This application claims priority to Japanese Patent Application No. 2021-001393 filed on Jan. 7, 2021, which is incorporated herein by reference in its entirety including the specification, claims, drawings, and abstract.
This application discloses a rotor of a permanent magnet type rotary electric machine having permanent magnets embedded inside a rotor core.
Conventionally, a rotor having permanent magnets inserted and fixed in magnet holes formed inside a rotor core is known. As a structure for fixing permanent magnets, there is a structure in which the clearance between the magnet hole and the permanent magnet is filled with a resin or the like. Such a structure can reliably fix the permanent magnets, but manufacturing processes tend to be complicated. One of various conventional techniques proposed in view of this is a structure in which end plates arranged at both axial ends of the rotor core are used to fix the permanent magnets in the magnet holes.
For example, Patent Literature 1 discloses a technique in which end plates are bent and deformed toward the magnet hole side (i.e., inner side in the axial direction) at portions corresponding to magnet holes to form claw-shaped protrusions. When a direction orthogonal to the axial direction of the rotor is defined as a “lateral direction”, the protrusions are provided on both sides of the permanent magnet in the lateral direction, and the permanent magnet is sandwiched between a pair of protrusions. With this arrangement, the movement of the permanent magnet in the lateral direction can be restricted.
However, the structure disclosed in Patent Literature 1 requires arranging one end plate at one axial end of the rotor core, then inserting the permanent magnet into the magnet hole, and subsequently arranging another end plate at the other axial end of the rotor core. According to such an arrangement of the end plates, or at the time of inserting the permanent magnets, the protrusions move in the axial direction while keeping tight contact with peripheral surfaces of the permanent magnets, and therefore the permanent magnets may be cracked or scratched due to friction.
Accordingly, this application discloses a rotary electric machine rotor capable of easily fixing permanent magnets while preventing the permanent magnets from being damaged.
A rotor of a rotary electric machine disclosed in this application includes a rotor core having one or more magnet holes each being formed so as to extend in an axial direction, a permanent magnet inserted in each of the one or more magnet holes, and one or more end plates each being arranged at an axial end face of the rotor core, as one or more end plates each being provided with one or more fixing holes via which the permanent magnet is exposed to the outside in the axial direction, wherein one or more fixing pieces extend from the periphery of the fixing hole, with a fixing piece having an inclined part that extends in a direction approaching the center of the permanent magnet when advancing to the outside in the axial direction and being in contact with the permanent magnet, thereby pressing the permanent magnet in both the axial direction and a lateral direction orthogonal to the axial direction.
With such a configuration, the contact area between the fixing piece and the permanent magnet, and thus the friction, can be reduced, and the permanent magnet can be effectively prevented from being damaged. Further, the inclined part presses the permanent magnet in both the axial direction and the lateral direction, and therefore the permanent magnet can be reliably positioned in both the axial direction and the lateral direction. As a result, it is possible to easily fix the permanent magnet while preventing the permanent magnet from being damaged.
In this case, the fixing pieces may be positioned on both sides of the permanent magnet intervening therebetween in the lateral direction, and the permanent magnet may be sandwiched by a pair of inclined parts positioned on both sides of the permanent magnet intervening therebetween in the lateral direction.
With such a configuration, the permanent magnet can be naturally positioned at a position where the urging forces of a pair of inclined parts aligned in the lateral direction are balanced.
Further, the end plates may be provided on both sides of the rotor core in the axial direction, and the inclined parts may be present on both sides of each permanent magnet in the axial direction.
With such a configuration, the permanent magnet can be naturally positioned at a position where the urging forces of a pair of inclined parts aligned in the axial direction are balanced.
Further, the magnet hole may have a main part, which larger than the permanent magnet, and a pocket part being a cavity continuous to the main part, and the fixing piece may be provided at a position where at least a part thereof is overlapped with the pocket part in the axial direction.
Depending on a relative positional relationship with the permanent magnet, it may be desired that at least a part of the fixing piece advances axially inward from the end plate. Adopting the above-described configuration enables the pocket part to partly receive the fixing piece advancing axially inward.
