JP6964796B2 - Rotor, Consequent Pole Rotor, Motor, Blower, Refrigeration and Air Conditioner, Rotor Manufacturing Method, and Consequential Pole Rotor Manufacturing Method - Google Patents

Description

The present invention relates to a rotor for an electric motor, particularly a concave pole type rotor.

A sequential pole type rotor is used as the rotor of the electric motor. In the concave pole type rotor, two or more permanent magnets are arranged on the rotor core so that one of the north and south poles of the permanent magnet faces the stator of the motor. The number of permanent magnets arranged in the rotor core is half the number of magnetic poles in the rotor. For example, when the number of magnetic poles of the rotor is 4, the number of permanent magnets is 2. For example, when the north pole side of each permanent magnet faces the stator, the region (also referred to as salient pole) between two permanent magnets adjacent to each other in the circumferential direction functions as an south pole (for example, Patent Document). 1).
In the sequential pole type rotor disclosed in Patent Document 1, the magnetic flux from each permanent magnet easily flows into the region between two permanent magnets adjacent to each other. That is, the leakage flux tends to increase. As a result, there is a problem that the torque of the electric motor tends to decrease.
Therefore, in the rotor disclosed in Patent Document 2, the rotor core is divided into an inner magnetic pole portion and an outer magnetic pole portion. Since a space is formed on the outside of the outer magnetic pole portion in the circumferential direction, the leakage flux is reduced.

Japanese Unexamined Patent Publication No. 2012-244783 Japanese Unexamined Patent Publication No. 2012-147644

However, in the conventional technique, since the inner magnetic pole portion and the outer magnetic pole portion separated from each other are fixed by the cover member, it is not easy to assemble the rotor and the rigidity of the rotor is insufficient. If the rotor is not rigid enough, the motor will vibrate and make noise. On the other hand, if the inner magnetic pole portion and the outer magnetic pole portion are integrated, the rigidity of the rotor is increased, but there is a problem that the leakage flux increases and the torque of the motor decreases.

An object of the present invention is to facilitate the assembly of the rotor, reduce the leakage flux in the rotor, and reduce the vibration and noise in the motor having the rotor.

The consequent pole type rotor according to one aspect of the present invention is a consequent pole type rotor having a plurality of iron cores having slits extending in the axial direction and permanent magnets arranged in the slits. The first core of the plurality of iron cores having slits, the slit, the first inner core portion located inside the slit in the radial direction, and the first inner core portion separated from the first inner core portion and having the diameter. A second core among the plurality of iron cores having a first outer core portion located outside the slit in the direction, the slit, and a second inner core portion located inside the slit in the radial direction. And a third iron core among the plurality of iron cores, which is separated from the second inner core portion and has a second outer core portion located outside the slit in the radial direction. The iron core, the second core, and the third core are laminated in the axial direction, and at least one of the first inner core portion and the first outer core portion faces the permanent magnet in the circumferential direction. Has protrusions.
The rotor according to another aspect of the present invention is a rotor having a plurality of iron cores having slits extending in the axial direction and a permanent magnet arranged in the slits, and the plurality of rotors having the slits. The first core in the iron core, the slit, the first inner core portion located inside the slit in the radial direction, and the first inner core portion separated from the first inner core portion, and outside the slit in the radial direction. The second core of the plurality of iron cores having the first outer core portion located, the slit, the second inner core portion located inside the slit in the radial direction, and the second inner core portion. A third core among the plurality of iron cores having a second outer core portion separated from the portion and located outside the slit in the radial direction, the first core, the second core, and the like. The third iron core is laminated in the axial direction, and at least one of the first inner core portion and the first outer core portion has protrusions facing the permanent magnet in the circumferential direction.

According to the present invention, it is possible to facilitate the assembly of the rotor, reduce the leakage flux in the rotor, and reduce the vibration and noise in the motor having the rotor.

It is a partial cross-sectional view which shows schematic structure of the electric motor which concerns on Embodiment 1 of this invention. It is sectional drawing which shows typically the structure of the electric motor 1 in the xy plane. It is a figure which shows the plurality of division iron core parts arranged in a row. It is an enlarged view which shows the structure of the region E1 shown by the broken line in FIG. It is a figure which shows the plurality of division iron core portions arranged in a ring shape. It is an enlarged view which shows the structure of the region E2 shown by the broken line in FIG. It is sectional drawing which shows schematic structure of a rotor. It is a figure which shows roughly the structure of the 1st iron core. It is a figure which shows roughly the structure of the 2nd iron core. It is a figure which shows roughly the structure of the 3rd iron core. It is a figure which shows another example of the 1st iron core. It is a figure which shows another example of the 2nd iron core. It is a figure which shows still another example of the 2nd iron core. It is sectional drawing which shows the other example of a rotor schematicly. It is sectional drawing which shows the other example of a rotor schematicly. It is sectional drawing which shows another example of a rotor core. It is sectional drawing which shows still another example of a rotor core. It is a flowchart which shows an example of the manufacturing process of a rotor. It is a figure which shows an example of the resin molding process. It is a figure which shows an example of the resin molding process. It is a figure which shows schematic structure of the rotor which is a conceit pole type rotor as a comparative example. It is an enlarged view which shows the structure of a part of the rotor shown in FIG. It is a figure which shows schematic structure of the fan which concerns on Embodiment 2 of this invention. It is a figure which shows schematic the structure of the air conditioner which concerns on Embodiment 3 of this invention.

