Rotating electric machine and method for manufacturing a rotating electric machine
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- DENSO CORP
- Filing Date
- 2022-03-16
- Publication Date
- 2026-08-04
Smart Images
Figure 0007899547000001 
Figure 0007899547000002 
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Abstract
Description
Technical Field
[0001] The present invention relates to a rotating electric machine.
Background Art
[0002] Conventionally, in order to improve the output torque of a rotating electric machine, a technique has been proposed in which a sintered magnet with a devised orientation direction of the easy magnetization axis is adopted to improve the maximum magnetic flux density (for example, Patent Document 1).
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] In the case of the magnet as described above, it is common that a plurality of magnets are manufactured and arranged along the circumferential direction of the rotation axis so as to form an annular shape. By the way, when manufacturing a magnet in which the orientation of the easy magnetization axis is oriented parallel to the d-axis on the side of the d-axis which is the magnetic pole center, compared with the side of the q-axis which is the magnetic pole boundary, it is easier to perform orientation and magnetization by dividing along the d-axis and the q-axis than by dividing between adjacent d-axes (or q-axes) in the circumferential direction. That is, it is easier to manufacture a magnet having one magnetic pole on the magnet surface on the stator side than to manufacture magnets having different magnetic poles on the magnet surface on the stator side, and it is easier to increase the magnetic force.
[0005] However, when adopting magnets divided by the d-axis, when arranging the magnetized magnets in an annular shape, the same poles are formed on the d-axis and they repel each other. For this reason, there is a problem that assembly becomes difficult.
[0006] This invention has been made in view of the above circumstances, and its main purpose is to provide a rotating electric machine and a method for manufacturing a rotating electric machine that can be easily assembled. [Means for solving the problem]
[0007] A first means for solving the above problem is a rotating electric machine comprising a field magnet having a magnet portion containing a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature having a multiphase armature winding, wherein either the field magnet or the armature is used as a rotor, wherein the magnet portion comprises a plurality of magnets arranged in a line in the circumferential direction, and a magnet holding portion to which the plurality of magnets are fixed, wherein the magnets are oriented such that the direction of the easy magnetization axis is parallel to the d axis on the side of the d axis, which is the magnetic pole center, compared to the side of the q axis, which is the magnetic pole boundary, and a magnetic path is formed along the easy magnetization axis, and the plurality of magnets are fixed to the magnet holding surface of the magnet holding portion via an adhesive in a state where they are arranged in a line in the circumferential direction, and the magnets are separated at least along the d axis, and the gaps between adjacent magnets in the circumferential direction along the d axis are filled with a resin member.
[0008] This creates a gap along the d-axis, making it easier to fix the magnets to the magnet holder. Furthermore, by filling the gaps between the d-axis sides of the magnets with a resin material, the gaps between the magnets are eliminated, preventing circumferential misalignment.
[0009] A second means for solving the above problem is a method for manufacturing a rotating electric machine comprising a field magnet having a magnet portion containing a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature having a multiphase armature winding, wherein either the field magnet or the armature is used as a rotor, wherein the magnet portion comprises a plurality of magnets arranged in a line in the circumferential direction, and a magnet holding portion to which the plurality of magnets are fixed, and the magnets are divided along the d axis, and are oriented such that the direction of the easy magnetization axis is parallel to the d axis on the side of the d axis which is the magnetic pole center, compared to the side of the q axis which is the magnetic pole boundary, and along the easy magnetization axis A magnetic path is formed in the magnet, and the magnets are arranged alternately on the magnet holding surface of the magnet holding part along the circumferential direction, with a gap corresponding to the circumferential dimension of the magnets, and fixed with an adhesive, and the magnets are arranged in the gaps between each magnet formed in the first fixing step, with a predetermined gap between magnets between the d axes of adjacent magnets in the circumferential direction, and fixed with an adhesive, and the magnets are arranged in the gaps between each magnet formed in the first fixing step, and fixed with an adhesive, and the predetermined gaps between magnets formed in the second fixing step are filled with resin.
[0010] This creates a gap between magnets along the d-axis, making it easier to fix the magnets to the magnet holder. Furthermore, by filling the gaps between the d-axis sides of the magnets with resin, the gaps between the magnets are eliminated, preventing circumferential misalignment. In addition, since every other magnet is fixed in the first fixing step, it is easier to fix compared to fixing all the magnets at once.
[0011] A third means for solving the above problems is a method for manufacturing a rotating electric machine comprising a field magnet having a magnet portion containing a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature having a multiphase armature winding, wherein either the field magnet or the armature is used as a rotor, wherein the magnet portion comprises a plurality of magnets arranged in a line in the circumferential direction, and a magnet holding portion to which the plurality of magnets are fixed, the magnets are divided along the d axis and the q axis, and on the side of the d axis which is the magnetic pole center, the orientation of the easy magnetization axis is parallel to the d axis compared to the side of the q axis which is the magnetic pole boundary, and a magnetic path is formed along the easy magnetization axis, and the q axis side end face of the magnet The process includes: a bonding step of forming a magnetic couple by attracting them together with magnetic force; a first fixing step of arranging the magnetic couples alternately on the magnet holding surface of the magnet holding part so that a gap corresponding to the circumferential dimension of the magnetic couple is formed along the circumferential direction, and fixing them with an adhesive; a second fixing step of arranging the magnetic couples in the gaps between each magnetic couple formed in the first fixing step so that a predetermined gap between magnets is formed between the d axes of adjacent magnets in the circumferential direction, and fixing them with an adhesive to the magnet holding surface of the magnet holding part; and a filling step of filling the predetermined gap between magnets formed in the second fixing step with resin.
