Magnetic pole piece module, production method for magnetic pole piece module, and magnetic geared rotary machine

Abstract

Provided is a magnetic pole piece module having high bonding strength.　This magnetic pole piece module (2) comprises: a plurality of magnetic pole pieces (21) that are disposed in annular arrangement and spaced apart from each other; a positioning component (24) that determines the positions of the plurality of magnetic pole pieces in the circumferential direction; and a molded resin (22) that is disposed between the plurality of magnetic pole pieces disposed spaced apart from each other and integrates the plurality of magnetic pole pieces and the positioning component. The material of the positioning component and the material of the molded resin are the same.

Description

Pole piece module, manufacturing method of pole piece module, and magnetic-geared rotating machine

[0001] The present disclosure relates to a pole piece module, a method for manufacturing a pole piece module, and a magnetic-geared rotating machine.

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

[0003] The low-speed rotor is composed of a pole piece module with multiple pole pieces arranged at equal intervals in a circular ring shape. The inner and outer diameter sides of this pole piece module face the high-speed rotor and stator, respectively, via gaps. If the radial and circumferential positioning accuracy of the pole pieces is low, it is necessary to increase the gap. However, increasing the gap poses the problem of reduced torque transmission efficiency.

[0004] In a conventional pole piece module with improved pole piece positioning accuracy, the pole pieces are disposed between cylindrical outer and inner cover members to determine their radial and circumferential positions (see, for example, Patent Document 1). Another pole piece module is disclosed that includes a cylindrical frame with equally spaced gaps, and the pole pieces are inserted into the gaps in the frame to determine their radial and circumferential positions (see, for example, Patent Document 2).

[0005] JP 2021-116843 A International Publication No. 2022 / 118598

[0006] In conventional pole piece modules, the position of the pole piece is determined by positioning members such as a cover member and a frame that define the position of the pole piece. These positioning members are fixed to a shaft that supports the pole piece module using a fixing member such as resin. In conventional pole piece modules, the positioning member and the fixing member are made of different materials, which causes a problem of reduced joint strength due to differences in thermal expansion coefficients, etc.

[0007] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a pole piece module with high bonding strength.

[0008] The pole piece module of the present disclosure comprises a plurality of pole pieces arranged spaced apart in a ring shape, a positioning component that determines the circumferential positions of the plurality of pole pieces, and a molded resin that is arranged between the plurality of spaced apart pole pieces and integrates the plurality of pole pieces and the positioning component, and the material of the positioning component is the same as that of the molded resin.

[0009] In the pole piece module of the present disclosure, the positioning components and the molded resin are made of the same material, resulting in a pole piece module with high bonding strength.

[0010] 1 is a cross-sectional view of a magnetic-geared rotating machine according to embodiment 1. FIG. 1 is a cross-sectional view of a magnetic-geared rotating machine according to embodiment 1. FIG. 2 is a perspective view of a pole piece module according to embodiment 1. FIG. 3 is a cross-sectional view of a pole piece module according to embodiment 1. FIG. 4 is a cross-sectional view of a pole piece module according to embodiment 1. FIG. 5 is a cross-sectional view of a pole piece module according to embodiment 1. FIG. 6 is a side view of a pole piece module according to embodiment 1. FIG. 7 is a perspective view of a positioning component according to embodiment 1. FIG. 8 is an enlarged perspective view of a positioning component according to embodiment 1. FIG. 9 is a perspective view of a pole piece according to embodiment 1. FIG. 10 is a cross-sectional view of a mold for manufacturing the pole piece module according to embodiment 1. FIG. 11 is a see-through perspective view of a bottom plate according to embodiment 1. FIG. 12 is a side view of a core according to embodiment 1. FIG. 13 is a side view of an outer frame according to embodiment 1. FIG. 14 is a diagram for explaining a method for manufacturing the pole piece module according to embodiment 1. FIG. 15 is a perspective view of a positioning component according to embodiment 3. FIG. 16 is a perspective view of a positioning component according to embodiment 4. FIG. 17 is a perspective view of a positioning component according to embodiment 5. FIG. 18 is a flowchart showing the steps of manufacturing a pole piece module according to embodiment 5.

[0011] A pole piece module and a magnetic-geared rotating machine according to embodiments of the present disclosure will be described in detail below with reference to the drawings. Note that the same reference numerals in each drawing indicate the same or corresponding parts. In the following description, the magnetic-geared rotating machine will be described as a magnetic speed reducer. However, the same applies when the magnetic-geared rotating machine is a magnetic speed increaser or a magnetic-geared rotating electric machine.

