The present invention relates to a so-called interior permanent magnet rotary electric machine where a permanent magnet is embedded in a field element.
An interior permanent magnet rotary electric machine is a desirable rotary electric machine from a view point that so-called reluctance torque is used. With respect to a permanent magnet embedded in a field element of the interior permanent magnet rotary electric machine, various shapes including shapes exemplified in International Publication No. 2008/114692, Japanese Patent Application Laid-Open No. 2011-91911, Japanese Patent Application Laid-Open No. 11-206075 (1999) and Japanese Patent Application Laid-Open No. 2003-47212 have been proposed.
In an embedded type rotary electric machine, to increase a field magnetic flux so as to increase an output of the embedded type rotary electric machine, it is desirable to increase a surface area of a magnetic pole face of a permanent magnet which generates the field magnetic flux. To satisfy such a request, it is desirable that a shape of the magnetic pole face of the permanent magnet is concaved toward an armature as viewed from the direction parallel to a rotation axis which is the center of rotation of the rotary electric machine. Such a shape is described in Japanese Patent Application Laid-Open No. 11-206075 (1999) and Japanese Patent Application Laid-Open No. 2003-47212, for example.
Japanese Patent Application Laid-Open No. 11-206075 (1999) and Japanese Patent Application Laid-Open No. 2003-47212 also exemplify a manufacturing method when a resin magnet is used as the permanent magnet.
There may be a case where a magnetic field generated by an armature winding (hereinafter referred to as “armature magnetic field”) is applied in the direction that a permanent magnet is demagnetized. Particularly as in the case described above where the magnetic pole face of the permanent magnet exhibits a concaved shape with respect to the armature, both ends of the permanent magnet are disposed closer to the armature than a center portion of the permanent magnet and hence, both ends of the permanent magnet are liable to be demagnetized.
When the armature magnetic field is large, there may be a case where the demagnetization of permanent magnet reaches irreversible demagnetization. In this case, the indentation of the magnetic pole face toward the armature for increasing an output of the embedded type rotary electric machine by increasing the magnetic pole face of the permanent magnet impedes the improvement of an output of the embedded type rotary electric machine to the contrary.
In view of the above-mentioned points, it is an object of the present invention to provide an interior permanent magnet rotary electric machine having the structure which makes the effects of the demagnetization caused by an armature magnetic field difficult while increasing areas of the magnetic pole faces of the permanent magnet.
An interior permanent magnet rotary electric machine according to the present invention includes: an armature (1, 19); and a field element (2, 29) rotating relative to the armature about a rotation axis (J) which constitutes the center of rotation.
According to the first aspect of the present invention, the field element includes: a core (21); and a plurality of permanent magnets (22, 221, 222, 223, 229) extending in the axial direction which is the direction parallel to the rotation axis and embedded in the core. Each of the plurality of permanent magnets has a pair of magnetic pole faces (22a, 22b, 221a, 221b, 222a, 222b, 223a, 223b, 229a, 229b) which show arcs concaved toward the armature as viewed from the axial direction. A radius (R2, R4, R6, R29) of a second arc which is the arcs shown by the magnetic pole face (22b, 221b, 222b, 223b, 229b) away from the armature out of the pair of magnetic pole faces is larger than a radius (R1, R3, R5, R19) of a first arc which is the arcs shown by the magnetic pole face (22a, 221a, 222a, 223a, 229a) close to the armature out of the pair of magnetic pole faces, in the each of the plurality of permanent magnets. A focal point (P2, P4, P6, P29) of the second arc is further away from the permanent magnet than a focal point (P1, P3, P5, P19) of the first arc. Alternatively, the focal point of the second arc is closer to the permanent magnet than a focal point of the first arc. The focal point of the first arc, the focal point of the second arc and the rotation axis in the each of the plurality of permanent magnets are arranged on one straight line as viewed from the axial direction.
A second aspect of the interior permanent magnet rotary electric machine according to the present invention is, in the first aspect of the interior permanent magnet rotary electric machine, characterized in that the field element (2) further includes a magnetic barrier (23) mounted on an end portion different from the pair of magnetic pole faces in one of the plurality of permanent magnets.
A third aspect of the interior permanent magnet rotary electric machine according to the present invention is, in the second aspect of the interior permanent magnet rotary electric machine, characterized in that a length (23c) formed by the magnetic barrier at a position remotest from the end portion and a side surface (210) of the core closest to the armature (1) is smaller than a width (22d) on the one straight line in the one of the plurality of permanent magnets.
