Patent Application
20230246526
The present international application claims priority based on Japanese Patent Application No. 2020-112817 filed with the Japan Patent Office on Jun. 30, 2020, the entire contents of which are incorporated by reference into the present international application.
The present disclosure relates to a method for manufacturing an interior permanent magnet (IPM) type rotor core and relevant techniques.
The rotor core of a rotor for rotating electric machines is configured such that a large number of electromagnetic steel sheets are stacked in the thickness direction, for example, as described in Patent Document 1.
Patent Document 1: JP2011-6741A
In an interior permanent magnet (IPM) type rotor, permanent magnets are embedded in the rotor core, and therefore some of the magnetic field lines are short-circuited so as to draw a closed curve in the rotor core and, for example, may not reach the stator. This will cause a reduced (apparent) permeance between the rotor and the stator, resulting in a decrease in the efficiency of a rotating electric machine such as an electric motor.
In view of the above points, the present disclosure discloses an example of a method for manufacturing a rotor core capable of suppressing a decrease in the efficiency of an interior permanent magnet (IPM) type rotating electric machine.
A method for manufacturing a rotor core (1) is provided. In the rotor core (1), electromagnetic steel sheets (2) are stacked in the thickness direction and one or more permanent magnets are partially embedded. The method preferably includes, for example, performing modification to melt at least a part of a bridge portion (4) of each electromagnetic steel sheet (2) together with a modifying metal or modifying alloy to make a magnetic permeability of the part lower than that of other sites and stacking the electromagnetic steel sheets (2) that have undergone the modification.
This allows the bridge portions (4) of the rotor core (1) to have a lower magnetic permeability than that of other sites, and it is therefore possible to prevent some of the magnetic field lines from being short-circuited so as to draw a closed curve in the rotor core. Accordingly, a decrease in the efficiency of an interior permanent magnet (IPM) type rotating electric machine can be suppressed.
Bridge portions refer to sites of each electromagnetic steel sheet (also referred to as a core sheet) that are generally called “outer bridges” or “inner bridges (also referred to as “ribs”). The bridge portions refer, for example, to “sites of each electromagnetic steel sheet (2) that connect between an outer core located on the outer peripheral side of magnet holes (3) in which permanent magnets are embedded and an inner core located on the inner side of the magnet holes.”
Each of the above reference numerals in parentheses is an example representing the correspondence relationship with a specific configuration or the like described in the embodiments, which will be described later, and the present disclosure is not limited to the specific configurations or the like represented by the above reference numerals in parentheses.
The following “embodiments of the invention” each represent an example of an embodiment that belongs to the technical scope of the present disclosure. In other words, matters or the like specifying the invention recited in the scope of claims are not limited to the specific configurations, structures, etc. illustrated in the following embodiments.
Direction arrows, hatchings, etc. in the figures are illustrated to facilitate understanding of the relationship between figures and the shape of each member or site. Accordingly, the invention illustrated in the present disclosure is not limited by the directions in the figures. Figures with hatching may not necessarily be cross-sectional views.
The number of a member or members or a site or sites that are described at least with the reference numerals is at least one, unless otherwise stated as “one” or the like. In other words, two or more members may be provided unless otherwise stated as “one” or the like. The rotor core and other components illustrated in the present disclosure include constitutional elements, such as members or sites that are described at least with the reference numerals, and structural sites illustrated in the figures.
In the present embodiment, an example of the method for manufacturing a rotor core according to the present disclosure is applied to a method for manufacturing a rotor core used in an electric motor for traveling of an electric vehicle. A rotor core 1 according to the present embodiment is a rotor that rotates in a stator by electromagnetic force.
The rotor core 1 has a large number of electromagnetic steel sheets (also referred to as core sheets) 2 composed of silicon steel sheets illustrated in
Permanent magnets (not illustrated) are embedded in the rotor core 1. To this end, each electromagnetic steel sheet 2 is provided with a plurality of magnet holes 3. Each magnet hole 3 is a through hole in which the permanent magnet is embedded. The type of permanent magnet embedded in each magnet hole 3 and the embedding scheme are not limited.
Manufacturing of the rotor core 1 is carried out, for example, in accordance with the process chart illustrated in
At least a part of a bridge portion 4 (see
Bridge portions 4 refer to sites of each electromagnetic steel sheet 2 that are generally called “outer bridges” or “inner bridges (also referred to as “ribs”). As illustrated in
Note that, in
As illustrated in
The predetermined shape refers, for example, to a shape illustrated in
That is, the magnet holes 3 are not formed in a step (e.g., the modifying step) before the punching step, and are formed in the punching step. Likewise, the circular outer shape of each electromagnetic steel sheet 2, that is, of the core sheet, is also not formed.
