 45 are inserted to reduce the gap. This completes the arrangement of the components of the rotor 4 (the main shaft 41, the inner diameter side iron core 42, the magnets 43, the outer diameter side iron core 44, and the magnetic body 45) on the lower die 61 of the molding die 60.

[0044] In a resin injection process of step 03 (S03), resin is injected from a resin injection hole of the molding die 60 to form resin portions 50 between the circumferential end faces of adjacent structures 46 and on both axial end faces of the structures 46.

[0045] The specific steps of the resin injection process will be described. In this step, resin is injected into the molding die 60 in which the arrangement of each component of the rotor 4 has been completed, to form the resin portion 50 and to integrate each component of the rotor 4. After the arrangement of the components of the rotor 4 has been completed, an upper die 62 is placed on the lower die 61 of the molding die 60. Next, resin is injected from a resin injection port of the molding die 60 to form the resin portion 50 (first resin portion 51, second resin portion 52, third resin portion 53). That is, a first resin portion 51 is formed between the structures 46, a second resin portion 52 is formed on the upper end surface side of the structures 46, and a third resin portion 53 is formed on the lower end surface side of the structures 46. Resin is injected into the molding die 60 to form the resin portion 50 (the first resin portion 51, the second resin portion 52, and the third resin portion 53), thereby integrating the various components of the rotor 4.

[0046] The rotating electric machine 1 of FIG. 1 is constructed by disposing the rotor 4, the structure of which has been described above, and the stator 2 so as to face the rotor 4 in the radial direction.

[0047] The rotating electric machine 1 can be manufactured by using a rotor 4 manufactured using the rotor manufacturing method described in the flowchart of Figure 9, and by providing a stator arrangement process in which a stator 2 is arranged on the outer diameter side of the rotor 4 via an air gap 3.

[0048] In the rotor 4 and rotating electric machine 1 according to embodiment 1, the areas equivalent to the bridges in a conventional IPM structure are filled with resin, thereby reducing circumferential leakage magnetic flux. Furthermore, the gaps between the magnets 43 and the inner diameter side core 42 and the outer diameter side core 44, which are caused by the machining accuracy of the inner diameter side core 42, the magnets 43, and the outer diameter side core 44, are filled with magnetic material 45, which allows the magnetic flux of the magnets 43 to pass through, thereby making effective use of the magnetic flux of the magnets 43.

[0049] Furthermore, the air gap 3, which is the radial gap between the stator 2 and the rotor 4, is formed by positioning the main shaft 41 and the outer diameter side iron core 44 using the forming die 60, so that the dimensions can be stabilized, the air gap 3 can be reduced, and the roundness can be improved.

[0050] In addition, in the explanation of the rotor 4 according to the embodiment 1, a cylindrical rotor 4 with eight poles has been given as an example, but a rotor with another number of poles may be used as long as it follows the configuration of the embodiment 1. Also, a so-called petal-shaped rotor may be used in which the outer diameter curvature of the outer diameter side iron core 44 is larger than the curvature of the outermost diameter of the rotor.

[0051] As described above, the rotor 4 of the rotating electric machine 1 of the first embodiment includes the main shaft 41 serving as a rotating shaft, the inner diameter side iron core 42 arranged on the outer diameter side of the main shaft 41, the magnet 43 arranged on the outer diameter side of the inner diameter side iron core 42, and the outer diameter side iron core 44 arranged on the outer diameter side of the magnet 43. Furthermore, the rotor 4 of the rotating electric machine 1 includes a magnetic body 45 that passes the magnetic flux of the magnet 43 and is arranged between the inner diameter side iron core 42 and the magnet 43, or between the magnet 43 and the outer diameter side iron core 44, or in close contact with both. Furthermore, the rotor 4 of the rotating electric machine 1 includes a structure 46 composed of the magnet 43, the outer diameter side iron core 44, and the magnetic body 45 arranged on the outer diameter side of the inner diameter side iron core 42 in the circumferential direction relative to the main shaft 41, the number of which corresponds to the number of poles of the rotor 4. Furthermore, in the rotor 4 of the rotating electric machine 1, a first resin portion 51 is formed between the circumferential end faces of the adjacent structures 46, and a second resin portion 52 and a third resin portion 53 are formed on both axial end faces of the structures 46. Here, the first resin portion 51, the second resin portion 52, and the third resin portion 53 are connected to form the resin portion 50.