[0012] This creates a gap along the d-axis, making it easier to fix the magnets to the magnet holder. Furthermore, by filling the gaps between the magnets on their d-axis sides with resin, the gaps between the magnets are eliminated, preventing circumferential misalignment. In addition, since every other magnet coupler is fixed in the first fixing step, it is easier to fix compared to fixing all magnet couplers simultaneously. [Brief explanation of the drawing]
[0013] [Figure 1] A perspective view showing the entire rotating electric machine in the first embodiment. [Figure 2] Plan view of a rotating electric machine. [Figure 3] Longitudinal cross-sectional view of a rotating electric machine. [Figure 4] Cross-sectional view of a rotating electric machine. [Figure 5] Exploded cross-sectional view of a rotating electrical machine. [Figure 6] Cross-sectional view of a rotor. [Figure 7] Partial cross-sectional view showing the cross-sectional structure of a magnet unit. [Figure 8] Flowchart showing the process of manufacturing a magnet unit. [Figure 9] Cross-sectional view showing the manufacturing process of a magnet unit. [Figure 10] Perspective cross-sectional view showing a rotor carrier of a modified example. [Figure 11] Perspective view showing a ring member. [Figure 12] Perspective cross-sectional view showing a ring member. [Figure 13] (a) is a longitudinal end view showing a rotor carrier of a modified example, and (b) is a perspective view schematically showing a protrusion. [Figure 14] Cross-sectional view showing a magnet of a modified example.
Mode for Carrying Out the Invention
[0014] The rotating electrical machine in the present embodiment is used, for example, as a vehicle power source. However, the rotating electrical machine can be widely used for industrial, vehicle, aircraft, home appliance, OA equipment, gaming machine, etc. In addition, in the following embodiments, parts that are identical or equivalent to each other are denoted by the same reference numerals in the drawings, and the description of the parts with the same reference numerals is incorporated.
[0015] (First Embodiment) The rotating electrical machine 10 according to this embodiment is a synchronous polyphase AC motor and has an outer rotor structure (outer rotation structure). The outline of the rotating electrical machine 10 is shown in FIGS. 1 to 5. FIG. 1 is a perspective view showing the entire rotating electrical machine 10, FIG. 2 is a plan view of the rotating electrical machine 10, FIG. 3 is a longitudinal sectional view of the rotating electrical machine 10 (sectional view taken along line 3-3 of FIG. 2), FIG. 4 is a cross-sectional view of the rotating electrical machine 10 (sectional view taken along line 4-4 of FIG. 3), and FIG. 5 is an exploded sectional view showing the components of the rotating electrical machine 10 disassembled. In the following description, in the rotating electrical machine 10, the direction in which the rotating shaft 11 extends is defined as the axial direction, the direction extending radially from the center of the rotating shaft 11 is defined as the radial direction, and the direction extending circumferentially around the rotating shaft 11 is defined as the circumferential direction.
[0016] The rotating electrical machine 10 is roughly divided into a rotating electrical machine main body having a rotor 20, a stator unit 50, and a bus bar module 200, and a housing 241 and a housing cover 242 provided so as to surround the rotating electrical machine main body. All of these members are coaxially arranged with respect to a rotating shaft 11 provided integrally with the rotor 20, and the rotating electrical machine 10 is configured by being assembled axially in a predetermined order. The rotating shaft 11 is supported by a pair of bearings 12 and 13 provided in the stator unit 50 and the housing 241, respectively, and is rotatable in that state. The bearings 12 and 13 are, for example, radial ball bearings having an inner ring, an outer ring, and a plurality of balls arranged therebetween. When the rotating shaft 11 rotates, for example, the axle of a vehicle rotates. The rotating electrical machine 10 can be mounted on a vehicle by fixing the housing 241 to a vehicle body frame or the like.
[0017] In the rotating electrical machine 10, the stator unit 50 is provided so as to surround the rotating shaft 11, and the rotor 20 is arranged on the radially outer side of the stator unit 50. The stator unit 50 has a stator 60 and a stator holder 70 assembled to the radially inner side thereof. The rotor 20 and the stator 60 are arranged to face each other radially with an air gap interposed therebetween. When the rotor 20 rotates integrally with the rotating shaft 11, the rotor 20 rotates on the radially outer side of the stator 60. The rotor 20 corresponds to the "field magnet", and the stator 60 corresponds to the "armature".
[0018] The stator 60 has stator windings 61 and a stator core 62. The stator windings 61 correspond to the "armature windings". In this embodiment, the stator 60 has a slotless structure without teeth for forming slots, but teeth may be provided.