A predetermined number of the electromagnetic steel sheets 2 that have undergone the punching step are stacked in the thickness direction (stacking step: S50). In the stacking step according to the present embodiment, recesses (not illustrated) and protrusions (not illustrated) formed on the electromagnetic steel sheets 2 are press-fitted and fixed to each other.
The modifying step according to the present embodiment includes a powder application step, a preheat treatment step, a melting modification step, a postheat treatment step, etc. The powder application step is a step of applying a modifying metal or modifying alloy (such metal or alloy will be referred to as a modifier, hereinafter) to melting regions.
The melting regions refer to sites to be modified that each include at least a part of a bridge portion 4. Note that “at least a part of a bridge portion 4” means “a part of each of the plurality of bridge portions 4” rather than “any or some of the plurality of bridge portions 4.”
Each bridge portion 4 and each melting region are a portion and a region that are determined appropriately by experiments, numerical simulations using a computer, or the like in accordance with the shape, size, required magnetic specs, etc. of the electromagnetic steel sheets 2.
In the modifying step, the magnet holes 3 have not yet been formed. The bridge portions 4 in the modifying step therefore refer to sites that will become the bridge portions 4 when the magnet holes 3 are formed in the subsequent steps.
In the present specification, a “bridge portion 4” refers to any bridge portion of the plurality of bridge portions 4. Likewise, a “magnet hole 3” refers to any magnet hole 3 of the plurality of magnet holes 3. That is, a bridge portion 4 and a magnet hole 3 as referred to in the present specification are not intended to mean a specific bridge portion 4 and a specific magnet hole 3.
The preheat treatment step is a heating step of heating at least the melting regions of the electromagnetic steel sheets 2, which have undergone the powder application step, to a predetermined temperature lower than the melting point of the electromagnetic steel sheets 2. The melting modification step is a step of heating the melting regions together with a modifier to perform modification.
In the melting modification step according to the present embodiment, the melting regions are melted by being irradiated with a beam such as a laser beam or an electron beam. In the following description, start regions each refer to a predetermined region that includes a site at which irradiation with the beam is started in a melting region, and the predetermined region is a site located outside a bridge portion 4.
On the other hand, end regions each refer to a predetermined region that includes a site at which irradiation with the beam is completed in a melting region, and the predetermined region is a site located outside a bridge portion 4. Thus, the start regions and the end regions are sites located outside the bridge portions 4.
Fundamentally, the scanning direction of the beam is not limited. As illustrated in
That is, in an outer bridge, the beam is scanned in the direction Did while oscillating at high speed in the direction Cid. Further, in the present embodiment, macroscopically, that is, ignoring the scanning in the direction Cid, the beam is scanned approximately from the center side of the rotor core 1 toward the outer side in the direction Did.
In a bridge portion 4 on the inner side (also referred to as an inner bridge) according to the present embodiment, the beam is scanned in a direction orthogonal to the direction Did while being scanned at high speed in the direction Did. That is, the beam in the inner bridge is macroscopically scanned in a direction orthogonal to the direction Did.
The macroscopic scanning direction of the beam is a direction approximately parallel to the direction from a magnet hole 3 toward the outer peripheral surface, or a direction approximately parallel to the direction from one magnet hole 3 of two adjacent magnet holes 3 to the other magnet hole 3.
The start regions according to the present embodiment each refer to a region on the side indicated as “Start” in
The start regions and the end regions are regions that are determined appropriately by experiments, numerical simulations using a computer, or the like in accordance with the shape, size, required magnetic specs, etc. of the electromagnetic steel sheets 2.
The postheat treatment step is a heat treatment step of cooling the regions, which have been heated in the melting modification step, while maintaining the cooling rate in the regions to be equal to or lower than a predetermined cooling rate. This will be more specifically described. In the preheat treatment step, the melting regions are heated to a predetermined temperature lower than the melting point of the electromagnetic steel sheets 2.
In the melting modification step, the sites irradiated with the beam have a temperature higher than the predetermined temperature. Then, the postheat treatment step suppresses rapid cooling of the regions which have been heated in the preheat treatment step and the melting modification step.
The insulating film according to the present embodiment is formed on at least a part of a bridge portion 4, that is, on the melting region. Specifically, after an organic resin is applied or sprayed onto the melting regions, the resin is heated at about 100 C° to 400 C°.
The insulating film is formed on at least one side (only one side in the present embodiment) of the sheet surfaces of each electromagnetic steel sheet 2. In other words, the insulating film is formed so that adjacent electromagnetic steel sheets 2 are in a state of being electrically insulated when a large number of electromagnetic steel sheets 2 are stacked.
Each electromagnetic steel sheet 2 that has undergone the modifying step is press-formed into a predetermined shape by punching with a press machine. In the punching step, a trimming step is also performed for removing at least a part of at least one region of a start region and an end region (at least a part of each of the start regions and the end regions in the present embodiment).