[0052] Moreover, the rotating electric machine 1 of the first embodiment includes a stator 2 disposed radially opposite the rotor 4 described above.

[0053] In addition, the manufacturing method of rotor 4 in embodiment 1 includes a rotor member arrangement process in which rotor members (shaft 41, inner diameter side core 42, magnet 43, outer diameter side core 44) are arranged inside molding die 60, a magnetic body insertion process in which magnetic body 45 is inserted between inner diameter side core 42 and magnet 43, or between magnet 43 and outer diameter side core 44, or both, and the outer diameter side core 44b is pressed against the inner wall surface of molding die 60, and a resin injection process in which resin is injected from a resin injection hole in molding die 60 to form resin portions 50 between the circumferential end faces of adjacent structures 46 and on both axial end faces of structure 46.

[0054] The rotor 4, rotating electric machine 1, and rotor and rotor manufacturing method according to embodiment 1 can reduce circumferential leakage magnetic flux of magnets 43 of the IPM rotor. Also, gaps between inner diameter side core 42, outer diameter side core 44, and magnets, which are caused by the machining accuracy of inner diameter side core 42, outer diameter side core 44, and magnets, can be reduced (preferably eliminated). As a result, it is possible to obtain a rotor 4 and a rotating electric machine 1, as well as a manufacturing method for a rotor and a rotating electric machine, which are capable of effectively utilizing the magnetic flux of the magnets 43 and stabilizing the air gap dimensions.

[0055] Embodiment 2 In the second embodiment, half of the total magnetic poles of the rotor are replaced with iron cores, and a consequent pole structure is adopted in which the thickness of the magnets is increased.

[0056] The rotor of the rotating electric machine according to the second embodiment will be described with reference to FIG. 10, which is a cross-sectional view of the rotor, focusing on the differences from the first embodiment. In the configuration diagram of the second embodiment, the same or corresponding parts as those in the first embodiment are denoted by the same reference numerals. In order to distinguish from the first embodiment, the second embodiment includes a rotating electric machine 100, a rotor 104, an inner diameter side iron core 142, a magnet 143, an outer diameter side iron core 144, a magnetic body 145, a structure 146, and a first resin portion 151.

[0057] In the first embodiment, the magnets and outer diameter side iron cores are arranged in the same number as the number of magnetic poles of the rotor, but in the second embodiment, a structure is provided that can reduce the number of parts and further reduce the machining costs of the magnets.

[0058] As shown in FIG. 10, rotor 104 has a consequent pole structure in which half (4) of the total number of magnetic poles (8) are replaced with iron cores and magnets 143 are made thicker. Magnets 143, half of whose magnetic poles have the same polarity on the radially outer side, are arranged circumferentially on rotor 104. Outer diameter side iron core 144, or magnetic body 145 in close contact with outer diameter side iron core 144, is in close contact with the outer diameter end face of magnet 143. Inner diameter side iron core 142, or magnetic body 145 in close contact with inner diameter side iron core 142, is in close contact with the inner diameter end face of magnet 143. The magnet 143 , the magnetic body 145 , and the outer diameter side iron core 144 form a structure 146 . In FIG. 10, the radially outer side of magnet 143 is the N pole, but it may be the S pole.

[0059] The inner diameter side core 142 has a protrusion 147 that protrudes radially so as to fit between two circumferentially adjacent structures 146, and the outermost diameter end face of the protrusion 147 of the inner diameter side core 142 forms a magnetic pole portion as an arc of the same radius as the outermost diameter end face 144b of the outer diameter side core 144.

[0060] A resin is filled into a gap between the inner diameter side iron core 142, the protruding portion 147, and the structure 146 (the magnet 143, the magnetic body 145, and the outer diameter side iron core 144), and a first resin portion 151 is formed.

[0061] The protruding portion 147 may be provided with a flux barrier 148 for correcting the flow of magnetic flux in a magnetic pole portion that forms a magnetic circuit with the stator 2 (not shown).

