Patent Application
20160362762
The present invention relates to a steel sheet for a rotor core for an interior permanent magnet motor (hereafter “IPM motor”) that is used mainly for electric vehicles, hybrid vehicles and machine tools, and to a method for manufacturing same.
Generally, IPM motors, which use expensive permanent magnets, are expensive, but are more efficient than induction motors. For this reason, IPM motors are widely used, for example, for driving motors and power generating motors for hybrid vehicles and electric vehicles, and also motors for home electric appliances, various machine tools and industrial machines.
An iron core of an IPM motor is composed of a stator and a rotor. Since an AC magnetic field is directly applied to the iron core on the stator side through windings, the iron core on the stator side must have high magnetic permeability and also high volume resistivity so as to reduce iron loss. Therefore, electromagnetic steel sheets with soft magnetic characteristics improved by the addition of Si to ultra-low-carbon steel are used for the iron core on the stator side (see, for example, Patent Documents 1 and 2).
On the other hand, since a permanent magnet is embedded in the iron core on the rotor side, this iron core mainly acts as a yoke to increase magnetic flux density. The iron core on the rotor side is slightly affected by the AC magnetic field generated from the stator side, but this influence is limited. Therefore from the standpoint of characteristics, it is not necessary to use electromagnetic steel sheets, which are advantageous for the iron loss characteristic, for the iron core on the rotor side. However, the same electromagnetic steel sheets as used for the stator side are also usually used for the iron core on the rotor side because the product yield of the electromagnetic steel sheets decreases and the production costs of the motor increase when the electromagnetic steel sheets are used only for the stator.
When an IPM motor is to be installed in a vehicle, the IPM motor needs to be reduced in size because of the need to reduce the size and weight of the vehicle. In this case, the rotational speed of the rotor is increased in order to obtain a motor output (torque) equal to or greater than that of a conventional motor despite the reduction in size. The efficiency of a motor generally improves as the rotational speed of the rotor increases. However, in an IPM motor, an induced electromotive force is generated on the stator windings by the rotation of the embedded permanent magnets. This induced electromotive force increases with the increase in the rotational speed. Where the electromotive force exceeds the input voltage, the motor can no longer rotate. Therefore, in an IPM motor, field-weakening control, which generates a magnetic flux from the stator side in a direction to cancel the magnetic flux of the permanent magnets and suppresses the induced electromotive force, is performed when the motor is operated in a high-speed rotational range, as indicated, for example, in Patent Document 3. The field-weakening control enables the operation in a high-speed rotational range, but decreases the motor torque because power is used for cancelling the magnetic flux of the permanent magnets. Patent Document 3 indicates that the amount of electricity to be used for the field-weakening control is decreased by improving the shape of the magnets.
Meanwhile, even if the IPM motor is reduced in size, there is a problem that where rotational speed of the rotor is increased so as to obtain a torque equal to or higher than that in a conventional motor, the centrifugal forces that act upon the permanent magnets embedded in the rotor increase thereby damaging the rotor. To prevent this damage, it is preferred that a material with a high yield strength be used for the rotor. For example, a non-orientated electromagnetic steel sheet (35A300) containing about 3% Si has a yield strength after magnetic annealing of approximately 400 N/mm2. Therefore in the case of a comparatively large IPM motor with a rotor diameter of 80 mm or more, the limit of the rotational speed at which damage is not caused is about 20,000 rpm, although the specific value somewhat differs depending on the structure of the rotor. A variety of research has been conducted to increase the yield strength of iron cores based on electromagnetic steel sheets, but still the yield strength is at most about 780 N/mm2. As a method for suppressing damage to a rotor core caused by high-speed rotation, for example, Patent Document 4 suggests using steel sheet with high strength and high saturation magnetic flux density, rather than electromagnetic steel sheet, as a material for the rotor core.
In Patent Document 3, the amount of electricity used for the field-weakening control is reduced by improving the shape of the magnets, but adjusting the residual magnetic flux density and coercivity of the base steel sheets is not considered. In Patent Document 4, the increase in strength makes it possible to increase the rotational speed, but the residual magnetic flux density and coercivity are not mentioned and the possibility of increasing the torque during the field-weakening control is unclear.