[0012] Embodiment 1. Figure 1 is a cross-sectional view of a magnetic-geared rotating machine according to embodiment 1. Figure 1 is a cross-sectional view of a plane perpendicular to the inner rotor shaft. The magnetic-geared rotating machine 10 of this embodiment has an inner rotor 1, a pole piece module 2, and an outer rotor 3. The inner rotor 1 has an inner rotor shaft 11 serving as a rotation axis, an inner rotor core 12 fixed to the outer diameter side of the inner rotor shaft 11, and a plurality of inner rotor magnets 13 arranged at equal intervals on the outer peripheral surface of the inner rotor core 12. Note that, hereinafter, the direction parallel to the inner rotor shaft 11 is referred to as the axial direction, the direction perpendicular to the inner rotor shaft 11 is referred to as the radial direction, and the direction rotating around the inner rotor shaft 11 is referred to as the circumferential direction. In addition, in the radial direction, the direction away from the inner rotor shaft 11 is referred to as the outer diameter side, and the opposite direction is referred to as the inner diameter side.

[0013] The pole piece module 2 has a plurality of pole pieces 21 and molded resin 22 for fixing the plurality of pole pieces 21. The outer rotor 3 has a cylindrical outer rotor core 31 and a plurality of outer rotor magnets 32 arranged at equal intervals on the inner circumferential surface of the outer rotor core 31. In the magnetic-geared rotating machine 10 of this embodiment, the inner rotor 1, pole piece module 2, and outer rotor 3 are arranged in this order from the inner diameter side with gaps between them. The inner rotor 1, pole piece module 2, and outer rotor 3 are also arranged coaxially with the inner rotor shaft 11 as the central axis.

[0014] The inner rotor core 12, the pole pieces 21, and the outer rotor core 31 are made of, for example, magnetic steel sheets stacked in the axial direction. The inner rotor magnet 13 and the outer rotor magnet 32 ​​are permanent magnets.

[0015] FIG. 2 is a cross-sectional view of the magnetic-geared rotating machine according to this embodiment. FIG. 2 is a cross-sectional view taken along the line A-A in FIG. 1 . The pole piece module 2 is fixed at both axial ends by a non-magnetic member 23 made of resin, aluminum, or the like. This non-magnetic member 23 is fixed to an external frame (not shown) of the outer rotor 3. The multiple pole pieces 21 of the pole piece module 2 transmit magnetic flux from the inner rotor 1 to the outer rotor 3, or from the outer rotor 3 to the inner rotor 1. Note that the pole pieces 21 in this embodiment are made of electromagnetic steel sheets stacked in the axial direction. As long as the pole pieces 21 are made of a magnetic material, they may be made of electromagnetic steel sheets stacked in the radial direction, or may be powder iron cores.

[0016] The inner rotor shaft 11 and the inner rotor core 12 are integrally formed. The inner rotor shaft 11 extends outward from one axial end. The inner rotor 1 is disposed on the inner diameter side of the non-magnetic member 23 via a bearing 41. The outer rotor shaft 33 is formed integrally with the outer rotor core 31 at the other axial end of the outer rotor core 31. The center of rotation of the inner rotor shaft 11 and the center of rotation of the outer rotor shaft 33 are the same. The outer rotor 1 is disposed on the outer diameter side of the non-magnetic member 23 via a bearing 41.

[0017] Let Nh be the number of pole pairs of the inner rotor magnet 13 of the inner rotor 1, Np be the number of magnetic poles of the pole pieces of the pole piece module 2, and Nl be the number of pole pairs of the outer rotor magnet 32 ​​of the outer rotor 3. In the magnetic-geared rotating machine of this embodiment, the relationship Np = Nl + Nh holds. In this case, if Gr is the reduction ratio, then Gr = Nl / Nh. The rotational speed of the inner rotor 1 is multiplied by 1 / Gr and transmitted to the outer rotor 3, and the torque of the inner rotor 1 is multiplied by Gr and transmitted to the outer rotor 3. In the magnetic-geared rotating machine of this embodiment, for example, if Nh = 4, Np = 30, and Nl = 26, then Gr = 6.5. The reduction ratio equation also holds even if the relationship Np = Nl - Nh holds.