[0062] The magnetic body 145 can be made up of one sheet or multiple thin plates. As explained in FIG. 8 of the first embodiment, magnet 143 may be sandwiched between folded magnetic body 145 and inserted between inner diameter side iron core 142 and outer diameter side iron core 144 .

[0063] The rotating electric machine 100 is configured by arranging the rotor 104, the structure of which has been described above, and a stator (not shown) radially opposite the rotor 104.

[0064] According to the rotor and rotating electric machine 100 in the second embodiment, the number of parts can be nearly halved while maintaining the advantages of the first embodiment, and processing costs, including the reduction in the number of magnets 143, can be suppressed.

[0065] Although the present application 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 modifications not exemplified are assumed within the scope of the technology disclosed in this application, including, for example, modifying, adding, or omitting at least one component, and further, extracting at least one component and combining it with a component of another embodiment. [Explanation of symbols]

[0066] 1,100 rotating machine, 2 stator, 3 air gap, 4,104 rotor, 21 teeth, 22 stator winding, 41 main shaft, 42,142 inner diameter side core, 42a magnet side outer diameter end surface, 43, 143 magnet, 44, 144 outer diameter side iron core, 44a Inner diameter end face on magnet side, 44b Outermost diameter end face, 45,45A,145 Magnetic material, 46,146 Structure, 50 Resin part, 51,151 First resin part, 52 Second resin part, 53 Third resin part, 60 Molding die, 61 Lower die, 61a Bottom surface, 61b Fitting part, 61c Lower die inner diameter end surface, 62 Upper die, 63 Spacer, 66a, 66b, 66c, 66d Locating pins, 147 Protrusions, 148 Flux Barrier.

Claims

1. A main shaft that serves as the axis of rotation; an inner diameter side iron core arranged on the outer diameter side of the spindle; A magnet disposed on the outer diameter side of the inner diameter side iron core; An outer diameter side iron core arranged on the outer diameter side of the magnet; a magnet is disposed between the inner diameter side iron core and the magnet such that the inner diameter side surface is in contact with the outer diameter side surface of the inner diameter side iron core, Alternatively, the magnet is disposed between the magnet and the outer diameter side iron core such that the outer diameter side surface is in contact with the inner diameter side surface of the outer diameter side iron core, and a magnetic body disposed on the first or second magnetic pole, A rotor in which a plurality of structures each consisting of the magnet, the magnetic material, and the outer diameter side iron core, which are arranged on the outer diameter side of the inner diameter side iron core, are arranged circumferentially about the main shaft, and a first resin portion is formed between the circumferential end faces of adjacent structures.

2. A main shaft that serves as the axis of rotation; an inner diameter side iron core arranged on the outer diameter side of the spindle; magnets arranged on the outer diameter side of the inner diameter side iron core, the number of the magnet poles of the rotor being half the number of the magnet poles, with the same polarity on the outer side in the radial direction; An outer diameter side iron core arranged on the outer diameter side of the magnet; a protrusion protruding from an inner diameter side of the inner diameter side iron core between the magnet and the outer diameter side iron core; a magnet is disposed between the inner diameter side iron core and the magnet such that the inner diameter side surface is in contact with the outer diameter side surface of the inner diameter side iron core, Alternatively, the magnet is disposed between the magnet and the outer diameter side iron core such that the outer diameter side surface is in contact with the inner diameter side surface of the outer diameter side iron core, or a magnetic body disposed on both of the first and second electrodes; an outermost end surface of the protruding portion of the inner core has an arc of the same radius as an outermost end surface of the outer core, forming a magnetic pole portion; a circumferential end face of the protrusion is spaced apart from a circumferential end face of a structure formed of the magnet, the magnetic body, and the outer diameter side iron core, the structure being disposed on the outer diameter side of the inner diameter side iron core, A rotor, wherein a first resin portion is formed between a circumferential end surface of the protrusion and a circumferential end surface of the structure.