Therefore, the present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a steel sheet that makes it possible to further increase the output torque in a high-speed rotational range and further increase the maximum rotational speed when using the steel sheet for a rotor core for an IPM motor.
Another object of the present invention is to provide a method for manufacturing such a steel sheet for a rotor core for an IPM motor.
The inventors of the present invention have produced test IPM motors by using various steel sheets and performed performance evaluations of the motors in order to solve the above-mentioned problems. The results obtained have demonstrated that adjusting the magnetic flux density and residual magnetic flux density of the base steel sheet is an effective method, and adjusting the magnetic flux density, residual magnetic flux density, and coercivity is an even more effective method for reducing the leaking magnetic flux from the permanent magnets, increasing the magnetic flux which is effective for the magnet torque, and also obtaining a large output torque in a high-speed rotational range in which the field-weakening control is performed.
Thus, the present invention provides a steel sheet for a rotor core for an IPM motor, wherein the steel sheet has a magnetic flux density B8000 of 1.65 T or more as measured when a magnetic field strength is 8000 A/m, a residual magnetic flux density Br of 0.5 T or more as measured at that time, and optionally a coercivity Hc of 100 A/m or more as measured after a magnetization reaches 8000 A/m.
The present invention also provides a method for manufacturing a steel sheet for a rotor core for an IPM motor, which has a magnetic flux density B8000 of 1.65 T or more as measured when a magnetic field strength is 8000 A/m, a residual magnetic flux density Br of 0.5 T or more as measured at that time, and optionally a coercivity Hc of 100 A/m or more as measured after a magnetization reaches 8000 A/m, wherein a hot-rolled steel sheet having a composition consisting of C: more than 0.0005% by mass to 0.90% by mass, Si: 0% by mass to 3.0% by mass, Mn: 0% by mass to 2.5% by mass, P: 0.05% by mass or less, S: 0.02% by mass or less, acid-soluble Al: 0.005% by mass to 3.0% by mass, and Si+Al: 5.0% by mass or less, with a balance of Fe and inevitable impurities, is cold rolled once, or cold rolled two or more times with an intermediate annealing, at a final reduction of 10% or more and then heated to a temperature of 200° C. to 500° C.
When the steel sheet of the present invention is used for a rotor core for an IPM motor, it is possible to reduce the leaking magnetic flux from the permanent magnets, increase the magnetic flux which is effective for the magnet torque, and also further increase the output torque in a high-speed rotational range, and further increase the maximum rotational speed of the steel sheet.
The steel sheet for a rotor core for an IPM motor in accordance with the present invention is characterized by a magnetic flux density B8000 of 1.65 T or more as measured when a magnetic field strength is 8000 A/m, a residual magnetic flux density Br of 0.5 T or more as measured at that time, and optionally a coercivity Hc of 100 A/m or more as measured after a magnetization reaches 8000 A/m.
The reasons for placing limitations on the magnetic characteristics are explained hereinbelow.
<Magnetic Flux Density B8000 as Measured when a Magnetic Field Strength is 8000 A/m: 1.65 T or More>
The magnetic flux density B8000 is set to 1.65 T or more in order to effectively use the reluctance torque based on the difference in the inductance value between a position (d axis) at which a permanent magnet 12 is inserted and a position (q axis) at which the magnet is not inserted when the rotor rotates at a high speed, and to demonstrate the torque performance equal to or better than that of the conventional steel sheets, in particular, in a high-speed rotational range.