Further, the permanent magnet may protrude outward from the end plate in the axial direction, and the fixing piece may linearly extend from the periphery of the fixing hole to a terminating end, without being bent.
Forming the fixing piece so as to have a simple shape is desirable in that the fixing piece can be easily improved in various kinds of accuracies. This leads to improvement in positioning accuracy of the permanent magnet.
Further, an axial end face of the permanent magnet may be positioned axially inside an axial end face of the end plate, and the fixing piece may be bent once or more in a region from a proximal end thereof to a terminating end thereof, so that an axial inner end of the inclined part is positioned more toward the inside in the axial direction than the axial end face of the permanent magnet.
With such a configuration, the axial dimension of the permanent magnet can be prevented from increasing, and the cost can be further reduced.
Further, the rotor core may be configured by a plurality of electro-magnetic steel sheets laminated in the axial direction, and the end plate may be configured by an electro-magnetic steel sheet, which is the same type as the electro-magnetic steel sheets configuring the rotor core.
With such a configuration, the number of component types can be reduced, and the cost can be further reduced.
Further, the end plate may be configured by a non-magnetic material.
With such a configuration, leakage fluxes flowing through the end plate can be reduced, and the efficiency of the rotary electric machine can be further improved.
According to the technique disclosed in this application, it is possible to easily fix the permanent magnets while preventing the permanent magnets from being damaged.
Embodiment(s) of the present disclosure will be described based on the following figures, wherein:
Hereinafter, an exemplary configuration of a rotor 10 will be described with reference to attached drawings.
This rotor 10 is used for a rotary electric machine such as a three-phase synchronous rotary electric machine that serves as a power source of an electrically driven vehicle, for example. The rotor 10 includes a rotor core 12, permanent magnets 14 embedded inside the rotor core 12, and a pair of end plates 16 arranged on both axial ends of the rotor core 12.
The rotor core 12 is substantially a toroid having an axial bore formed in the center thereof. The rotor core 12 is composed of a plurality of electro-magnetic steel sheets (e.g., silicon steel sheets) laminated in the axial direction. In the vicinity of the outer periphery of the rotor core 12, a plurality of magnet holes 18 are arranged side by side at intervals in the circumferential direction. Each magnet hole 18 penetrates in the axial direction and has an inner space in which the permanent magnet 14 configuring a magnetic pole of the rotor 10 is arranged. In order to explain the shape of the magnet hole 18, one magnet hole 18 in which the permanent magnet 14 is not inserted is illustrated in
In the present example, neighboring permanent magnets 14 are arranged so as to form a V shape. That is, each magnetic pole 15 is configured by a pair of permanent magnets 14 in a V-shaped arrangement, which is widened outward in the radial direction. In the example of
Further, in the present example, the axial dimension of the permanent magnet 14 is larger than the axial dimension of the rotor core 12. Therefore, as illustrated in
In order to receive the permanent magnets 14 having the V-shaped arrangement, neighboring magnet holes 18 are arranged so as to form a corresponding V shape. That is, the rotor core 12 is provided with the magnet holes 18 in a plurality of pairs (6 pairs in the illustrated example) that are evenly arranged in the circumferential direction, in which each pair of magnet holes 18 is arranged in the V shape that is widened outward in the radial direction. The magnet hole 18 has a substantially rectangular shape and is larger than the permanent magnet 14 in major axis dimension. More specifically, the magnet hole 18 has a main part 20, which is larger than the permanent magnet 14, and pocket parts 22 being cavities continuous to both ends of the main part 20 in the major axial direction. The pocket parts 22 are provided to reduce useless magnetic fluxes not contributing to torque production (so-called leakage fluxes) and increase valid magnetic fluxes.
The end plates 16 are fixed to both axial ends of the rotor core 12. For example, the end plate 16 is configured by an electro-magnetic steel sheet, which is the same type as the electro-magnetic steel sheets configuring the rotor core 12, namely, an electro-magnetic steel sheet that has the same material and dimensions. Such a configuration can reduce the number of components configuring the rotor 10 and accordingly contribute to cost reduction. However, it is needless to say that the end plate 16 may be configured by a plate member different in type from the electro-magnetic steel sheet of the rotor core 12. For example, the end plate 16 may be configured by a non-magnetic material such as brass.