3. A rotor as described in claim 2, having no magnet in the protrusion.

4. A main shaft serving as a rotation axis; an inner diameter side iron core arranged on the outer diameter side of the spindle; magnets arranged on the outer diameter side of the inner diameter side iron core, the number of the magnet poles of the rotor being half the number of the magnet poles, with the same polarity on the outer side in the radial direction; An outer diameter side iron core arranged on the outer diameter side of the magnet; a protrusion protruding from an inner diameter side of the inner diameter side iron core between the magnet and the outer diameter side iron core; a magnetic body disposed between the inner diameter side iron core and the magnet, or between the magnet and the outer diameter side iron core, or both; an outermost end surface of the protruding portion of the inner core has an arc of the same radius as an outermost end surface of the outer core, forming a magnetic pole portion; a circumferential end face of the protrusion is spaced apart from a circumferential end face of a structure formed of the magnet, the magnetic body, and the outer diameter side iron core, the structure being disposed on the outer diameter side of the inner diameter side iron core, a first resin portion is formed between a circumferential end surface of the protrusion and a circumferential end surface of the structure, A rotor having a flux barrier on the protrusion.

5. A main shaft serving as a rotation axis; an inner diameter side iron core arranged on the outer diameter side of the spindle; A magnet disposed on the outer diameter side of the inner diameter side iron core; An outer diameter side iron core arranged on the outer diameter side of the magnet; a magnetic body disposed between the inner diameter side iron core and the magnet, or between the magnet and the outer diameter side iron core, or both; a plurality of structures each composed of the magnet, the magnetic body, and the outer diameter side iron core, each of which is disposed on the outer diameter side of the inner diameter side iron core, are disposed in a circumferential direction with respect to the main shaft, and a first resin portion is formed between circumferential end faces of adjacent structures; The magnetic body is a rotor which is one or more thin plates.

6. A main shaft serving as a rotation axis; an inner diameter side iron core arranged on the outer diameter side of the spindle; magnets arranged on the outer diameter side of the inner diameter side iron core, the number of the magnet poles of the rotor being half the number of the magnet poles, with the same polarity on the outer side in the radial direction; An outer diameter side iron core arranged on the outer diameter side of the magnet; a protrusion protruding from an inner diameter side of the inner diameter side iron core between the magnet and the outer diameter side iron core; a magnetic body disposed between the inner diameter side iron core and the magnet, or between the magnet and the outer diameter side iron core, or both; an outermost end surface of the protruding portion of the inner core has an arc of the same radius as an outermost end surface of the outer core, forming a magnetic pole portion; a circumferential end face of the protrusion is spaced apart from a circumferential end face of a structure formed of the magnet, the magnetic body, and the outer diameter side iron core, the structure being disposed on the outer diameter side of the inner diameter side iron core, a first resin portion is formed between a circumferential end surface of the protrusion and a circumferential end surface of the structure, The magnetic body is a rotor which is one or more thin plates.

7. A main shaft serving as a rotation axis; an inner diameter side iron core arranged on the outer diameter side of the spindle; A magnet disposed on the outer diameter side of the inner diameter side iron core; An outer diameter side iron core arranged on the outer diameter side of the magnet; a magnetic body disposed between the inner diameter side iron core and the magnet, or between the magnet and the outer diameter side iron core, or both; a plurality of structures each composed of the magnet, the magnetic body, and the outer diameter side iron core, each of which is disposed on the outer diameter side of the inner diameter side iron core, are disposed in a circumferential direction with respect to the main shaft, and a first resin portion is formed between circumferential end faces of adjacent structures; The first resin portion is connected to a second resin portion and a third resin portion formed of resin on both axial end surfaces of the structure.

8. A main shaft serving as a rotation axis; an inner diameter side iron core arranged on the outer diameter side of the spindle; magnets arranged on the outer diameter side of the inner diameter side iron core, the number of the magnet poles of the rotor being half the number of the magnet poles, with the same polarity on the outer side in the radial direction; An outer diameter side iron core arranged on the outer diameter side of the magnet; a protrusion protruding from an inner diameter side of the inner diameter side iron core between the magnet and the outer diameter side iron core; a magnetic body disposed between the inner diameter side iron core and the magnet, or between the magnet and the outer diameter side iron core, or both; an outermost end surface of the protruding portion of the inner core has an arc of the same radius as an outermost end surface of the outer core, forming a magnetic pole portion; a circumferential end face of the protrusion is spaced apart from a circumferential end face of a structure formed of the magnet, the magnetic body, and the outer diameter side iron core, the structure being disposed on the outer diameter side of the inner diameter side iron core, a first resin portion is formed between a circumferential end surface of the protrusion and a circumferential end surface of the structure, The first resin portion is connected to a second resin portion and a third resin portion formed of resin on both axial end surfaces of the structure.