[0019] Figure 6 is a longitudinal cross-sectional view of the rotor 20. As shown in Figure 6, the rotor 20 has a substantially cylindrical rotor carrier 21 and an annular magnet unit 22 fixed to the rotor carrier 21. The rotor carrier 21 has a cylindrical portion 23 and an end plate portion 24 provided at one axial end of the cylindrical portion 23, and these are integrated together. The magnet unit 22 is fixed in an annular shape to the radially inner side of the cylindrical portion 23 of the rotor carrier 21. A through hole 24a is formed in the end plate portion 24, and the rotating shaft 11 is fixed to the end plate portion 24 by fasteners 25 such as bolts while inserted through the through hole 24a. The rotating shaft 11 has a flange 11a extending in a direction that intersects (orthogonal to) the axial direction, and the rotor carrier 21 is fixed to the rotating shaft 11 with the flange 11a and the end plate portion 24 in a surface-jointed state.
[0020] The magnet unit 22 includes a cylindrical magnet holder 31, a plurality of magnets 32 fixed to the inner circumferential surface of the magnet holder 31, and end plates 33 fixed on both axial sides, on the side opposite to the end plate portion 24 of the rotor carrier 21. In this embodiment, the magnet holder 31 corresponds to the "magnet holding portion," and the inner circumferential surface of the magnet holder 31 corresponds to the "magnet holding surface." The end plates 33 are formed in an annular shape and are configured to cover part or all of the axial end faces of the magnets 32 to prevent the magnets 32 from falling out. Each magnet 32 is fixed to the inner circumferential surface of the magnet holder 31 by adhesive 37.
[0021] The magnet holder 31 has the same length as the magnet 32 in the axial direction. The magnet 32 is mounted in a state where it is surrounded by the magnet holder 31 from the radially outer side. The magnet holder 31 and the magnet 32 are fixed in contact with the end plate 33 at one end on the axial side. The magnet unit 22 corresponds to the "magnet part".
[0022] Figure 7 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit 22. In Figure 7, the direction of the easy magnetization axis of the magnet 32 is indicated by an arrow.
[0023] In the magnet unit 22, the magnets 32 are arranged along the circumferential direction of the rotor 20 such that their polarity alternates. As a result, the magnet unit 22 has multiple magnetic poles in the circumferential direction. The magnets 32 are anisotropic permanent magnets, and are constructed using sintered neodymium magnets with an intrinsic coercivity of 400 [kA / m] or more and a residual magnetic flux density Br of 1.0 [T] or more.
[0024] In the magnet 32, the radially inner surface (towards the stator 60) is the magnetic flux acting surface 34 where magnetic flux is exchanged. The magnet unit 22 concentrates the magnetic flux in the region near the d-axis, which is the center of the magnetic pole, on the magnetic flux acting surface 34 of the magnet 32. Specifically, in the magnet 32, the orientation of the easy magnetization axis differs between the d-axis side (the part closer to the d-axis) and the q-axis side (the part closer to the q-axis). On the d-axis side, the easy magnetization axis is parallel to the d-axis, while on the q-axis side, the easy magnetization axis is perpendicular to the q-axis. In this case, an arc-shaped magnetic path is formed along the direction of the easy magnetization axis. In short, the magnet 32 is oriented such that on the d-axis side, which is the center of the magnetic pole, the orientation of the easy magnetization axis is parallel to the d-axis compared to the q-axis side, which is the magnetic pole boundary.
[0025] In magnet 32, the magnetic path is formed in an arc shape, resulting in a magnetic path length that is longer than the radial thickness of magnet 32. This increases the permeance of magnet 32, making it possible to achieve performance equivalent to that of a magnet with a larger magnetic mass, even with the same amount of magnetic force.
[0026] The magnets 32 are arranged so that two adjacent magnets in the circumferential direction form a pair to constitute one magnetic pole. In other words, the multiple magnets 32 arranged in the circumferential direction in the magnet unit 22 have split surfaces on the d axis and q axis, respectively, and each of these magnets 32 is positioned in contact with or close to each other. More specifically, on the d-axis side, each magnet 32 is positioned so that its d-axis side surfaces are slightly separated from each other, while on the q-axis side, its q-axis side surfaces are in contact with each other.
[0027] As described above, the magnet 32 has an arc-shaped magnetic path, and along the q-axis, the north and south poles of adjacent magnets 32 in the circumferential direction face each other. Therefore, the permeance near the q-axis can be improved. In addition, the magnets 32 on both sides of the q-axis attract each other, so these magnets 32 can maintain contact with each other. Therefore, this also contributes to improving the permeance.
[0028] In the magnet unit 22, the magnetic flux flows in an arc shape between adjacent N and S poles due to each magnet 32, resulting in a longer magnetic path compared to, for example, a radial anisotropic magnet. As a result, the magnetic flux density distribution is close to a sine wave. Consequently, unlike the magnetic flux density distribution of a radial anisotropic magnet, the magnetic flux can be concentrated towards the center of the magnetic pole, making it possible to increase the torque of the rotating electric machine 10. In other words, with each magnet 32 in the above configuration, the magnetic flux in the d-axis of the magnet unit 22 is strengthened, and the change in magnetic flux near the q-axis is suppressed. This makes it possible to suitably realize a magnet unit 22 in which the surface magnetic flux change from the q-axis to the d-axis is smooth at each magnetic pole.