[0018] In the magnetic-geared rotating machine of this embodiment, the pole piece modules 2 are fixed and do not rotate. The inner rotor 1 and the outer rotor 3 rotate in the same direction, and rotational force is transmitted from the inner rotor 1 to the outer rotor 3. When the pole piece modules 2 are fixed, the transmitted torque is lower than when they are not fixed, i.e., when the outer rotor 3 is fixed and the pole piece modules 2 rotate. However, because the pole piece modules 2 are fixed, centrifugal force is not applied to the pole piece modules 2, so measures to counteract centrifugal force are not necessary. For example, connecting components to counter centrifugal force are not required on the outer or inner surfaces of the pole pieces 21. This allows the inner rotor 1 and the outer rotor 3 to be positioned with a minimum gap width across the pole piece modules 2, which improves magnetic flux density and transmission torque.

[0019] Although the magnetic-geared rotating machine of this embodiment shown in FIGS. 1 and 2 is a cylindrical rotating type device, it may also be a disk rotating type, a flat linear type, or a cylindrical linear type device.

[0020] Next, the pole piece module of the magnetic-geared rotating machine of this embodiment will be described in detail. Fig. 3 is a perspective view of the pole piece module according to this embodiment. As shown in Fig. 3, in the axial center portion of the pole piece module 2 of this embodiment, pole pieces 21 and molded resin 22 are arranged alternately in the circumferential direction. Positioning components 24 are arranged at both axial ends of the pole pieces 21. The positioning components 24 will be described later.

[0021] FIG. 4 is a cross-sectional view of a pole piece module according to this embodiment. FIG. 4 is a cross-sectional view of a plane perpendicular to the axial direction at the position indicated by B-B in FIG. 3. As shown in FIG. 4, the pole pieces 21 and the molded resin 22 are alternately arranged in the circumferential direction in the central portion of the pole piece module according to this embodiment. FIG. 5 is a cross-sectional view of the pole piece module taken at a position intersecting the pole pieces indicated by C-C in FIG. 4. Note that FIG. 5 is a view immediately after the molded resin 22 has been molded. FIG. 6 is a cross-sectional view of the pole piece module taken at a position intersecting the molded resin indicated by D-D in FIG. 4. As shown in FIG. 5, the positioning components 24 are arranged at both ends of the pole pieces in the axial direction, and the molded resin 22 is in contact with the pole pieces 21 and the positioning components 24. For convenience, the molded resin 22 will be described below as a first molded resin 22a, a second molded resin 22b, and a third molded resin 22c, based on the positions at which the molded resin 22 is arranged. At both axial ends of the pole piece 21, first molded resin 22a is arranged axially between the protrusions of positioning components 24 (described later), i.e., in the circumferential gaps of the pole piece 21. In addition, second molded resin 22b is arranged on the outer diameter side of the first molded resin 22a. And third molded resin 22c is arranged on the outer diameter side of the positioning components 24 arranged at both axial ends of the pole piece 21. In addition, third molded resin 22c is arranged on both axial ends of the second molded resin 22b.

[0022] 5, the inner diameter side surface and the outer diameter side surface of the pole piece 21 may or may not be in contact with the mold resin 22, and may be molded or machined to ensure the required strength. On the other hand, if the pole piece 21 and the positioning component 24 are flush with each other on the inner diameter side, i.e., if the positioning component 24 is also disposed on the inner circumferential surface of the pole piece in a cross section perpendicular to the axial direction, the mold resin will not flow into the gap between the pole piece and the mold core 52, which is located axially between the positioning components located on both sides in the axial direction, and therefore the inner circumferential surface of the pole piece module can be finished with the precision of the mold, and the surface to be machined to the required dimensions can be reduced.

[0023] Figure 7 is a side view seen from side E in Figure 6. The surface on side E is the surface that will be processed after molding. As shown in Figure 7, the boundary line between the positioning component 24 and the molded resin 22 is on the processed surface that is processed after molding. Since the boundary line between the positioning component 24 and the molded resin 22 is on the processed surface, the positioning component 24 and the molded resin 22 are made of the same material, which not only results in high joint strength and no deformation due to processing, but also eliminates the need to change processing conditions depending on the material, which has the effect of preventing deterioration of processing tools.

[0024] FIG. 8 is a perspective view of a positioning component according to this embodiment. As shown in FIG. 8, the positioning component 24 according to this embodiment is composed of a cylindrical main body 24a and a plurality of protrusions 24b protruding from one axial end of the main body 24a. The plurality of protrusions 24b protrude from the main body 24a in a direction parallel to the axial direction. The plurality of protrusions 24b are also arranged at equal intervals in the circumferential direction. FIG. 9 is an enlarged view of the positioning component according to this embodiment. As shown in FIG. 9, the circumferential width of the protrusions 24b of the positioning component decreases from the outer diameter side toward the inner diameter side. The positioning component 24 is composed of a non-magnetic material. The positioning component is manufactured, for example, by cutting a cylindrical material.