Fixing holes 30 via which the permanent magnets 14 are exposed in the axial direction are formed at positions of the end plates 16 where they are overlapped with the permanent magnets 14 in the axial direction. The number of the provided fixing holes 30 is the same as the number of the permanent magnets 14. Like the permanent magnet 14, each fixing hole 30 has a flat shape elongated in one direction.
Fixing pieces 32 for fixing the permanent magnet 14 extend from the periphery of the fixing hole 30. For example, these fixing pieces 32 are provided on both sides of the permanent magnet 14 in the lateral direction. In the example of
The fixing piece 32 is a cantilever-shaped portion having a proximal end connected to the end plate 16 and a distal end serving as a free end. A part or the whole of the fixing piece 32 functions as an inclined part 40. The inclined part 40 is a portion extending in an inclined direction so as to approach the center of the permanent magnet 14 when advancing to the outside in the axial direction. In the example illustrated in
The inclined part 40 extends in the inclined direction, as mentioned above, and functions as a leaf spring having an appropriate elasticity. This inclined part 40 is in line contact with the periphery of the axial end face of the permanent magnet 14. Further, while being in contact with the permanent magnet 14, the inclined part 40 presses the permanent magnet 14 in both of the axial direction and the lateral direction. As a result, the permanent magnet 14 is automatically positioned and fixed in both the lateral direction and the axial direction, as will be described below. The end plate 16 having the fixing holes 30 and the fixing pieces 32 as described above can be manufactured by press-molding an electro-magnetic steel sheet, for example.
Next, the reason why the fixing holes 30 and the fixing pieces 32 described above are provided will be described by giving a comparison with a comparative example. In general, the magnet hole 18 is larger than the permanent magnet 14. Therefore, it is necessary to position and fix the permanent magnet 14 in the magnet hole 18. For this fixing, a structure in which the clearance between the magnet hole 18 and the permanent magnet 14 is filled with a resin or the like is known. However, such a fixing structure using a resin or the like encounters a problem that processes for manufacturing the rotor 10 are complicated and time-consuming.
In view of the above, there is a proposed structure in which the end plates 16 are used to fix the permanent magnets 14. For example, as will be understood from a comparative example illustrated in
However, the comparative example of
In addition, when manufacturing the rotor 10 of
On the other hand, in the rotor 10 of the present example, the fixing pieces 32 (the inclined parts 40) extend in the inclined direction so as to approach the center of the permanent magnet 14 when advancing to the outside in the axial direction, and are in line contact with the permanent magnet 14. Therefore, the fixing pieces 32 can press the permanent magnet 14 in both the axial direction and the lateral direction. As a result, the fixing pieces 32 can fix the permanent magnet 14 not only in the lateral direction but also in the axial direction.
Further, at this time, the fixing pieces 32 are in contact with only the periphery of the axial end face of the permanent magnet 14. This means that the contact area between the end plate 16 including the fixing piece 32 and the permanent magnet 14 can be kept smaller. As a result, even if the end plate 16 is configured by a magnetic material, for example, by an electro-magnetic steel sheet of the same type as the electro-magnetic steel sheets configuring the rotor core 12, the leakage flux can be kept smaller.
Further, in the case of the rotor 10 of the present example, during the manufacturing processes, there is no chance that the fixing pieces 32 will slide while keeping planar contact with the permanent magnet 14. Accordingly, the permanent magnet 14 can be effectively prevented from being damaged. This will be described with reference to
As illustrated in
Subsequently, in step S2, the permanent magnet 14 is inserted into the magnet hole 18 from the other axial end side of the rotor core 12 (the upper side of the paper in the illustrated example). When the insertion is completed, one axial end face of the permanent magnet 14 is in line contact with the fixing pieces 32 of the first end plate 16a. On the other hand, in an insertion process, the permanent magnet 14 can advance through the magnet hole 18 without contacting the fixing pieces 32. As a result, in the process of inserting the permanent magnet 14, the permanent magnet 14 is not damaged by the fixing pieces 32.