[0029] The magnet 32 has a recess 35 formed on its radially outer circumferential surface within a predetermined range including the d-axis. In other words, on the d-axis side, the corners on the circumferential surface side of each magnet 32 are chamfered, and the d-axis side surfaces of each magnet 32 come into close proximity on the d-axis side, thereby forming a groove-shaped recess 35 along the axial direction.
[0030] In this case, depending on the orientation of the easy magnetization axis of the magnet 32, the magnetic path becomes shorter near the d-axis on the outer surface of the magnet 32. Therefore, considering that it becomes difficult to generate sufficient magnetic flux in the magnet 32 in areas where the magnetic path length is short, the magnet is removed in areas where the magnetic flux is weak.
[0031] Furthermore, the gap formed between the recess 35 and the d-axis side surface of the magnet 32 (hereinafter referred to as the gap between magnets 39) is filled with resin to form a resin member 38. In other words, the recess 35 and the gap between magnets 39 are filled with the resin member 38. This resin member 38 has a certain degree of elastic modulus and prevents circumferential displacement of the magnet 32.
[0032] Furthermore, the magnet 32 has a recess 36 formed on its radially inward inner circumferential surface (magnetic flux acting surface 34) within a predetermined range including the q-axis. In other words, on the q-axis side, the corners on the inner circumferential surface side of each magnet 32 are chamfered, and the q-axis side surfaces of each magnet 32 come into contact with each other on the q-axis side, thereby forming a groove-shaped recess 36 along the axial direction.
[0033] In this case, depending on the orientation of the magnetization axis of the magnet 32, the magnetic path becomes shorter near the q-axis on the inner circumferential surface of the magnet 32. Therefore, considering that it becomes difficult to generate sufficient magnetic flux in the magnet 32 in areas where the magnetic path length is short, the magnet is removed in areas where the magnetic flux is weak. In this embodiment, the recess 36 may or may not be formed.
[0034] Furthermore, the inner circumferential surface (armature side circumferential surface) of the magnet 32 is covered with a thin protective sheet 41 as a protective material. The protective sheet 41 is made of a non-magnetic metal or copper with low magnetic resistance. The protective sheet 41 may also be made of resin or the like.
[0035] Next, the manufacturing method of the magnet unit 22, which is part of the manufacturing method of the rotating electric machine in this embodiment, will be described.
[0036] First, let's briefly explain the manufacturing method of the magnets 32. Each magnet 32 is a sintered magnet manufactured by a sintering method. Specifically, raw materials such as neodymium, boron, and iron are melted and alloyed (first step). Next, the alloy obtained in the first step is crushed into particles (second step). Then, the powder obtained in the second step is placed in a mold and pressure-molded in a magnetic field (third step). Molding in this mold gives the cross-sectional shape of the magnet 32 a roughly arc shape. After pressure molding, the molded product is sintered (fourth step), and after sintering is complete, it is heat-treated (fifth step). The heat treatment involves heating and cooling several times. Then, machining such as grinding and surface treatment are performed (sixth step). After that, the magnets are magnetized (seventh step), and each magnet 32 is completed.
[0037] Next, the process of assembling the completed magnets 32 to form the magnet unit 22 will be explained with reference to Figures 8 and 9.
[0038] First, as shown in Figure 9(a), a coupling process (step S11) is performed in which the q-axis end faces of the magnetized magnets 32 are attracted to each other by magnetic force to form a magnetic coupler 81.
[0039] Next, as shown in Figure 9(b), a first fixing step (step S12) is performed in which the magnet couplers 81 are placed alternately on the inner circumferential surface (magnet holding surface) of the magnet holder 31 along the circumferential direction, such that a gap 82 corresponding to the circumferential dimension of the magnet coupler 81 is formed, and then fixed with adhesive 37. In the first fixing step, half of the magnet couplers 81 are fixed. Note that although a room-temperature adhesive (for example, an adhesive that hardens at an ambient temperature of 50 degrees Celsius or less) is used as the adhesive 37, any adhesive may be used, and a thermosetting adhesive may also be used. A resin adhesive may also be used. Alternatively, an adhesive sheet may be used. The elastic modulus of this adhesive 37 is preferably 500 MPa or less at 20°C.
[0040] In the first fixing step, the remaining magnet assemblies 81 are placed in the gaps 82 between each magnet assembly 81 formed in the first fixing step, as shown in Figure 9(c), and the second fixing step (step S13) is performed in which these magnet assemblies 81 are fixed to the inner circumferential surface of the magnet holder 31 with adhesive 37.
[0041] In the second fixing step, when placing another magnet coupler 81 in the gap 82 between every other magnet coupler 81, the like poles face each other along the d-axis, causing the adjacent (newly placed) magnet coupler 81 to repel each other. Therefore, in this embodiment, each newly placed magnet 32 is held in place by a jig or the like to prevent the magnet coupler 81 from moving until the adhesive 37 hardens. As mentioned above, the d-axis sides of each magnet 32 repel each other along the d-axis, causing them to separate and forming a gap 39 between the magnets. This gap 39 between each magnet 32 communicates with the recess 35, as shown in Figure 9(c).