[0025] FIG. 10 is a perspective view of a pole piece according to this embodiment. FIG. 10 shows only the pole pieces of a pole piece module. The pole piece module of this embodiment has 30 pole pieces 21. As shown in FIG. 10, the circumferential width of each pole piece 21 is smallest at the center in the radial direction and increases from the center toward the inner diameter side and the outer diameter side. The pole piece module of this embodiment is composed of the pole piece 21 shown in FIG. 10, a positioning component 24 that determines the position of the pole piece 21, and a molded resin that integrates the pole piece 21 and the positioning component 24.

[0026] Next, a method for manufacturing the pole piece module according to this embodiment will be described. Fig. 11 is a cross-sectional view of a mold for manufacturing the pole piece module according to this embodiment. As shown in Fig. 11, the mold according to this embodiment is composed of a disk-shaped bottom plate 51, a cylindrical core 52, and a cylindrical outer frame 53. A space is formed between the core 52 and the outer frame 53 for arranging positioning components and pole pieces and for filling the space with molding resin. Fig. 12 is a see-through perspective view of the bottom plate 51, Fig. 13 is a side view of the core 52, and Fig. 14 is a side view of the outer frame 53.

[0027] 15 is a diagram illustrating a manufacturing method of the pole piece module according to this embodiment. First, the core 52 is placed on the upper surface of the bottom plate 51. Then, the positioning component 24 is placed on the upper surface of the bottom plate 51 along the core 52 with the protrusion 24b facing upward. Next, the pole piece 21 is placed on the positioning component 24 with the inner circumferential surface of the core 52 aligned with the outer circumferential surface of the core 52. At this time, the surface of the pole piece 21, whose circumferential width increases from the center toward the inner diameter, comes into contact with the surface of the protrusion 24b of the positioning component 24, whose circumferential width decreases from the outer diameter toward the inner diameter, thereby determining the circumferential and radial positions of the pole piece 21.

[0028] Next, with the protrusions 24b facing downward, the positioning component 24 is placed on the pole piece 21 along the center core 52. At this time, too, the surface of the pole piece 21, whose circumferential width increases from the center toward the inner diameter side, comes into contact with the surface of the protrusions 24b of the positioning component 24, whose circumferential width decreases from the outer diameter side toward the inner diameter side, thereby determining the circumferential and radial positions of the pole piece 21.

[0029] In this way, the circumferential position of the pole piece 21 is determined from both axial ends by the positioning parts 24, so the pole piece 21 does not twist in the circumferential direction. Next, the outer frame 53 is placed on the upper surface of the bottom plate 51. The entire mold is then heated in the state shown in Figure 15. Next, molding resin that has been vacuum-degassed and heated to melt is poured into the space between the core 52 and the outer frame 53. After the molding resin has filled up to the top of the outer frame 53, the entire mold is vacuum-heated again to degas the molding resin. Next, the entire mold is cooled to harden the molding resin, and the pole piece module is removed from the mold. Finally, cutting is performed as necessary to complete the pole piece module.

[0030] In a pole piece module manufactured in this manner, the circumferential, radial, and axial positions of the pole pieces are determined by positioning components located at both axial ends, improving the positional accuracy of the pole pieces. Furthermore, since there is no need to provide cover members on the outer or inner diameter sides of the pole pieces, the gaps between the pole pieces and the inner and outer rotors can be reduced, thereby improving torque transmission efficiency.

[0031] In the pole piece module of this embodiment, the positioning components are made of the same material as the molded resin. Materials that can be used for the positioning components and molded resin include, for example, PPS resin (Poly Phenylene Sulfide), glass-fiber-reinforced glass epoxy resin, PBT resin (Poly Butylene Terephthalate), epoxy resin, and unsaturated polyester resin. The molded resin that constitutes the pole piece module and the non-magnetic member shown in FIG. 2 may also be integrally molded.

[0032] In a pole piece module configured in this manner, the positioning components and the molded resin are made of the same material, so the bonding strength does not decrease due to differences in thermal expansion coefficients, resulting in a pole piece module with high bonding strength.

[0033] The outer rotor core, pole pieces, and inner rotor core are made of soft magnetic materials such as electromagnetic steel sheets, pressed iron cores, amorphous metals, and permendur. However, if specifications allow, these materials may also be made of ferromagnetic materials such as carbon steel S45C and SS400. When electromagnetic steel sheets are used for the outer rotor core, pole pieces, and inner rotor core, they are made of multiple thin sheets stacked together to prevent eddy currents caused by changes in magnetic flux.