<Residual Magnetic Flux Density Br as Measured after a Magnetization Reaches 8000 A/m: 0.5 T or More>
The effect of setting the residual magnetic flux density Br as measured after a magnetization reaches 8000 A/m to 0.5 T or more is described below. Thus, in an IPM motor, a magnetic flux (q-axis magnetic flux) passing through the inside of the rotor is made to flow from the stator side in order to obtain a reluctance torque, in addition to the magnet magnetic flux (d-axis magnetic flux) created by the permanent magnets, the torque is increased, and efficiency is also increased. However, it is well known, as indicated, for example, in “Heisei 23 Nendo Denki Gakkai Sangyo Oyo Bumon Daikai Koen Rombunshu (2011 IEEE-Japan Industry Applications Society Conference, National Convention Record), 3-24 (2011), PIII-179”, that where the input current of the motor is increased and the q-axis magnetic flux is increased, the orientation of the d-axis magnetic flux is shifted and deflected in the direction opposite to the rotational direction due to interference with the d-axis magnetic flux, and the maximum torque is reduced through the change of d-axis and q-axis inductance. This phenomenon is called dq-axes interference and is caused by strengthening of the magnetic flux forward in the rotational direction and weakening of the magnetic flux rearward in the rotational direction with respect to the original d-axis magnetic flux. In a material with high magnetic permeability, in which coercivity is small and residual magnetic flux density is also small, as in an electromagnetic steel sheet, the weakening of the magnetic flux rearward in the rotational direction proceeds smoothly, whereas in a material with low magnetic permeability, which has large coercivity, the weakening of the magnetic flux is suppressed due to large residual magnetic flux density, thereby reducing the deflection caused by the aforementioned shift of the d-axis magnetic flux. As a result, it is possible to suppress the decrease in the maximum torque associated with the dq-axes interference. In order to obtain such a result, it is necessary to make the residual magnetic flux density Br of 0.5 T or more, preferably 1.0 T or more, as measured after a magnetization reaches at least 8000 A/m. The inventors of the present invention have fabricated test IPM motors by using various steel sheets and evaluated the performance of the motors. The results obtained demonstrate that where a rotor core is formed using a steel sheet with a residual magnetic flux density Br of 0.5 T or more, desirably 1.0 T or more, power consumption of the field-weakening control performed during high-speed rotation can be reduced and the output torque can be increased.
<Coercivity Hc as Measured after a Magnetization Reaches 8000 A/m: 100 A/m or More>
When high torque is needed in a high-speed rotational range, it is preferred that the steel sheet in accordance with the present invention have a coercivity of 100 A/m or more. The reason therefore is explained below. Thus, since the magnetic permeability decreases as the coercivity increases, the leaking magnetic flux from the permanent magnet in a bridge portion decreases. As a result, the magnetic flux from the permanent magnet can be effectively used. In order to obtain such an effect, the coercivity Hc after a magnetization reaches 8000 A/m should be preferably 100 A/m or more, more preferably 300 A/m or more, and most preferably 1000 A/m or more. The effectiveness of this effect increases in a structure in which the leaking magnetic flux from the permanent magnet is large, for example, when the permanent magnet is split in two and a center bridge is provided in order to increase resistance to centrifugal forces acting during high-speed rotation, although the results vary depending on the rotor structure.
Although no mechanical strength is necessarily required for the steel sheet in accordance with the present invention, when the steel sheet is used for an IPM motor for which high-speed rotation is needed, it is preferred that the steel sheet have a yield strength of 780 N/mm2 or more. Where the yield strength is within this range, the rotor core can withstand the centrifugal forces acting upon the permanent magnet during high-speed rotation and the rotor is not damaged even in a high-speed rotational range. Furthermore, since the steel sheet in accordance with the present invention excels in field-weakening controllability, the decrease in torque can be suppressed even in a high-speed rotational range. Therefore, a high-performance motor in which high-speed rotation and high torque are obtained can be provided. Therefore, the motor can be used for various applications, such as automobiles and home electric appliances. Further, by imparting sufficient strength to the steel sheet, it is possible to reduce the width of the bridge provided in the permanent magnet insertion holes of the rotor, thereby making it possible to further reduce the leaking magnetic flux. Where the leaking magnetic flux can be decreased without damaging the rotor even when the bridge width is reduced due to the increased strength of the rotor core, the degree of freedom in designing the rotor is increased. Furthermore, since the permanent magnet can be reduced in size due to the reduction in the leaking magnetic flux, the motor can be greatly reduced in terms of cost. The output torque can also be increased without reducing the permanent magnet in size. The bridge width may also be designed in consideration of both the increase in torque, which results from the possible high-speed rotation, and the reduction of the permanent magnets in size. The upper limit of the yield strength of the steel sheet in accordance with the present invention is 2000 N/mm2. This is because the magnetic flux density B8000 of 1.65 T or more cannot be obtained at a magnetic field strength of 8000 A/m in a material with a yield strength above 2000 N/mm2.