Next, in step S3, a second end plate 16b is fixed to the other axial end side of the rotor core 12 (the upper side of the paper in the illustrated example). With this arrangement, the other axial end face of the permanent magnet 14 is brought into contact with the fixing pieces 32 of the second end plate 16b, but this contact is a line contact and therefore the friction is very small. Accordingly, at the time of fixing the second end plate 16b, there is no chance that the permanent magnet 14 will be damaged by the fixing pieces 32. Finally, an axial compression force (so-called axial force) is applied to the entire rotor 10 including the end plates 16, thereby completing the manufacturing of the rotor 10. Upon application of this axial force, two fixing pieces 32 axially aligned with the permanent magnet 14 intervening therebetween come close to each other. With such a configuration, an increased urging force is applied to the permanent magnet 14 from the fixing pieces 32, and the permanent magnet 14 can be firmly fixed.
As will be apparent from the above description, in the present example, the end plates 16 having the fixing pieces 32 formed thereon are fixed to axial end faces of the rotor core 12. Accordingly, the permanent magnet 14 can be fixed in both the axial direction and the lateral direction. Further, at the time of this fixing, the contact between the permanent magnet 14 and the fixing pieces 32 can be kept small, and therefore the permanent magnet 14 can be effectively prevented from being damaged. That is, according to this example, it is possible to easily fix the permanent magnet 14 while preventing the permanent magnet 14 from being damaged.
The above-described configuration is merely an example. As long as the end plate 16 has the fixing piece 32 extending from the periphery of the fixing hole 30 and the fixing piece 32 has the inclined part 40 extending in a direction approaching the center of the permanent magnet 14 when advancing to the outside in the axial direction and is brought into contact with the permanent magnet 14, other configurations may be changed appropriately. For example, the number of the end plates 16 arranged at axial end faces of the rotor core 12 may be changed appropriately. Accordingly, as illustrated in
Further, it suffices that the end plate 16 having the fixing piece 32 is provided at least at one axial end face of the rotor core 12, and the fixing piece 32 need not be provided on the other axial end face. That is, as illustrated in
Further, in the above description, the fixing piece 32 extends linearly from its proximal end to its terminating end without being bent. However, the fixing piece 32 may be bent once or more at an intermediate part thereof as long as it has the inclined part 40. For example, as illustrated in
Forming the fixing piece 32 extending inward in the axial direction from the end plate 16 as illustrated in
Further, in the above description, the fixing pieces 32 are provided on both sides of the permanent magnet 14 intervening therebetween in the lateral direction. In other words, in the above description, two fixing pieces 32 are provided in one fixing hole 30. However, it suffices that one fixing hole 30 is provided with one or more fixing pieces 32 and the number of the fixing pieces 32 is not particularly limited. For example, as illustrated in
Further, as another embodiment, one fixing hole 30 may be provided with only one fixing piece 32 as illustrated in
Further, the rotor core 12 and the permanent magnet 14 may have other configurations appropriately modified. For example, the number and arrangement of the permanent magnets 14 may be appropriately changed. Accordingly, the permanent magnets 14 are not limited to the V shape arrangement, and straight line arrangement or arc-shaped arrangement may be adopted. Further, the rotor core 12 may be configured by a powder magnetic core formed by compressing magnetic powder, instead of a laminated steel sheet formed by laminating a plurality of electro-magnetic steel sheets.
Number | Date | Country | Kind |
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2021-001393 | Jan 2021 | JP | national |
Number | Name | Date | Kind |
---|---|---|---|
8970085 | Takahashi | Mar 2015 | B2 |
20170317544 | Watanabe | Nov 2017 | A1 |
Number | Date | Country |
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2007181254 | Jul 2007 | JP |
2012191750 | Oct 2012 | JP |
2016005419 | Jan 2016 | JP |
2016092984 | May 2016 | JP |
2018131402 | Jul 2018 | WO |
2018163319 | Sep 2018 | WO |
WO-2018163319 | Sep 2018 | WO |
Number | Date | Country | |
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20220216755 A1 | Jul 2022 | US |