[0042] Subsequently, a filling process (step S14) is performed to fill the gaps 39 between the magnets and the recesses 35 with resin. In this filling process, resin is poured into the recesses 35 formed on the outer circumferential surface side (anti-armature side) of each magnet 32 on the d-axis side, causing the resin to flow into the gaps 39 between the magnets that communicate with the recesses 35, thereby filling them with resin. As a result, a resin member 38 is formed between the d-axis side surfaces of the magnets 32.
[0043] After the filling process, a protective process (step S15) is performed in which the inner surface of the magnet 32 is covered with a protective sheet 41. This completes the magnet unit 22 as shown in Figure 7. After the completion of the magnet unit 22, the rotor 20 is assembled by attaching it to the rotor carrier 21, and the rotating electric machine 10 is completed by combining the rotor 20 with the stator unit 50, etc.
[0044] According to the first embodiment described above, the following effects can be obtained.
[0045] The magnet 32 is oriented such that the direction of its easy magnetization axis is parallel to the d-axis on the d-axis side, which is the magnetic pole center, compared to the direction of the q-axis side, which is the magnetic pole boundary, and a magnetic path is formed along the easy magnetization axis. The magnet 32 is divided along the d-axis and the q-axis. As a result, the q-axis side surfaces of the magnet 32 are attracted to each other by magnetic force, while the d-axis side surfaces are repelled by magnetic force.
[0046] Therefore, when fixing the magnet 32 to the inner circumferential surface of the magnet holder 31, the q-axis sides of the magnets 32 are attracted to each other, while the d-axis sides are spaced apart. This makes it easier to fix the magnet 32 to the magnet holder 31. In addition, by filling the gap 39 between the d-axis sides of the magnets 32 with resin and forming a resin member 38, there is no gap between the magnets 32, and circumferential displacement can be prevented. As a result, the magnets 32 do not shift circumferentially, and circumferential stress is not applied to the adhesive 37, which weakens the adhesive force and prevents the magnets 32 from falling off.
[0047] On the d-axis side of each magnet 32, the corners of the outer circumferential surface (anti-armature side) are chamfered to form recesses 35 along the axial direction. A resin member 38 is then positioned to fill these recesses 35. This allows the resin member 38 to have a certain thickness in the circumferential direction, enabling it to effectively function as a rotation stopper for the magnet 32 in the circumferential direction. Furthermore, on the d-axis side of each magnet 32, the corners of the outer circumferential surface (anti-armature side) are areas where the magnetic path tends to be shortened. Therefore, removing these corners has little impact on the magnetic flux density, allowing for a suitable reduction in the amount of magnet.
[0048] When assembling the magnet unit 22, first, in the joining process, the q-axis end faces of the magnets 32 are attracted to each other by magnetic force to form the magnet coupler 81. Therefore, compared to the case where the magnets 32 are placed individually, the q-axis end faces of the magnets 32 are attracted to each other, preventing misalignment in the circumferential direction and making assembly easier.
[0049] Furthermore, in the first fixing step, the magnet couplers 81 are placed on the inner circumferential surface of the magnet holder 31, with every other coupler positioned along the circumferential direction, such that a gap 82 corresponding to the circumferential dimension of the magnet coupler 81 is formed, and then fixed with adhesive 37. In other words, since the magnet couplers 81 with the same poles are not placed along the d-axis and fixed with adhesive 37, the fixing is easier compared to fixing them while they are adjacent to each other.
[0050] Subsequently, the remaining magnet couplers 81 are placed in the gaps 82 between each magnet coupler 81 formed in the first fixing step and fixed to the magnet holder 31 with adhesive 37. In other words, since one of the magnet couplers 81 that are adjacent in the d-axis and have the same poles is already fixed, it can be fixed more easily compared to the case where both must be held in place until adhesive is applied.
[0051] Furthermore, in the filling process, resin is filled into the recess 35 formed on the outer surface side (anti-armature side) of each magnet 32 on the d-axis side, thereby filling the gap 39 between magnets that communicates with the recess 35 with resin. Therefore, even if the gap 39 between magnets formed on the d-axis side is small, it is easy to fill it with resin.
[0052] Furthermore, the inner surface (armature side surface) of each magnet 32 is covered by a protective sheet 41, and the axial end surface is covered by an end plate 33. This effectively prevents the magnets 32 from falling off.
[0053] (modified version) Some parts of the configuration of the above embodiment may be changed. The following describes some modified examples.
[0054] In the above embodiment, the shapes of the magnet holder 31 and the rotor carrier 21 may be changed. For example, the magnet holder 31 may be integrated with the cylindrical portion 23 of the rotor carrier 21. That is, the magnet 32 may be fixed to the inner circumferential surface of the cylindrical portion 23. This cylindrical portion 23 of the rotor carrier 21 corresponds to the magnet holding portion.
[0055] Alternatively, as shown in Figure 10, a rotor carrier 121 may be adopted that is configured as a bottomed cylindrical shape and has a flange portion 121a that extends radially outward at the outer edge of the opening. In this case, a magnet unit 22 such as a magnet 32 will be fixed to the inner circumferential surface of the cylindrical portion 123 of the rotor carrier 121.