The yield strength in the present invention is measured by a tensile test method stipulated by JIS Z 2241 by using a JIS No. 5 tensile test piece.
It is also preferred that the steel sheet in accordance with the present invention have a flatness equal to or less than 0.1%, the flatness being defined by a steepness per sheet width. Since a rotor for an IPM motor is manufactured by laminating steel sheets punched to a rotor shape, a good space factor during the lamination is preferred. In order to obtain a good space factor, it is preferred that the flatness defined by the steepness per sheet width be equal to or less than 0.1%. The flatness in the present invention is obtained by representing (in percentage) maximum height (height obtained by subtracting the sheet thickness) per unit length in the width direction in a state in which a steel sheet with a length of 1 m or more is placed on a fixed table.
The steel sheet in accordance with the present invention preferably has a composition consisting of C: more than 0.0005% by mass to 0.90% by mass, Si: 0% by mass to 3.0% by mass, Mn: 0% by mass to 2.5% by mass, P: 0.05% by mass or less, S: 0.02% by mass or less, acid-soluble Al: 0.005% by mass to 3.0% by mass, and Si+Al: 5.0% by mass or less, with a balance of Fe and inevitable impurities. The components of the steel material may include one or more components selected from the group consisting of Ti, Nb, and V at 0.01% by mass to 0.20% by mass in total, one or more components selected from the group consisting of Mo: 0.1% by mass to 0.6% by mass, Cr: 0.1% by mass to 1.0% by mass and B: 0.0005% by mass to 0.005% by mass, and one or more components selected from the group consisting of Cu: 0.05% by mass to 1.5% by mass and Ni: 0.05% by mass to 1.0% by mass.
The reasons for restricting the composition of the steel material are explained below.
<C: More than 0.0005% by Mass to 0.90% by Mass>
C is an element that precipitates as a solid solution or cementite (Fe3C) in steel and effectively increases the steel strength. The content of C in excess of 0.0005% by mass is preferred for obtaining a yield strength suitable for use in a rotor core for an IPM motor. However, where the content is above 0.90% by mass, the magnetic flux density tends to decrease. In particular, it is preferred that the content of C be equal to or higher than 0.05% by mass in order to obtain a yield strength of 780 N/mm2 or more.
<Si: 0% by Mass to 3.0% by Mass>
Si is an element effective in increasing the steel strength and also effective in increasing volume resistivity and reducing eddy current loss, but in the present invention, the addition thereof is optional. In order to obtain the effect of suppressing eddy current loss and increasing strength, it is preferred that the content of silicon be equal to or higher than 0.01% by mass. However, where the content is higher than 3.0% by mass, the toughness of the steel sheet is degraded, and in addition, the magnetic flux can be reduced.
<Mn: 0% by Mass to 2.5% by Mass>
Mn is an element effective in increasing the steel strength, but in the present invention, the addition thereof is optional. In order to obtain the effect of increasing strength, it is preferred that the content of manganese be equal to or higher than 0.05% by mass. However, where the content exceeds 2.5% by mass, the strength increasing effect is saturated and the magnetic flux density can be decreased.
<P: 0.05% by Mass or Less>
P is an element effective in increasing the steel strength, but it greatly decreases the steel toughness. Since the content up to 0.05% by mass is allowed, the upper limit is set to 0.05% by mass.
<S: 0.02% by Mass or Less>
S is an element causing high-temperature embrittlement, and when contained in a large amount, it causes surface defects during hot rolling and degrades the surface quality. Therefore, it is preferred that the content thereof be as low as possible. Since a content up to 0.02% by mass is allowed, the upper limit is set to 0.02% by mass.
<Soluble Al: 0.005% by Mass to 3.0% by Mass, and Si+Al: 5.0% by Mass or Less>
Al is an element that is added as a deoxidizing agent and it is also effective, similarly to Si, in increasing the volume resistivity of steel. For this effect to be demonstrated, it is preferred that acid-soluble Al be contained at 0.005% by mass or more. However where the total content thereof and Si exceeds 5.0% by mass, the decrease in magnetic flux density increases and the performance of the motor can be degraded.