A fourth aspect of the interior permanent magnet rotary electric machine according to the present invention is, in any one of the first to third aspects of the interior permanent magnet rotary electric machine, characterized in that the plurality of permanent magnets include a plurality of permanent magnets (221, 222, 223) stacked between the rotation axis and the armature.
A fifth aspect of the interior permanent magnet rotary electric machine according to the present invention is, in any one of the first to fourth aspects of the interior permanent magnet rotary electric machine, characterized in that the plurality of permanent magnets are formed of resin magnets.
A sixth aspect of the interior permanent magnet rotary electric machine according to the present invention is, in the fifth aspect of the interior permanent magnet rotary electric machine, characterized in that a magnetization magnetic flux supplied from the outside for obtaining the resin magnet at the time of forming the resin magnets by injection molding is set parallel to the one straight line as viewed from the axial direction.
A seventh aspect of the interior permanent magnet rotary electric machine according to the present invention is, in the fifth aspect of the interior permanent magnet rotary electric machine, characterized in that the resin magnets are formed by injection molding, and have anisotropy such that the thickness direction of the plurality of permanent magnets becomes the magnetization easy axis.
An eighth aspect of the interior permanent magnet rotary electric machine according to the present invention is, in any one of the first to seventh aspects of the interior permanent magnet rotary electric machine, characterized in that the armature (1) has an armature winding (12) wound by concentrated winding.
According to the first aspect of the interior permanent magnet rotary electric machine of the present invention, the magnetic pole face of the permanent magnet is concaved toward the armature setting the thickness of the permanent magnet such that the thickness is large in the vicinity of end portions which differ from the pair of magnetic pole faces and the thickness of the permanent magnet is thin in the vicinity of the center of the permanent magnet. Thus, the effect of demagnetization caused by the armature magnetic field is decreased while increasing an area of the magnetic pole face of the permanent magnet and, a volume of the magnet is reduced.
According to the second aspect of the interior permanent magnet rotary electric machine of the present invention, it is possible to prevent a magnetic flux from flowing in a short-circuited manner between the pair of magnetic pole faces of the permanent magnet.
According to the third aspect of the interior permanent magnet rotary electric machine of the present invention, it is possible to prevent a magnetic barrier from impairing advantageous effects brought about by the first aspect of the interior permanent magnet rotary electric machine when the rotary electric machine is stopped.
According to the fourth aspect of the interior permanent magnet rotary electric machine of the present invention, reluctance torque of the rotary electric machine is increased.
According to the fifth aspect of the interior permanent magnet rotary electric machine of the present invention, it is easy to provide the permanent magnet in the core by injection molding.
According to the sixth aspect of the interior permanent magnet rotary electric machine of the present invention, magnetization in the vicinity of the center of the permanent magnet is ensured.
According to the seventh aspect of the interior permanent magnet rotary electric machine of the present invention, residual magnetic flux density in the vicinity of the armature out of the pair of magnetic pole faces is increased so that it is easy to increase a field magnetic flux.
According to the eighth aspect of the interior permanent magnet rotary electric machine of the present invention, it is resist to the demagnetization even at the armature which adopts concentrated winding by which demagnetization of the permanent magnet is liable to be generated.
Objects, technical features, modes and advantages of the present invention will become apparent by the detailed explanation made hereinafter and attached drawings.
Referring to
The field element 2 includes a core 21 and a plurality of permanent magnets 22 which are embedded in the core 21. The permanent magnets 22 extend in the axial direction (in the direction perpendicular to a surface of paper on which
The armature 1 has teeth 11, an armature winding 12 and a yoke 13. The yoke 13 connects the teeth 11 on a side opposite to the field element 2.
The armature winding 12 is wound around the teeth 11 by concentrated winding. When the armature 1 adopts such concentrated winding, a demagnetization effect becomes conspicuous for the field element 2.
In this specification, unless otherwise specified, the armature winding 12 does not mean the individual conductive wires which constitute the armature winding 12 but means collective conducive wires in a mode where the conductive wires are wound in a bundle. It is also applied to attached drawings. Lead lines on a winding start side and lead lines on a winding finish side, and connecting them is also omitted from the drawing.