[0056] In the above embodiment, the configuration of the protective sheet 41 covering the inner circumferential surface of the magnet 32 may be arbitrarily changed. For example, as shown in Figure 11, a ring member 141 made of a non-magnetic metal may be press-fitted into the inner circumferential surface of the magnet unit 22 to cover the inner circumferential surface of the magnet unit 22. By press-fitting into the inner circumferential surface of the magnet unit 22, the magnet 32 is pressed radially outward, and the magnet 32 can be pressed against the inner circumferential surface (magnet holding surface) of the magnet holder 31 (or rotor carrier 121). This effectively prevents the magnet 32 from falling out.
[0057] Furthermore, as shown in Figure 11, a flange portion 142 may be provided on the outer circumference of one end of the ring member 141 in the axial direction. In this case, as shown in Figure 12, by press-fitting the flange portion 142 onto the inner circumferential surface of the magnet 32, the axial end face of the magnet 32 can be covered by the flange portion 142, thereby preventing it from falling off. The ring member 141 can be fixed by fixing the flange portion 142 to the flange portion 121a of the rotor carrier 121 by adhesive or the like.
[0058] Furthermore, a flange portion 143 may be provided on the inner circumference of the other end of the ring member 141. In this case, the ring member 141 can be more firmly fixed by fixing the flange portion 142 to the bottom portion 121b of the rotor carrier 121 by adhesive or the like. If a gap is formed between the ring member 141 and the magnet 32 (for example, between the flange portion 142 and the axial end face of the magnet 32), it is desirable to fill it with resin or the like.
[0059] Furthermore, although the ring member 141 was configured in an annular shape in this modified example, it may also be C-shaped with a portion interrupted. Alternatively, the ring member 141 may be divided into multiple parts in the circumferential direction.
[0060] In the above embodiment, the magnet 32 may be divided in the axial direction, and the gap in the axial direction may be insulated by resin filling, bonding, plating or painting, etc.
[0061] In the above embodiment, one axial end of the protective sheet 41 may be fixed to the flange portion 121a of the rotor carrier 121 by adhesive or the like, similar to the ring member 141 described above. Similarly, the other axial end of the protective sheet 41 may be fixed to the bottom portion 121b of the rotor carrier 121 by adhesive or the like. This makes it possible to fix it more firmly.
[0062] In the above embodiment, an end plate 33 is provided at one axial end of the magnet unit 22 to prevent it from falling off. However, the magnet holder 31 or rotor carriers 21, 121 may be provided with a projection that engages with the axial end of the magnet 32 and restricts the movement of the magnet 32 in the axial direction. For example, as shown in Figure 13, a projection 151 that restricts the movement of the magnet unit 22 in the axial direction may be provided at the open end of the rotor carrier 21. It is desirable that this projection 151 be crimped and fixed to the axial end face side of the magnet 32 after the magnet 32 has been fixed.
[0063] In the above embodiment, the protective sheet 41 may be made of resin, and the protective sheet 41 and the resin member 38 may be formed as a single unit. That is, the inner circumferential surface (armature side circumferential surface) of the magnet 32 may be entirely covered with resin, and the gaps 39 between the magnets 32 and the recesses 35 may be filled with resin. In the above embodiment, the inner circumferential surface (armature side circumferential surface) of the magnet 32 may be painted to form a protective sheet. In the above embodiment, since the q-axis sides of the magnets are in contact with each other, surface treatment (such as rust prevention treatment) is not required for the q-axis sides of the magnets.
[0064] In the above embodiment, the magnet 32 is divided along the d-axis and the q-axis, but it may also be configured to be divided along only the d-axis. That is, a magnet corresponding to the magnet coupling 81 may be used in which both ends of the magnet 32 are the d-axis in the circumferential direction and the center is the q-axis. In other words, the magnet 32 may be provided with one magnet between the d-axis, which is the center of each magnetic pole, for two adjacent magnetic poles in the circumferential direction. In this case, the coupling process (step S11) can be omitted when assembling the magnet unit 22. Note that the other assembly steps are the same as in the above embodiment, so their explanation will be omitted. This makes assembly easier.
[0065] In the above embodiment, an adhesive reservoir, which is a space where adhesive 37 accumulates, may be provided between the d-axis and the q-axis. That is, the outer circumferential surface of the magnet 32 (the surface facing the inner circumferential surface of the magnet holder 31) is formed with the same curvature as the inner circumferential surface of the magnet holder 31. On the other hand, a part of the outer circumferential surface of the magnet 32 is configured to be radially separated from the inner circumferential surface (magnet holding surface) of the magnet holder 31. For example, as shown in Figure 14, a flat portion is provided in the central part (the intermediate part between the d-axis and the q-axis) of the outer circumferential surface of the magnet 32, which is radially separated from the inner circumferential surface (magnet holding surface) of the magnet holder 31, and is configured to form a gap between it and the inner circumferential surface of the magnet holder 31. The gap thus formed is used as an adhesive reservoir 160. This makes it possible to make the adhesive force stronger. Note that in Figure 14, the adhesive reservoir 160 is emphasized in order to make the explanation easier to understand. [Explanation of Symbols]
[0066] 10...Rotating electric machine, 20...Rotor, 22...Magnet unit, 31...Magnet holder, 32...Magnet, 37...Adhesive, 38...Resin component, 60...Stator, 61...Stator winding, 81...Magnet assembly.