[0034] As shown in FIG. 10 , the shape of the pole pieces according to this embodiment has a circumferential width that is smallest at the radial center and increases from the center toward the inner and outer diameter sides. The shape of the pole pieces is not limited to this. For example, the radial center of the pole pieces may be recessed in an arc shape, or may be bulged outward. Furthermore, the cross section of the pole pieces perpendicular to the axial direction may be Z-shaped or trapezoidal. Furthermore, the pole pieces arranged circumferentially do not all need to have the same shape; pole pieces of different shapes may be arranged circumferentially. The positioning components may have any shape that corresponds to the shape of the pole pieces. The shape of the positioning components may be any shape that determines the circumferential, radial, and axial positions of the pole pieces when combined with the positioning components. Furthermore, the positioning components may be chamfered as necessary.

[0035] In addition, in the pole piece module of this embodiment, the axial length of the positioning component can be freely determined, so even if the pole piece length differs depending on the model, it can be used for multiple models of products by using one or more positioning components of a certain determined length. Furthermore, since the positioning component of this embodiment has no restrictions on the axial position, the shape of the pole piece can be designed more freely.

[0036] Embodiment 2. In the magnetic-geared rotating machine of embodiment 1, positioning components are arranged at both axial ends of the pole piece module. In the magnetic-geared rotating machine of embodiment 2, positioning components are arranged at only one axial end of the pole piece module.

[0037] In order to determine the circumferential position, radial position, and axial position of the pole pieces of the pole piece module, a positioning component is always required at one axial end. In the magnetic-geared rotating machine of this embodiment, the pole piece module can be manufactured by placing a positioning component only at one axial end of the pole piece module, thereby reducing the number of processing steps.

[0038] In the pole piece module of this embodiment, the positioning components and the molded resin are made of the same material, as in embodiment 1. Therefore, the bonding strength is not reduced due to differences in thermal expansion coefficients, resulting in a pole piece module with high bonding strength.

[0039] Furthermore, since no positioning component is disposed at the other axial end of the pole piece module, there is a concern that the circumferential, radial, and axial positional accuracy of the pole piece may be reduced. In the magnetic-geared rotating machine of this embodiment, the axial length of the protrusion of the positioning component can be increased so that the axial end contacts the bottom surface of the mold. Furthermore, by temporarily fixing part or all of the positioning component and the pole piece with an adhesive to prevent the positioning component from tilting when installing the pole piece, it is expected that not only axial positional accuracy but also circumferential and radial positional accuracy can be ensured.

[0040] Third Embodiment A magnetic-geared rotating machine according to a third embodiment differs from the first embodiment in the shape of the positioning components of the pole piece module.

[0041] FIG. 16 is a perspective view of a positioning component according to this embodiment. As shown in FIG. 16, the positioning component 24 of this embodiment has a structure in which protrusions 24b protrude from a main body 24a on both axial sides. The circumferential width of the protrusions 24b decreases from the outer diameter side toward the inner diameter side. Also, as shown in FIG. 16, the annular main body 24a circumferentially connects the protrusions 24b radially inside the axial center of the protrusions 24b. The axial length of the annular main body 24a according to this embodiment is shorter than the axial length of the protrusions 24b. The axial length of the annular main body 24a may be the same as the axial length of the protrusions 24b.

[0042] In the pole piece module of this embodiment, the positioning components and the molded resin are made of the same material, as in embodiment 1. Therefore, the bonding strength is not reduced due to differences in thermal expansion coefficients, resulting in a pole piece module with high bonding strength.

[0043] The positioning components 24 configured in this manner can be placed at any axial position of the pole piece module, not just at both axial ends. Even if the axial length of the pole piece is long, the pole piece can be supported by placing this positioning component at the axial center.

[0044] Furthermore, the axial length of the main body 24 a may be the same as the axial length of one of the axial protrusions 24 b. The positioning component 24 configured in this manner can stand on its own, improving workability during the manufacture of the pole piece module.

[0045] Furthermore, by making the axial length of the main body portion 24a the same as the length to the axial end of the pole piece, the positioning component 24 can also serve as the core 52 shown in Figure 13 of embodiment 1.

[0046] In the positioning component of this embodiment, the upper and lower protrusions 24b protruding from the main body 24a on both sides in the axial direction may be offset from each other in the circumferential direction, with the main body 24a as the boundary. The pole pieces of the pole piece module may be divided into multiple pieces in the axial direction, and the positioning component may be disposed at the axial connection points of the divided pole pieces. In a pole piece module configured in this manner, the pole pieces are skewed. In this embodiment, "skew" refers to the pole pieces being arranged at an angle to the axial direction in order to improve cogging torque and torque ripple. In a magnetic-geared rotating machine configured in this manner, cogging torque and torque ripple can be improved.