When the trimming step according to the present embodiment is carried out, therefore, at least a part of the start region on one side and the end region on the other side of each bridge portion 4 is removed, and at least the bridge portions 4 remain.
In the present embodiment, at least a part of a bridge portion 4 of each electromagnetic steel sheet 2 is modified, and the modified electromagnetic steel sheets 2 are stacked. This allows the bridge portions 4 of the rotor core 1 according to the present embodiment to have a lower magnetic permeability than that of other sites, and it is therefore possible to prevent some of the magnetic field lines from being short-circuited so as to draw a closed curve in the rotor core 1. Accordingly, a decrease in the efficiency of an interior permanent magnet (IPM) type rotating electric machine can be suppressed.
In the modifying step, the electromagnetic steel sheets 2 are heated and melted, so the electrical insulation of the melted sites is destroyed. In the present embodiment, however, an electrical insulating film is formed on at least a part of a bridge portion 4 that has undergone the modifying step, and it is therefore possible to ensure the electrical insulation between adjacent electromagnetic steel sheets 2.
In the start regions, heat is not sufficiently transmitted, so there is a possibility that the melting portions, which are the targets of modification, cannot be sufficiently melted. If the melting is insufficient, it is difficult for the nonmagnetic modifying additive element, which is a modifier, to be sufficiently contained in the electromagnetic steel sheets 2, and the nonmagnetic modification failure is therefore likely to occur.
The end regions solidify in the last instance, so defects such as cracks and voids due to shrinkage cavities are likely to occur. This may cause deterioration of the strength in the end regions. In other words, the start regions and the end regions are sites that are highly likely to be inappropriate sites for the rotor core 1.
To overcome such problems, in the present embodiment, the trimming step is provided to remove at least a part of each of the start regions and the end regions, and therefore the sites in which the nonmagnetic modification failure is likely to occur and the sites in which the deterioration of strength may occur are removed from the electromagnetic steel sheets 2.
In the present embodiment, the beam is scanned in the direction Did while oscillating at high speed in the direction Cid. In other words, the beam is scanned in the macroscopic beam scanning direction while oscillating at high speed in a direction orthogonal to the scanning direction.
Therefore, in the electromagnetic steel sheets 2 manufactured by the manufacturing method according to the present embodiment, the occurrence of problems such as a magnetic short-circuit phenomenon due to the nonmagnetic modification failure and insufficient strength of the electromagnetic steel sheets 2 is suppressed. Thus, the rotor core 1 according to the present embodiment can respond to high-speed rotation.
In the present embodiment, the modifying step is carried out after predetermined regions including the melting regions are heated to a predetermined temperature lower than the melting point of the electromagnetic steel sheets 2 (preheat treatment step). Therefore, the occurrence of cracks can be suppressed as compared with the case in which only the melting regions are heated during the modifying step.
In the present embodiment, the regions which have been heated in the melting modification step are cooled while maintaining the cooling rate in the regions to be equal to or lower than a predetermined cooling rate (postheat treatment step). This can suppress rapid cooling of the heated regions, and the occurrence of cracks due to rapid contraction of the melting regions can be suppressed.
In the manufacturing method according to the present embodiment, as illustrated in
This will be more specifically described. As illustrated in
The same configurations and the like as in the above-described embodiment are denoted with the same reference numerals as in the above-described embodiment. In the present embodiment, therefore, redundant description is omitted.
In the manufacturing method according to the present embodiment, as illustrated in
Then, in the present embodiment, a modifier is applied to the depressed site to modify the site. The site to be depressed is at least one side of the one side and the other side in the thickness direction (in
In the present embodiment, therefore, the melting region can be maintained in a depressed state even after the modifying step is completed. Thus, even if the electrical insulation in the melting regions is destroyed, it may be possible to ensure the electrical insulation between adjacent electromagnetic steel sheets 2. Accordingly, it may be possible to omit the insulating film forming step.
In
When one side and the other side in the thickness direction are depressed, even after the modifying step is completed, the one side and the other side in the thickness direction of the melting regions can be maintained in a depressed state. In this case, the flattening can be omitted.
The present embodiment represents an example relating to a configuration for ensuring electrical insulation between adjacent electromagnetic steel sheets 2. That is, when one electromagnetic steel sheet 2 of two adjacent stacked electromagnetic steel sheets 2 is a first electromagnetic steel sheet 2, the other electromagnetic steel sheet 2 is a second electromagnetic steel sheet 2, a bridge portion 4 of the first electromagnetic steel sheet 2 is a first bridge portion, a bridge portion 4 of the second electromagnetic steel sheet 2 is a second bridge portion, and a virtual plane orthogonal to the stack direction is a projection plane, the stacking step according to the present embodiment includes stacking the electromagnetic steel sheets 2 so that the first bridge portion projected onto the projection plane is displaced from the second bridge portion projected onto the projection plane.