9. A main shaft serving as a rotation axis; an inner diameter side iron core arranged on the outer diameter side of the spindle; A magnet disposed on the outer diameter side of the inner diameter side iron core; An outer diameter side iron core arranged on the outer diameter side of the magnet; a magnetic body disposed between the inner diameter side iron core and the magnet, or between the magnet and the outer diameter side iron core, or both; a plurality of structures each composed of the magnet, the magnetic body, and the outer diameter side iron core, each of which is disposed on the outer diameter side of the inner diameter side iron core, are disposed in a circumferential direction with respect to the main shaft, and a first resin portion is formed between circumferential end faces of adjacent structures; The magnetic body has a folded shape and has a rotor structure in which the magnet is sandwiched from both sides.

10. A main shaft serving as a rotation axis; an inner diameter side iron core arranged on the outer diameter side of the spindle; magnets arranged on the outer diameter side of the inner diameter side iron core, the number of the magnet poles of the rotor being half the number of the magnet poles, with the same polarity on the outer side in the radial direction; An outer diameter side iron core arranged on the outer diameter side of the magnet; a protrusion protruding from an inner diameter side of the inner diameter side iron core between the magnet and the outer diameter side iron core; a magnetic body disposed between the inner diameter side iron core and the magnet, or between the magnet and the outer diameter side iron core, or both; an outermost end surface of the protruding portion of the inner core has an arc of the same radius as an outermost end surface of the outer core, forming a magnetic pole portion; a circumferential end face of the protrusion is spaced apart from a circumferential end face of a structure formed of the magnet, the magnetic body, and the outer diameter side iron core, the structure being disposed on the outer diameter side of the inner diameter side iron core, a first resin portion is formed between a circumferential end surface of the protrusion and a circumferential end surface of the structure, The magnetic body has a folded shape and has a rotor structure in which the magnet is sandwiched from both sides.

11. A rotor as described in claim 2 or claim 3, comprising a flux barrier on the protrusion.

12. A rotor described in any one of claims 1 to 4, wherein the magnetic body is one or more thin plates.

13. A rotor described in any one of claims 1 to 6, wherein the first resin part is connected to a second resin part and a third resin part formed of resin on both axial end faces of the structure.

14. A rotor described in any one of claims 1 to 8, wherein the magnetic body has a folded shape and has a structure in which the magnet is sandwiched from both sides.

15. A rotor according to any one of claims 1 to 14; a stator disposed radially opposite the rotor.

16. A rotor is constructed by using a main shaft which is a rotating shaft of a rotor, an inner diameter side core arranged on the outer diameter side of the main shaft, a magnet arranged on the outer diameter side of the inner diameter side core, an outer diameter side core arranged on the outer diameter side of the magnet, and a magnetic body arranged between the inner diameter side core, the magnet, and the outer diameter side core, a rotor member arrangement process in which the magnet is arranged on the outer diameter side of the inner diameter side core inside a molding die, the outer diameter side core is further arranged on the outer diameter side of the magnet, one set of the magnet and the outer diameter side core is arranged on the outer diameter side of the inner diameter side core, and the magnet and the outer diameter side core of the number of poles of the rotor are sequentially arranged on the outer diameter side of the inner diameter side core; a magnetic body insertion process in which a magnetic body is inserted between the inner diameter side iron core and the magnet, or between the magnet and the outer diameter side iron core, or both, to form a structure with the magnet, the outer diameter side iron core, and the magnetic body, and an outer peripheral surface of the outer diameter side iron core is pressed against an inner wall surface of the molding die; a resin injection step of injecting resin through a resin injection hole of the molding die to form a resin portion between circumferential end faces of adjacent structures and on both axial end faces of the structure; A method for manufacturing a rotor comprising the steps of:

17. Using a rotor manufactured by the rotor manufacturing method according to claim 16, a stator arrangement step of arranging a stator on an outer diameter side of the rotor via an air gap; A manufacturing method of a rotating electric machine equipped with the above-mentioned.

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