[0047] Fourth Embodiment A magnetic-geared rotating machine according to a fourth embodiment differs from the third embodiment in the shape of the positioning components of the pole piece module.

[0048] Fig. 17 is a perspective view of a positioning component according to this embodiment. As shown in Fig. 17, the positioning component 24 of this embodiment has a structure in which protrusions 24b protrude from a main body 24a on both axial sides. The circumferential width of the protrusions 24b decreases from the outer diameter side toward the inner diameter side. Also, as shown in Fig. 17, the annular main body 24a circumferentially connects the protrusions 24b radially inside the axial center of the protrusions 24b.

[0049] Furthermore, in the positioning component of this embodiment, the longitudinal orientation of the protrusions 24b is tilted relative to the axial direction. Therefore, the pole pieces whose circumferential, radial, and axial positions are determined by the positioning component are tilted relative to the axial direction. In other words, the pole pieces in the pole piece module of this embodiment are skewed. In a magnetic-geared rotating machine configured in this manner, cogging torque and torque ripple can be improved.

[0050] In the pole piece module of this embodiment, the positioning components and the molded resin are made of the same material, as in embodiment 1. Therefore, the bonding strength is not reduced due to differences in thermal expansion coefficients, resulting in a pole piece module with high bonding strength.

[0051] The magnetic-geared rotating machine having skewed pole pieces described in the third embodiment has a so-called step-skew configuration. The magnetic-geared rotating machine of this embodiment has a smoother skew, which allows for smoother improvements in cogging torque and torque ripple.

[0052] Fifth Embodiment In the pole piece module described in the first embodiment, as shown in FIG. 8, the pole piece positioning component is composed of a cylindrical main body 24a and a plurality of protrusions 24b protruding from one axial end of the main body 24a. That is, in the first embodiment, the positioning component is a single cylindrical component. In the pole piece module according to the fifth embodiment, the main body of the pole piece positioning component is not cylindrical, but is composed of a size corresponding to one or several pole pieces. The plurality of positioning components are then arranged in a circular ring shape.

[0053] 18 and 19 are perspective views of a positioning component of a pole piece module according to this embodiment. FIG. 18 is a perspective view of the positioning component 24 viewed obliquely from above, and FIG. 19 is a perspective view of the positioning component 24 viewed obliquely from below. As shown in FIGS. 18 and 19 , the positioning component 24 of this embodiment is composed of a main body 24a corresponding to one pole piece and one protrusion 24b protruding from one axial end of the main body 24a. The other axial end of the main body 24a is provided with an axially protruding mating protrusion 24c for alignment and an axially recessed mating hole 24d for alignment. A mold for manufacturing the pole piece module is formed with mating holes and mating protrusions that can be mated with the mating protrusion 24c and mating hole 24d of the positioning component 24, respectively. The positioning components 24 of this embodiment are aligned in a circular shape in the mold for manufacturing the pole piece module using the alignment mating protrusion 24c and mating hole 24d. When the size of the main body 24a is the size of one pole piece, the circumferential width of the positioning parts 24 is smaller than the pole piece pitch, so that the positioning parts 24 do not interfere with each other.

[0054] In this embodiment, the positioning part 24 and the mold for the pole piece module each need only be provided with either an alignment fitting protrusion or a fitting hole, so in the following explanation, it will be described as if the positioning part 24 is provided with an alignment fitting protrusion and the mold for the pole piece module is provided with a fitting hole.

[0055] 20 is a flowchart showing the steps for manufacturing the pole piece module of this embodiment. First, in step 1, a mold for a positioning component is manufactured to mold a positioning component provided with a fitting protrusion for alignment. Also in step 1, a mold for the pole piece module is manufactured with a fitting hole for alignment.

[0056] In step 3, the positioning components are aligned in a circular pattern on the pole piece module mold by inserting the alignment projections on the positioning components into the alignment holes on the pole piece module mold. At this stage, the positioning components are aligned in the circumferential direction on the pole piece module mold.