<One or More from Ti, Nb, and V: 0.01% by Mass to 0.20% by Mass>
Ti, Nb and V are elements that form carbonitrides in steel and are effective in increasing the steel strength by precipitation hardening. In order to obtain this effect, it is preferred that one, or two or more thereof be added at 0.01% by mass or more. However, where those elements are added in an amount above 0.20% by mass, the increase in strength is saturated by the coarsening of precipitates and the production costs can be increased.
<One or More from Mo: 0.1% by Mass to 0.6% by Mass, Cr: 0.1% by Mass to 1.0% by Mass and B: 0.0005% by Mass to 0.005% by Mass>
Mo, Cr, and B are elements increasing the quenching ability of steel and are effective in increasing the steel strength. In order to obtain such effects, it is preferred that one or more of Mo, Cr, and B be added in an amount equal to or higher than a lower limit value that has been set therefor. However, where those elements are added in excess of the upper limit values that have been set for each of them the effects reach saturation and the production costs increase. The effects are demonstrated when only one element is added and when two or more of the elements are added, but when two or more of the elements are added, where the amount added exceeds ½ of the upper limit value that has been set for each of them, the increase in production costs becomes large in comparison to the effects obtained. Therefore, it is preferred that the amount added be equal to or less than ½.
<One or More Cu: 0.02% by Mass to 1.5% by Mass and Ni: 0.02% by Mass to 1.0% by Mass>
Cu and Ni increase the quenching ability of steel and are effective in increasing the steel strength. They are also elements effective in raising the saturation magnetic flux density. In order to obtain those effects, it is preferred that the elements be added in an amount equal to or higher than the lower limit value that has been set therefor. However, where those elements are added in excess of the upper limit values that have been set for each of them, the effects reach saturation and the production costs increase.
The method for manufacturing a steel sheet for a rotor core for an IPM motor in accordance with the present invention will be explained below. In the method for manufacturing a steel sheet for a rotor core for an IPM motor in accordance with the present invention, a hot-rolled steel sheet having the above-described composition is cold rolled at a final reduction of 10% or more and then heated to a temperature of 200° C. to 500° C., or cold rolled once, or cold rolled two or more times with an intermediate annealing, at a final reduction of 3% or more.
<Hot Rolling Conditions>
Hot rolling conditions need not be particularly specified, and hot rolling may be implemented by the usual method, but it is preferred that the finish temperature of hot rolling be in a γ single-phase region. Further, where the coiling temperature is too high, oxide scale becomes thick, thereby impeding subsequent pickling. Therefore, it is preferred that the coiling temperature be equal to or lower than 700° C.
<Metallographic Structure>
In order to obtain a high magnetic flux density, it is preferred that the metallographic structure of the steel sheets obtained by hot rolling (the steel sheet before the cold rolling) consists of one or more selected from the group consisting of ferrite, pearlite, bainite and martensite, which are ferromagnetic, and optionally includes a carbonitride including one or more selected from the group consisting of Fe, Ti, Nb, V, Mo, and Cr. Since the magnetic flux density decreases when a nonmagnetic austenite phase is contained, the structure does not include austenite.
<Cold Rolling Conditions>
The obtained hot-rolled steel sheet may be cold rolled once after annealing, or may be cold rolled two or more times with intermediate annealing, but it is preferred that the final reduction is 10% or more. Where the cold rolling reduction is less than 10%, the yield strength can be below 780 N/mm2.
<Press Tempering Treatment>
By performing the press tempering treatment of the as-cold-rolled steel sheet at 200° C. to 500° C., which is a comparatively low-temperature range below the recrystallization temperature, it is possible to rearrange the dislocations introduced by cold rolling, reduce the residual stresses, and obtain a flatness of the steel sheet of 0.1% or less. Where the heating temperature is below 200° C., good flatness cannot be obtained. Meanwhile, where the heating temperature is above 500° C., the advance of dislocation recovery is accompanied by significant softening and sufficient yield strength cannot be obtained. The pressure in press tempering need not be particularly high, provided that the flat shape of the steel sheet is maintained. For example, in the case of a thin steel sheet with a thickness equal to or less than 1.0 mm, a low pressure of less than 1 kg/cm2 is sufficient.