This allows the adjacent modified sites, in particular, adjacent sites with broken electrical insulation, to be prevented from coming into contact with each other; therefore, even when the electrical insulation is broken by the modification, it may be possible to ensure the electrical insulation between the adjacent electromagnetic steel sheets 2. Accordingly, it may be possible to omit the insulating film forming step.
As described above, a part of a bridge portion 4 composed of a silicon steel sheet is provided with a modified portion that is modified by being heated together with a modifier (e.g., nickel or chromium). The modified portion is formed with an austenite phase, and its magnetic permeability is lower than that of other sites.
Here, in the rotor core 1 which rotates at high speed, a large tensile stress is generated in the bridge portions 4 (see
Fortunately, however, the present inventor has found that the tensile strength of the entire bridge portion 4 including the modified portion is improved by pressing at least the modified portion, that is, performing the flattening step of applying mechanical pressure to the modified portion, after the modifying step.
In other words, the inventor has found that “a silicon steel sheet manufactured by a manufacturing method including the manufacturing method according to the second embodiment is a high-strength steel sheet with improved tensile strength as compared with a normal silicon steel sheet to which the manufacturing method is not applied.”
That is, when at least a part of a bridge portion 4 of each electromagnetic steel sheet 2 composed of a silicon steel sheet is provided with a modified portion that satisfies the following requirement, the tensile strength is improved as compared with that of a normal silicon steel sheet.
The requirement is that the modified portion is “a modified portion obtained through irradiating the portion with a laser beam or electron beam to melt and modify the portion together with a modifying metal or modifying alloy and then pressing the portion.” In a preferred configuration, at least a part of the modified portion may reach from one surface to the other surface of the silicon steel sheet in its thickness direction.
Here, when the tensile strength of an inner bridge (rib) 4 of
In the above-described embodiments, the melting regions are irradiated with the beam to heat and melt the melting regions. However, the present disclosure is not limited to this. That is, in the present disclosure, for example, the regions may be heated and melted for modification by electrical heating.
In the insulating film forming step according to the above-described embodiments, the insulating film is formed on at least a part of a bridge portion 4, that is, the melting region. However, the present disclosure is not limited to this. That is, the present disclosure may be directed, for example, to a case in which an insulating film is formed on the entire electromagnetic steel sheet 2 in the insulating film forming step or a case in which an insulating film is formed only on a region of each melting region excluding the start region and the end region.
In the trimming step according to the above-described embodiments, the start regions and the end regions are removed. However, the present disclosure is not limited to this. That is, the present disclosure may be directed, for example, to a case in which only the start regions are removed in the trimming step or a case in which only the end regions are removed in the trimming step.
The trimming step according to the above-described embodiments is executed by punching with a press machine. However, the present disclosure is not limited to this. That is, in the present disclosure, for example, the trimming step may be executed by cutting.
The above-described embodiments have the preheat treatment step and the postheat treatment step. However, the present disclosure is not limited to this. That is, the present disclosure may be directed, for example, to a manufacturing method in which at least one of the preheat treatment step and the postheat treatment step is omitted.
The preheat treatment step and the postheat treatment step according to the above-described embodiments are measures for suppressing the occurrence of cracks. However, the present disclosure is not limited to this. That is, in the present disclosure, for example, a non-magnetizing heat treatment may be carried out together with the crack countermeasures by these heat treatments.
The beam scanning method is not limited to the above. That is, as illustrated in
In the above-described first embodiment, the punching step (S40) is carried out after the insulating film forming step (S30) is performed. However, the present disclosure is not limited to this. That is, in the present disclosure, for example, the insulating film forming step (S30) may be carried out after the punching step (S40) is performed.
In the above-described first embodiment, the insulating film forming step (S30) is carried out after the modifying step (S20) is performed. However, the present disclosure is not limited to this. That is, in the disclosure, for example, a powder removal step of removing the residual modifier may be carried out before or after the postheat treatment step.
The modified portions according to the above-described embodiments have a configuration in which at least a part of a modified portion reaches from one surface to the other surface of the silicon steel sheet in its thickness direction. However, the present disclosure is not limited to this. That is, the present disclosure may be directed, for example, to a configuration in which the modified portion does not reach from one surface to the other surface of the silicon steel sheet in its thickness direction.
Further, the present disclosure is not limited to the above-described embodiments, provided that it conforms to the spirit of the disclosure described in the above-described embodiments. Possible configurations therefore include those in which at least two of the above-described embodiments are combined and those in which any one of the illustrated configurations or the configurations described with the reference numerals is omitted in the above-described embodiments.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-112817 | Jun 2020 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2021/024399 | 6/28/2021 | WO |