Claims
1. A rotating electric machine (10) comprising a field magnet (20) having a magnet portion (22) containing multiple magnetic poles with alternating polarities in the circumferential direction, and an armature (60) having a multiphase armature winding (61), wherein either the field magnet or the armature is used as a rotor, The aforementioned magnet section comprises a plurality of magnets (32) arranged in a circumferential direction, and a magnet holding section (31) to which the plurality of magnets are fixed. The magnet is oriented such that, on the side of the d-axis, which is the center of the magnetic pole, the direction of the easy magnetization axis is parallel to the d-axis compared to the side of the q-axis, which is the boundary of the magnetic pole, and a magnetic path is formed along the easy magnetization axis. The magnet holder portion is fixed to its magnet holder surface via an adhesive (37) with a plurality of magnets arranged in a circumferential direction. The magnets are separated at least along the d-axis, and the gaps (39) between adjacent magnets in the circumferential direction along the d-axis are filled with a resin member (38). The magnet portion has protective members (41, 141) that cover and protect the armature-side circumferential surface of the magnet. The protective member is in pressure contact with the magnet such that it presses the magnet toward the magnet holding portion in the radial direction, The protective member is a rotating electric machine having a flange portion (142) that protrudes radially on at least one of its axial ends so as to cover the axial end face of the magnet portion.
2. A rotating electric machine (10) comprising a field magnet (20) having a magnet portion (22) containing multiple magnetic poles with alternating polarities in the circumferential direction, and an armature (60) having a multiphase armature winding (61), wherein either the field magnet or the armature is used as a rotor, The aforementioned magnet section comprises a plurality of magnets (32) arranged in a circumferential direction, and a magnet holding section (31) to which the plurality of magnets are fixed. The magnet is oriented such that, on the side of the d-axis, which is the center of the magnetic pole, the direction of the easy magnetization axis is parallel to the d-axis compared to the side of the q-axis, which is the boundary of the magnetic pole, and a magnetic path is formed along the easy magnetization axis. The magnet holder portion is fixed to its magnet holder surface via an adhesive (37) with a plurality of magnets arranged in a circumferential direction. The magnets are separated at least along the d-axis, and the gaps (39) between adjacent magnets in the circumferential direction along the d-axis are filled with a resin member (38). The magnet portion has a protective member (141) that covers and protects the armature-side circumferential surface of the magnet. The protective member is a rotating electric machine having a flange portion (142) that protrudes radially on at least one of its axial ends so as to cover the axial end face of the magnet portion.
3. A rotating electric machine (10) comprising a field magnet (20) having a magnet portion (22) containing multiple magnetic poles with alternating polarities in the circumferential direction, and an armature (60) having a multiphase armature winding (61), wherein either the field magnet or the armature is used as a rotor, The aforementioned magnet section comprises a plurality of magnets (32) arranged in a circumferential direction, and a magnet holding section (31) to which the plurality of magnets are fixed. The magnet is oriented such that, on the side of the d-axis, which is the center of the magnetic pole, the direction of the easy magnetization axis is parallel to the d-axis compared to the side of the q-axis, which is the boundary of the magnetic pole, and a magnetic path is formed along the easy magnetization axis. The magnet holder portion is fixed to its magnet holder surface via an adhesive (37) with a plurality of magnets arranged in a circumferential direction. The magnets are separated at least along the d-axis, and the gaps (39) between adjacent magnets in the circumferential direction along the d-axis are filled with a resin member (38). The magnet portion has a protective member that covers and protects the entire circumferential surface on the armature side of the magnet. The protective member is made of resin and is integrated with a resin member that fills the gap between the magnets in the d-axis of the rotating electric machine.
4. The magnet portion has a protective member that covers and protects the armature-side circumferential surface of the magnet. The rotating electric machine according to claim 1 or 2, wherein the protective member is made of resin and is integrated with a resin member that fills the gap between the magnets in the d-axis.
5. A rotating electric machine (10) comprising a field magnet (20) having a magnet portion (22) containing multiple magnetic poles with alternating polarities in the circumferential direction, and an armature (60) having a multiphase armature winding (61), wherein either the field magnet or the armature is used as a rotor, The aforementioned magnet section comprises a plurality of magnets (32) arranged in a circumferential direction, and a magnet holding section (31) to which the plurality of magnets are fixed. The magnet is oriented such that, on the side of the d-axis, which is the center of the magnetic pole, the direction of the easy magnetization axis is parallel to the d-axis compared to the side of the q-axis, which is the boundary of the magnetic pole, and a magnetic path is formed along the easy magnetization axis. The magnet holder portion is fixed to its magnet holder surface via an adhesive (37) with a plurality of magnets arranged in a circumferential direction. The magnets are separated at least along the d-axis, and the gaps (39) between adjacent magnets in the circumferential direction along the d-axis are filled with a resin member (38). The opposing surface of the magnet facing the magnet holding surface is spaced radially apart from the magnet holding surface of the magnet holding part between the d axis and the q axis, and the gap thus formed is used as an adhesive reservoir (160) in a rotating electric machine.