<Tension Annealing Treatment>
By performing the tension annealing treatment of the as-cold-rolled steel sheet at 200° C. to 500° C., which is a comparatively low-temperature range below the recrystallization temperature, it is possible to rearrange the dislocations introduced by cold rolling, reduce the residual stresses, and obtain a flatness of the steel sheet of 0.1% or less, in the same manner as when the aforementioned press tempering treatment is performed. Where the heating temperature is below 200° C., good flatness cannot be obtained. Meanwhile, where the heating temperature is above 500° C., the softening occurs as mentioned above and sufficient yield strength cannot be obtained. The tensile tension in tension annealing need not be particularly large, provided that the flat shape of the steel sheet is maintained, and a sufficient effect can be obtained at a tension equal to or higher than 1 N/mm2. However, where a tension in excess of 200 N/mm2 is applied, the sheet can rupture inside a furnace. Therefore, it is preferred that the upper limit be set to 200 N/mm2.
<Formation of Insulating Coating>
In accordance with the present invention, it is preferred that an insulating coating consisting of an organic material, an insulating coating consisting of an inorganic material, or an insulating coating consisting of an organic-inorganic composite material be formed on at least one surface of the steel sheet with the object of reducing the eddy current loss generated in the rotor. An insulating coating consisting of an inorganic material can be obtained using an inorganic aqueous solution which includes aluminum dihydrogen phosphate and is free from hazardous substances such as hexavalent chromium. An insulating coating consisting of an organic material or an insulating coating consisting of an organic-inorganic composite material may also be used, provided that good insulation is obtained. The insulating coating can be formed by coating the material presented hereinabove by way of example on the surface of a steel sheet. When the press tempering treatment is performed, it is preferred that the material presented hereinabove by way of example be coated on the surface of a steel sheet before the press tempering treatment.
Steel having the compositions shown in Tables 1 and 2 was vacuum melted and the continuously cast slabs thereof were heated to 1250° C., finish rolled at 950° C., and coiled at 560° C. to obtain hot-rolled steel sheets with a sheet thickness of 1.8 mm. These hot-rolled steel sheets were pickled and cold rolled once to obtain cold-rolled steel strips with a thickness of 0.35 mm (final reduction: about 81%).
The cold-rolled steel strips were allowed to pass 60 seconds in a continuous furnace set at 400° C., and tension tempering treatment was performed by applying a tension of 100 N/mm2 in the furnace. Then, an insulating coating with a thickness of about 1 μm, having a semi-organic composition including Cr oxide and Mg oxide, was formed on both sides of the steel sheets.
Ring-shaped test pieces with an inner diameter of 33 mm and an outer diameter of 45 mm were fabricated by punching from the obtained steel strips and used for DC magnetization measurements under the condition of magnetization to 8000 A/m. The steepness per unit width of the obtained steel strips was measured, and JIS No. 5 test pieces were cut out from the obtained steel strips and provided for a tensile test. In the bending test, bendability was evaluated by assigning good bendability (◯) to test pieces in which no cracking occurred and assigning poor bendability (×) to test pieces in which cracking occurred. The sheet-thickness cross section in the rolling direction of each steel sheet before the cold rolling was etched with a 2% nital reagent (2% nitric acid-ethyl alcohol solution), and observations using a scanning electron microscope were used to classify the metallographic structure into ferrite, pearlite, bainite, and martensite on the basis of the morphology thereof.
The magnetic flux density B8000 at a magnetic field strength of 8000 A/m, residual magnetic flux density Br and coercivity Hc at this time, flatness, yield strength, tensile strength, yield ratio (YR), and metallographic structure before the cold rolling of each sample are shown in Tables 3 and 4.
1.62
1.63
1.62
1.60
1.62
As can be clearly seen from the results shown in Tables 3 and 4, although good values of the residual magnetic flux density Br and coercivity Hc were obtained in all of the steels due to processing strains caused by cold rolling, in steel No. 17 with a C content above the range of the invention of the present application, the magnetic flux density B8000 was low. Further, the magnetic flux density B8000 also decreased in steel Nos. 24 to 27 which have a high content of Si, Al, and Mn. Steel No. 24 with a high Si content had inferior bendability. By contrast, in steel having chemical components within the ranges of the invention of the present application, a high magnetic flux density B8000 which is equal to or higher than 1.65 T, good residual magnetic flux density Br which is equal to or higher than 0.5 T, and good coercivity Hc which is equal to or higher than 100 A/m were obtained.