[0057] In step 4, the pole pieces are inserted between the positioning components. The pole pieces are inserted from the axial direction of the positioning components, regardless of whether or not step-wise skew is used. Next, if step-wise skew is used, in step 5, positioning components are added in the axial direction and aligned in an annular shape. In step 6, the pole pieces are inserted from the axial direction between the positioning components. Here, step-wise skew refers to the pole pieces being arranged with a circumferential offset in stages toward the axial direction. If step-wise skew is used, steps 5 and 6 are repeated. Note that in step 6, the pole pieces are inserted from the axial direction between the positioning components. However, depending on the shape of the pole pieces, they may be inserted from the radially outer side rather than from the axial direction. If step-wise skew is not used, proceed to step 7. Next, in step 7, molding resin is filled into the gaps in the mold and then heat-cured. Next, in step 8, the pole piece module is removed from the mold. Finally, in step 9, the pole piece module is machined to the required dimensions using cutting or other processes.

[0058] The pole piece module manufactured by this process can provide a highly accurate step-by-step skew, even when step-by-step skew is provided. The pole piece module removed in step 8 is characterized by having an engaging protrusion remaining on the positioning component, but this engaging protrusion can be removed in step 9. This engaging protrusion can also be used as a protrusion for positioning the pole piece module relative to the non-magnetic member to which it is fixed.

[0059] In this embodiment, the positioning component of the pole piece module is the size of one pole piece, but it may be the size of a plurality of pole pieces arranged in the circumferential direction.

[0060] Various aspects of the present disclosure are summarized below as appendices.

[0061] (Supplementary Note 1) A pole piece module comprising: a plurality of pole pieces arranged at intervals in a ring shape; a ring-shaped positioning component that determines the circumferential positions of the plurality of pole pieces; and a molded resin arranged between the plurality of spaced-apart pole pieces and that integrates the plurality of pole pieces and the positioning component, wherein the material of the positioning component is the same as the material of the molded resin. (Supplementary Note 2) The pole piece module according to Supplementary Note 1, wherein the positioning component is arranged at at least one axial end of the plurality of pole pieces arranged at intervals in a ring shape. (Supplementary Note 3) The pole piece module according to Supplementary Note 1 or 2, wherein the positioning component has a ring-shaped main body and a plurality of protrusions protruding in the axial direction from the main body. (Supplementary Note 4) The pole piece module according to Supplementary Note 3, wherein the circumferential width of the protrusions decreases from the outer diameter side to the inner diameter side. (Appendix 5) The pole piece module according to Appendix 4, characterized in that the circumferential width of the pole piece is smallest at a radial center and increases from the center toward the outer diameter side and the inner diameter side. (Appendix 6) The pole piece module according to Appendix 3, characterized in that the protrusions of the positioning component protrude from the main body on both axial sides, and the main body connects the plurality of protrusions circumferentially radially inside the axial center of the protrusions. (Appendix 7) The pole piece module according to Appendix 6, characterized in that the protrusions are offset from each other in the circumferential direction with the main body as a boundary. (Appendix 8) The pole piece module according to Appendix 6, characterized in that the longitudinal direction of the protrusions is inclined with respect to the axial direction. (Appendix 9) The pole piece module according to any one of Appendices 6 to 8, characterized in that the pole piece is divided into a plurality of pieces in the axial direction, and the positioning component is disposed between the plurality of pole piece pieces divided in the axial direction.(Supplementary Note 10) A magnetic-geared rotating machine having an inner rotor, an intermediate cylindrical portion, and an outer rotor arranged coaxially with a gap between them, wherein the inner rotor has a cylindrical inner rotor core and a plurality of inner rotor magnets arranged at equal intervals on the outer peripheral surface of the inner rotor core, the outer rotor has a cylindrical outer rotor core and a plurality of outer rotor magnets arranged at equal intervals on the inner peripheral surface of the outer rotor core, and the intermediate cylindrical portion is composed of a pole piece module described in any one of Supplementary Notes 1 to 9.

[0062] Although various exemplary embodiments and examples are described in this disclosure, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are contemplated within the scope of the technology disclosed in this specification. For example, this includes cases where at least one component is modified, added, or omitted, or where at least one component is extracted and combined with components of another embodiment.

[0063] REFERENCE SIGNS LIST 1 Inner rotor, 2 Pole piece module, 3 Outer rotor, 11 Inner rotor shaft, 12 Inner rotor core, 13 Inner rotor magnet, 21 Pole piece, 22 Molded resin, 23 Non-magnetic member, 24 Positioning part, 24a Main body, 24b Protrusion, 24c Fitting protrusion, 24d Fitting hole, 31 Outer rotor core, 32 Outer rotor magnet, 33 Outer rotor shaft, 41 Bearing, 51 Bottom plate, 52 Center core, 53 Outer frame.