6. A rotating electric machine (10) comprising a field magnet (20) having a magnet portion (22) containing multiple magnetic poles with alternating polarities in the circumferential direction, and an armature (60) having a multiphase armature winding (61), wherein either the field magnet or the armature is used as a rotor, The aforementioned magnet section comprises a plurality of magnets (32) arranged in a circumferential direction, and a magnet holding section (31) to which the plurality of magnets are fixed. The magnet is oriented such that, on the side of the d-axis, which is the center of the magnetic pole, the direction of the easy magnetization axis is parallel to the d-axis compared to the side of the q-axis, which is the boundary of the magnetic pole, and a magnetic path is formed along the easy magnetization axis. The magnet holder portion is fixed to its magnet holder surface via an adhesive (37) with a plurality of magnets arranged in a circumferential direction. The magnets are separated at least along the d-axis, and the gaps (39) between adjacent magnets in the circumferential direction along the d-axis are filled with a resin member (38). The magnet portion has protective members (41, 141) that cover and protect the armature-side circumferential surface of the magnet. The protective member is in pressure contact with the magnet such that it presses the magnet toward the magnet holding portion in the radial direction. The opposing surface of the magnet facing the magnet holding surface is spaced radially apart from the magnet holding surface of the magnet holding part between the d axis and the q axis, and the gap thus formed is used as an adhesive reservoir (160) in a rotating electric machine.
7. The rotating electric machine according to any one of claims 1 to 5, wherein the opposing surface of the magnet facing the magnet holding surface of the magnet is spaced radially apart from the magnet holding surface of the magnet holding part between the d axis and the q axis, and the gap thus formed is used as an adhesive reservoir (160).
8. The rotating electric machine according to any one of claims 1 to 7, wherein the magnets are separated in the d-axis and the q-axis, and adjacent magnets in the circumferential direction along the q-axis are fixed in contact with each other.
9. The rotating electric machine according to any one of claims 1 to 8, wherein the corner on the d-axis side of each magnet, on the side opposite the armature, is chamfered to form a recess (35) along the axial direction.
10. A method for manufacturing a rotating electric machine (10) comprising a field magnet (20) having a magnet portion (22) containing a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature (60) having a multiphase armature winding (61), wherein either the field magnet or the armature is used as a rotor, The aforementioned magnet section comprises a plurality of magnets (32) arranged in a circumferential direction, and a magnet holding section (31) to which the plurality of magnets are fixed. The magnet is divided along the d-axis, and is oriented such that the direction of the easy magnetization axis is parallel to the d-axis on the side of the d-axis, which is the magnetic pole center, compared to the side of the q-axis, which is the magnetic pole boundary, and a magnetic path is formed along the easy magnetization axis. The first fixing step (S12) involves arranging the magnets alternately on the magnet holding surface of the magnet holding part so that a gap (82) corresponding to the circumferential dimension of the magnets is formed along the circumferential direction, and fixing them with an adhesive. A second fixing step (S13) involves arranging the magnets in the gaps formed between each magnet in the first fixing step so that a predetermined gap is formed between the d axes of adjacent magnets in the circumferential direction, and fixing them to the magnet holding surface of the magnet holding part with an adhesive. A method for manufacturing a rotating electric machine, comprising a filling step (S14) of filling a predetermined gap between magnets formed in the second fixing step with resin.
11. A method for manufacturing a rotating electric machine (10) comprising a field magnet (20) having a magnet portion (22) containing a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature (60) having a multiphase armature winding (61), wherein either the field magnet or the armature is used as a rotor, The aforementioned magnet section comprises a plurality of magnets (32) arranged in a circumferential direction, and a magnet holding section (31) to which the plurality of magnets are fixed. The magnet is divided along the d-axis and the q-axis, and is oriented such that the direction of the easy magnetization axis is parallel to the d-axis on the d-axis side, which is the magnetic pole center, compared to the direction of the easy magnetization axis on the q-axis side, which is the magnetic pole boundary, and a magnetic path is formed along the easy magnetization axis. A coupling step (S11) is performed to form a magnetic coupling body (81) by attracting the q-axis end faces of the aforementioned magnets together by magnetic force, A first fixing step (S12) involves arranging the magnet assemblies alternately on the magnet holding surface of the magnet holding portion so that a gap (82) corresponding to the circumferential dimension of the magnet assemblies is formed along the circumferential direction, and fixing them with an adhesive. In the second fixing step (S13), the magnet assemblies are placed in the gaps between each magnet assembly formed in the first fixing step so that a predetermined gap between magnets is formed between the d axes of adjacent magnets in the circumferential direction, and then fixed to the magnet holding surface of the magnet holding part with an adhesive. A method for manufacturing a rotating electric machine, comprising a filling step (S14) of filling a predetermined gap between magnets formed in the second fixing step with resin.
12. On the d-axis side of each of the aforementioned magnets, the corner on the anti-armature side is chamfered to form a recess (35) along the axial direction. The method for manufacturing a rotating electric machine according to claim 10 or 11, wherein in the filling step, resin is filled into the recess formed on the anti-armature side on the d-axis side of each magnet, thereby filling the gap between the magnets formed between the d-axis with resin.