Among the steel strips obtained, steel Nos. 1, 4, 11 and 29 were punched into rotors with an 8-pole (4 pole pairs) structure shown in
Mechanical properties and magnetic properties were evaluated for the commercial electromagnetic steel sheet (35A300, sheet thickness: 0.35 mm) by the same method as used for the base steel sheets in accordance with the present invention. The yield strength was 381 N/mm2, the tensile strength was 511 N/mm2, the saturation magnetic flux density B8000 was 1.76 T, the residual magnetic flux density Br was 0.42 T, and the coercivity Hc was 61 A/m.
Specifications of the fabricated rotor and stator are described below.
<Rotor Specifications>
Outer diameter: 80.1 mm, axial length: 50 mm
<Stator Specifications>
The maximum torque and efficiency of IPM motors incorporating respective rotors at 5000 rpm and a current advance angle (β) of 0°, and also the maximum torque and efficiency at 15,000 rpm obtained by implementing the field-weakening control such as to obtain the maximum torque are shown in Table 5 for the input conditions of a carrier frequency of 1000 Hz, a maximum voltage of 220 V, and a maximum current of 24 A.
0.42
As can be clearly seen from the results shown in Table 5, in a motor incorporating a rotor using as a material for the rotor core a steel sheet (electromagnetic steel sheet) with a residual magnetic flux density Br less than 0.5 and a coercivity Hc less than 100 A/m, the maximum torque at 5000 rpm and β=0° was low and the efficiency degraded. In addition, such motor also had a low maximum torque of less than 2.0 N·m and a low efficiency at 15,000 rpm when the field-weakening control was implemented. By contrast, in the motor using for the rotor core a steel sheet having the magnetic flux density (B8000 and Br) and coercivity Hc stipulated by the present invention, a high maximum torque was obtained at 5000 rpm and β=0° and the efficiency was also high. Furthermore, this motor had a high maximum torque equal to or higher than 2.5 N·m and a high efficiency at 15,000 rpm when the field-weakening control was implemented.
Because the deflection resulting from the shift of the d-axis magnetic flux caused by the dq-axes interference was small, the current advance angle β at which maximum torque was obtained at 15,000 rpm in the material of the present invention had a value lower than that of the comparative material.
Continuously cast slabs of steel Nos. 1, 2, 3, 4, 8, 9 and 11, among the steel having the compositions shown in Table 1, were heated to 1250° C., finish rolled at 950° C., and coiled at 560° C. to obtain hot-rolled steel sheets with a sheet thickness of 1.8 mm in the same manner as in Example 1. These hot-rolled steel sheets were pickled and cold rolled once to obtain cold-rolled steel strips with a thickness of 0.35 mm (final reduction: about 81%).
The obtained cold-rolled steel strips were subjected to recrystallization annealing by allowing the strips to pass for 60 seconds in a continuous furnace set at 800° C. After cooling down to 550° C. at a rate of 8° C./s, overaging treatment was performed in which the sheets were held for 120 seconds or longer in a continuous furnace set to 450° C. Soft cold rolling with an elongation of 0.3% was then performed and an insulating coating with a thickness of about 1 μm, having a semi-organic composition including Cr oxide and Mg oxide, was formed on both sides of the steel sheets.
The magnetic flux density B8000 at a magnetic field strength of 8000 A/m, residual magnetic flux density Br and coercivity Hc at this time, flatness, yield strength, tensile strength, yield ratio (YR), bendability and metallographic structure of each sample were evaluated in the same manner as in Example 1. The results are shown in Table 6.
0.45
0.48
0.46
0.49
As can be clearly seen from the results shown in Table 6, even when no strains are imparted by cold rolling and heat treatment, where the number of fine precipitates is large, as in steel No. 3, a residual magnetic flux density Br of 0.5 T or more was obtained. Further, where the C content is equal to or higher than 0.05% by mass, a good value of coercivity Hc which is equal to or higher than 100 A/m was obtained. Even when the C content was low, a steel sheet having the magnetic flux density (B8000 and Br) and coercivity Hc stipulated by the present invention can be obtained by imparting strains such as in Example 1, but the desirable range of C content is equal to or higher than 0.05% by mass.