To be more specific, a radius R02 of an arc shown by the magnetic pole face 22c is larger than a radius R01 of an arc shown by the magnetic pole face 22a as viewed in the axial direction, and both focal points of these arcs are set at a focal point P0. That is, the magnetic pole faces 22a, 22c respectively show the arcs which are portions of concentric circles as viewed in the axial direction. Accordingly, a distance between the magnetic pole faces 22a, 22c, that is, a thickness of the permanent magnet 22 (R02-R01) becomes uniform.
Of course, the difference between radii (R02-R01) can be increased so as to make the demagnetization caused by the armature difficult. However, the demagnetization of the permanent magnet 22 in the vicinity of the center of the arc is not so large as that of both ends of the arc. Accordingly, the mere increase of the difference between the radii (R02-R01) excessively increases the volume of the permanent magnet 22 thus impeding the effective use of the permanent magnet 22.
In view of the above, in the first embodiment, the thickness of the permanent magnet 22 is small at the substantially center of the arc and large at both end portions of the arc.
Hereinafter, the positional relationship of the respective parts as viewed in the axial direction is described. The permanent magnet 22 has a pair of magnetic pole faces 22a 22b both of which show arcs. Further, a radius R2 of the arc shown by the magnetic pole face 22b away from the armature (not shown in the drawing: see
For a comparison purpose, the magnetic pole face 22c and the radius R02 of the arc shown by the magnetic pole face 22c shown in
As is clearly understood from
In this manner, the magnetic pole faces 22a, 22b of the permanent magnet 22 are concaved toward the armature 1, and the thickness of the permanent magnet 22 is set thin in the vicinity of center of the arc while the thickness in the vicinity of end portions (that is, both ends of the arc) which are different from the magnetic pole faces 22a, 22b is set thick. Thus, the permanent magnet 22 is hardly effected by the demagnetization caused by an armature magnetic field while increasing areas of the magnetic pole faces 22a, 22b. Further, the permanent magnet 22 is reduced in the volume and is effectively used.
Permanent magnets embedded in a field element 2 may be stacked on each other between a rotation axis J and an armature 1.
Magnetic pole faces similar to shapes as the permanent magnet 22 of the first embodiment are shown on all permanent magnets 221, 222, 223. Hereinafter, to describe the positional relationship viewed in the axial direction specifically, the permanent magnet 221 has a pair of magnetic pole faces 221a, 221b both of which show arcs. A radius R2 of an arc shown by the magnetic pole face 221b away from an armature (not shown in the drawing: see
For a reference purpose, the respective shapes of permanent magnets 221, 222, 223, having the uniform thickness in the same manner as the permanent magnet 22 shown in
Also in this case, due to the similar action in the first embodiment, the permanent magnets 221, 222, 223 are hardly effected by the demagnetization caused by a magnet field of an armature while increasing areas of the magnetic pole faces. Further, respective the permanent magnets 221, 222, 223 are decreased in the volume and are effectively utilized.
Also in
The permanent magnets 22, 221, 222, 223 having shapes described in the first embodiment and the second embodiment can be formed by a known method, for example, using a resin magnet disclosed in Japanese Patent Application Laid-Open No. 11-206075 (1999) and Japanese Patent Application Laid-Open No. 2003-47212. With the use of the resin magnet, the permanent magnets 22, 221, 222, 223 are easily formed in the core 21 by injection molding. The resin magnet is also referred to as a bond magnet.
In injection molding for the resin magnet, it is desirable that a magnetization magnetic flux supplied from the outside for forming the resin magnet be arranged parallel to a straight line on which the rotation axis J and the focal points P1, P2, . . . are arranged as viewed in the axial direction. It is for surely providing the magnetization in the vicinity of the center of the permanent magnet (that is, near the straight line).
It is preferable that the injection molded resin magnet has anisotropy where a magnetization easy axis of a resin magnet is directed in the thickness direction of the permanent magnets 22, 221, 222, 223. For example, it is preferable that a magnetization easy axis of a resin magnet which is adopted as the permanent magnet 22 be arranged perpendicular to the arc shown by the magnetic pole face 22a of the permanent magnet 22 on an armature side. Since the resin magnet has such anisotropy, even when there is the disturbance in the magnetization magnetic flux, the residual magnetic flux density of the magnetic pole face 22a on an armature side is increased and hence, a field magnetic flux is easily increased. The same goes for the permanent magnets 221, 222, 223.