Claims

1. A plurality of magnetic pole pieces arranged at intervals in an annular shape, Positioning components that define the circumferential positions of the plurality of magnetic pole pieces, It is arranged between a plurality of the magnetic pole pieces arranged at intervals, and includes a mold resin that integrates the plurality of magnetic pole pieces and the positioning components, A magnetic pole piece module, characterized in that the material of the positioning component and the material of the mold resin are the same.

2. The magnetic pole piece module according to claim 1, characterized in that the boundary line between the positioning component and the mold resin is exposed on the processed surface of the mold resin.

3. The magnetic pole piece module according to claim 1 or 2, characterized in that the positioning component is also arranged on the inner peripheral surface of the magnetic pole piece in a cross-section perpendicular to the axial direction.

4. The magnetic pole piece module according to claim 1, characterized in that the positioning component is arranged at at least one end in the axial direction of the plurality of magnetic pole pieces arranged at intervals in an annular shape, and the boundary line between the positioning component and the mold resin is exposed on the processed surface of the mold resin.

5. The magnetic pole piece module according to claim 1 or 2, characterized in that the positioning component has a main body portion arranged at intervals in the circumferential direction at the axial end of the magnetic pole piece, and a protrusion portion that protrudes axially from the main body portion and is in contact with the plurality of magnetic pole pieces in the circumferential direction.

6. The magnetic pole piece module according to claim 5, characterized in that the positioning component has a fitting protrusion portion for fitting with a mold at the axial end of the main body portion or the protrusion portion.

7. The magnetic pole piece module according to claim 5, characterized in that the positioning component has a fitting hole for fitting with a mold at the axial end of the main body portion or the protrusion portion.

8. The magnetic pole piece module according to claim 6, characterized in that the fitting protrusion portion remains after molding.

9. The magnetic pole piece module according to claim 1 or 2, characterized in that the positioning component has an annular main body portion and a plurality of protrusion portions that protrude axially from the main body portion.

10. The magnetic pole piece module according to claim 9, characterized in that the positioning component is arranged at both axial ends of the magnetic pole piece, and the mold resin is arranged between the protrusion portions facing each other in the axial direction at both axial ends of the magnetic pole piece.

11. A second mold resin, which is a part of the mold resin, is disposed on the outer diameter side of a first mold resin, which is a part of the mold resin disposed between the protrusions in the axial direction. A third mold resin, which is a part of the mold resin, is disposed on the outer diameter side of the positioning parts disposed at both axial ends of the pole piece. The pole piece module according to claim 10, wherein the third mold resin is disposed at both axial ends of the second mold resin.

12. The pole piece module according to claim 9, wherein the circumferential width of the protrusion becomes smaller from the outer diameter side toward the inner diameter side.

13. The pole piece module according to claim 9, wherein the circumferential width of the pole piece is smallest at the central portion in the radial direction, and becomes larger from the central portion toward the outer diameter side and the inner diameter side.

14. In the pole piece module according to claim 9, the protrusions of the positioning parts protrude from both axial sides of the main body part, and the main body part connects a plurality of the protrusions in the circumferential direction inside the radial direction of the central portion in the axial direction of the protrusions.

15. The pole piece module according to claim 14, wherein the protrusions are displaced from each other in the circumferential direction with the main body part as a boundary.

16. The pole piece module according to claim 14, wherein the longitudinal direction of the protrusion is inclined with respect to the axial direction.

17. The pole piece module according to claim 14, wherein the pole piece is divided into a plurality of parts in the axial direction, and the positioning part is disposed between the pole pieces divided into a plurality of parts in the axial direction.

18. A magnetic gear drive rotator having an inner rotor, an intermediate cylindrical part, and an outer rotor coaxially arranged via gaps, wherein the inner rotor has a cylindrical inner rotor core and a plurality of inner rotor magnets arranged at equal intervals on the outer peripheral surface of the inner rotor core, the outer rotor has a cylindrical outer rotor core and a plurality of outer rotor magnets arranged at equal intervals on the inner peripheral surface of the outer rotor core, and the intermediate cylindrical part is constituted by the pole piece module according to claim 1 or 2.

19. A method for manufacturing a pole piece module including a plurality of pole pieces arranged at intervals in an annular shape, a positioning component that defines the circumferential positions of the plurality of pole pieces, and a mold resin disposed between the plurality of pole pieces arranged at intervals and integrating the plurality of pole pieces and the positioning component, comprising: A method for manufacturing a pole piece module, characterized in that a mold provided with a fitting portion that fits with at least one of a fitting protrusion and a fitting hole provided in the positioning component is used, wherein at least one of the fitting protrusion and the fitting hole is provided in the positioning component.