Rotors were fabricated in the same manner as in Example 1 by using steel Nos. 1, 2, 3, 9 and 11 among the obtained steel strips, and the rotors were provided for a motor performance evaluation test.
The maximum torque and efficiency of IPM motors incorporating respective rotors at 15000 rpm are shown in Table 7 for the input conditions of a carrier frequency of 1000 Hz, a maximum voltage of 220 V, and a maximum current of 24 A. All of the properties were evaluated under the optimum field-weakening control conditions at which the maximum torque was obtained.
0.45
0.48
As can be clearly seen from the results shown in Table 7, in a motor incorporating a rotor using as a material for the rotor core a steel sheet (steel Nos. 1 and 2) with a residual magnetic flux density Br less than 0.5 when magnetized to 8000 A/m, a maximum torque at 15,000 rpm had a low value of less than 2.0 N·m and also a low efficiency. By contrast, in the motor using for the rotor core a steel sheet having the magnetic flux density (B8000 and Br) stipulated by the present invention, a high maximum torque equal to or higher than 2.0 N·m and also good efficiency are obtained.
In
Continuously cast slabs of steel Nos. 1 and 9, among the steel having the compositions shown in Table 1, were heated to 1250° C., finish rolled at 950° C., and coiled at 560° C. to obtain hot-rolled steel sheets with a sheet thickness of 1.8 mm in the same manner as in Example 2. These hot-rolled steel sheets were pickled and cold rolled once to obtain cold-rolled steel strips with a thickness of 0.306 mm to 0.400 mm.
The obtained cold-rolled steel strips were subjected to recrystallization annealing by holding them for 60 seconds in a continuous furnace at 800° C. After cooling down to 550° C. at a rate of 8° C./s, overaging treatment was performed in which the sheets were held for 120 seconds or longer in a continuous furnace set to 450° C. Cold rolling was then performed to a thickness of 0.300 mm, and the final reduction was changed to 2% to 25%. Steel No. 1 was also subjected to tension annealing treatment (tensile tension 100 N/mm2) by allowing the steel to pass for 60 seconds through a continuous furnace that was set to 500° C. Then, an insulating coating with a thickness of about 1 μm, having a semi-organic composition including Cr oxide and Mg oxide, was formed on both sides of the steel sheets.
The magnetic flux density B8000 at a magnetic field strength of 8000 A/m, residual magnetic flux density Br and coercivity Hc at this time, flatness, yield strength, tensile strength, yield ratio (YR), bendability and metallographic structure of each sample were evaluated in the same manner as in Example 1. The results are shown in Table 8.
0.49
0.44
0.49
As can be clearly seen from the results shown in Table 8, in order to obtain a good residual magnetic flux density Br which is 0.5 T or more by cold rolling also in steel No. 1, it is sufficient to perform the cold rolling at a reduction of 3% or more when no heating is performed after the cold rolling, or cold rolling may be performed at a reduction of 10% or more when heating is conducted at 200° C. to 500° C. Further, it is clear that where the cold rolling is performed at 10% or more, good residual magnetic flux density Br and coercivity Hc can be obtained even when tension annealing is performed at 500° C. after the cold rolling. In steel No. 9 in which the C content was 0.05% by mass or more, a coercivity Hc of 100 A/m or more was obtained regardless of whether the cold rolling is performed, but the residual magnetic flux density Br and coercivity Hc tend to increase with the increase in the cold rolling reduction.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-081377 | Mar 2012 | JP | national |
| 2012-236812 | Oct 2012 | JP | national |
This application is a divisional of U.S. Ser. No. 14/389,602, filed Sep. 30, 2014, which is a 35 U.S.C. 371 National Phase Entry Application from PCT/JP2013/059010, filed Mar. 27, 2013, which claims the benefit of Japanese Patent Application No. 2012-081377 filed Mar. 30, 2012 and Japanese Patent Application No. 2012-236812 filed on Oct. 26, 2012, the disclosures of which are incorporated herein in their entirety by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14389602 | Sep 2014 | US |
| Child | 15245692 | US |