In this embodiment, a case is exemplified where a field element 29 includes a core 219 and permanent magnets 229, and an armature 19 includes teeth 119 and a yoke 139. The armature 19 is surrounded by the field element 29, and the yoke 139 connects the teeth 119 on a rotation axis J side.
Also in such an outer-rotor-type rotary electric machine, the shape of the permanent magnet 229 is described in the same manner as the first embodiment. That is, to describe the positional relationship as viewed in the axial direction, each permanent magnet 229 has a pair of magnetic pole faces 229a, 229b having an arc. A radius R29 of an arc shown by the magnetic pole face 229b away from the armature 19 is larger than a radius R19 of an arc shown by the magnetic pole face 229a closer to the armature 19. A focal point P29 of the arc shown by the magnetic pole face 229b is further away from the permanent magnet 229 than a focal point P19 of the arc shown by the magnetic pole face 229a (in other words, the focal point P19 is closer to the permanent magnet 229 than the focal point P29). Further, the focal points P19, P29 and the rotation axis J are arranged on one straight line (indicated by a double-dashed chain line in
For a reference purpose, the case where the shape of the permanent magnet 229 which has the uniform thickness is also described in
As described above, also in the outer-rotor-type rotary electric machine, due to the similar action in the first embodiment, the permanent magnet 229 is hardly effected by the demagnetization caused by a magnet field of the armature while increasing areas of the magnetic pole faces. Further, the permanent magnet 229 is decreased in the volume and hence, it is effectively utilized.
As a matter of course, the permanent magnet 229 according to the fourth embodiment is also formed in the same manner as the injection molding of the resin magnet in the third embodiment.
In this embodiment, the field element 2 (see
To prevent the concentration of an armature magnetic field on both ends of the permanent magnet 22, it is preferable that the armature magnetic field flows through the magnetic barriers 23 more easily than the permanent magnet 22.
To be more specific, it is preferable that a length 23c of a portion which is formed by the magnetic barrier 23 at a position furthest away from an end portion of the permanent magnet 22 and a side surface 210 of a core 21 closest to the armature 1 (can be also regarded as a side surface away from the rotation axis J in the case of the inner-rotor-type rotary electric machine) be smaller than a width 22d of the permanent magnet 22. Here, the width 22d is a width (thickness) of the permanent magnet 22 on a straight line which connects the rotation axis J and focal points P1, P2, and is a minimum value of the thickness of the permanent magnet 22.
Usually, the permanent magnet 22 per se has magnetic permeability to an extent that the magnetic barrier 23 has. Accordingly, when the thickness of the magnetic barrier 23 is larger than the thickness of the permanent magnet 22, the armature magnetic field avoids the magnetic barrier 23 and is liable to pass through the permanent magnet 22. Particularly, the magnetic barriers 23 are provided to the end portions of the permanent magnet 22 where the demagnetization is to be taken into consideration and hence, it is not desirable that a magnetic resistance of the magnetic barrier 23 as a path of the armature magnetic field becomes higher than that of the permanent magnet 22. This issue becomes apparent particularly when the rotary electric machine is in a stopped state.
Accordingly, it is preferable that the core 21 remains on a more armature 1 side than the magnetic barrier 23 with the length 23c smaller than the minimum value (width 22d) of the thickness of the permanent magnet 22.
To prevent a magnetic flux from flowing in a short-circuited manner between the magnetic pole faces 22a, 22b, a width 23a of the magnetic barrier 23 on a permanent magnet 22 side is selected to be substantially equal to or more than a width of the permanent magnet 22 at both ends. As described above, in all embodiments, the thickness of the permanent magnet 22 at both ends is larger than the thickness 22d at the center. Accordingly, the length 23c becomes shorter than the width 23a.
As a matter of course, in the same manner as the fifth embodiment, the magnetic barrier 23 can be also provided to end portions of the permanent magnet 229 which are different from the magnetic pole faces 229a, 229b are respectively formed according to the fourth embodiment. In this case, a side surface 290 of the core 219 closer to the rotation axis J becomes a side surface closer to the armature 19 and corresponds to the above-mentioned side surface 210.
Although the present invention has been described in detail heretofore, the above description is provided merely for an exemplifying purpose in all aspects and hence, the present invention is not limited by the description. It is construed that various modifications which are not exemplified here are conceivable without departing from the scope of the present invention.
Number | Date | Country | Kind |
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2012-134450 | Jun 2012 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2013/066221 | 6/12/2013 | WO | 00 |