Embodiment 1.
In the xyz Cartesian coordinate system shown in each figure, the z-axis direction (z-axis) indicates a direction parallel to the axis Ax of the electric motor 1, and the x-axis direction (x-axis) is orthogonal to the z-axis direction (z-axis). The y-axis direction (y-axis) indicates a direction orthogonal to both the z-axis direction and the x-axis direction. The axis Ax is the center of rotation of the rotor 3. The direction parallel to the axis Ax is also referred to as "axial direction of rotor 3" or simply "axial direction". The radial direction is the radial direction of the rotor 3 and is the direction orthogonal to the axis Ax. The xy plane is a plane orthogonal to the axial direction. The arrow D1 indicates a circumferential direction (hereinafter, also simply referred to as “circumferential direction”) about the axis Ax.

FIG. 1 is a partial cross-sectional view schematically showing the structure of the motor 1 according to the first embodiment of the present invention.
FIG. 2 is a cross-sectional view schematically showing the structure of the motor 1 in the xy plane. In FIG. 2, the mold resin 23 is removed from the stator 2.

The electric motor 1 includes a stator 2, a rotor 3, a circuit board 4, a magnetic sensor 5 that detects the rotational position of the rotor 3, a bracket 6, bearings 7a and 7b, and a rotational position detection of the rotor 3. It has a sensor magnet 8 as a magnet for use. The electric motor 1 is, for example, a permanent magnet synchronous motor driven by an inverter.

The rotor 3 is rotatably arranged inside the stator core 20.

The stator 2 has a stator core 20, a coil 21 wound around the stator core 20, and a mold resin 23. The stator core 20 has at least one yoke 20b and a plurality of teeth 20c. The insulator 22 may be arranged between the stator core 20 and the coil 21. In the example shown in FIG. 1, the mold resin 23 covers the stator core 20 and the coil 21. Therefore, the stator 2 shown in FIG. 1 is also referred to as a mold stator.

The circuit board 4 is provided on one end side of the stator 2 in the axial direction. Electronic components such as a control circuit and a magnetic sensor 5 are attached to the circuit board 4. Further, the lead wire is connected to the circuit board 4. The magnetic sensor 5 detects the rotational position of the rotor 3 by detecting the rotational position of the sensor magnet 8. The sensor magnet 8 is attached to the rotor 3 so as to face the magnetic sensor 5. The magnetic sensor 5 is, for example, a Hall IC.

As the mold resin 23, for example, an unsaturated polyester resin is used. Specifically, as the material of the mold resin 23, it is desirable to use a thermosetting resin (for example, Bulk Molding Compound: BMC) made by adding an additive to an unsaturated polyester resin.

As the material of the mold resin 23, a thermoplastic resin such as polybutylene terephthalate (PBT) or polyphenylene sulfide (PPS) may be used. In this case, the runner used when molding the mold resin 23 can be recycled.

When an unsaturated polyester resin and BMC are used as the mold resin 23, the strength of the stator 2 can be increased. As a result, deformation of the stator 2 due to the exciting force generated in the motor 1 can be prevented, and vibration and noise in the motor 1 can be reduced.

FIG. 3 is a diagram showing a plurality of divided iron core portions 20a arranged in a row.
FIG. 4 is an enlarged view showing the structure of the region E1 shown by the broken line in FIG.
FIG. 5 is a diagram showing a plurality of divided iron core portions 20a arranged in a ring shape.
FIG. 6 is an enlarged view showing the structure of the region E2 shown by the broken line in FIG.

The stator core 20 is composed of a plurality of divided iron core portions 20a (specifically, 12 divided iron core portions 20a). Each split iron core portion 20a has one yoke 20b and one tooth 20c protruding from the yoke 20b. The divided iron core portions 20a adjacent to each other are connected by a thin portion 20d of the yoke 20b.

For example, in the manufacturing process of the stator core 20, the coil 21 is wound around each tooth 20c with the 12 divided iron cores 20a arranged in a row. Further, these divided iron core portions 20a are bent in an annular shape.

Since the stator core 20 is composed of a plurality of divided iron core portions 20a, the coil 21 can be wound in a state where these divided iron core portions 20a are arranged in a row. As a result, the density of the coil 21 can be increased, which is effective for increasing the efficiency of the motor 1. However, since the split core portion 20a is connected by the thin portion 20d of the yoke 20b, the rigidity of the stator core 20 after the split core portion 20a is bent in an annular shape is weak.

Therefore, in a rotor having a large exciting force such as a concave pole type rotor, it is effective to cover the stator core 20 with the mold resin 23. Thereby, the rigidity of the rotor core 30 can be increased.

However, the structure of the stator core 20 is not limited to the examples shown in FIGS. 2 to 6. For example, the divided iron core portion 20a may be connected by a concave-convex dowel formed at the end portion of the yoke 20b instead of the thin-walled portion 20d. Instead of using a dowel, both ends of the divided iron core portion 20a may be welded, or one end of the divided iron core portion 20a may be fitted to the other end of the divided iron core portion 20a. By covering the stator core 20 formed by such a method with the mold resin 23, vibration and noise in the motor 1 can be reduced.

It is desirable that the split portion 20e, which is a region between two yokes 20b adjacent to each other in the circumferential direction, is filled with the mold resin 23. Thereby, the influence of the exciting force applied to the teeth 20c can be reduced.

A hole 20f is formed between two yokes 20b adjacent to each other in the circumferential direction. In the present embodiment, a plurality of holes 20f are formed in the stator core 20. Each hole 20f is adjacent to the divided portion 20e. Each hole 20f extends in the axial direction. In the manufacturing process of the stator 2, when the mold resin 23 is molded around the stator core 20, the mold resin 23 is filled in each hole 20f.

The mold resin 23 may not be filled in all the regions in each hole 20f. That is, the mold resin 23 may not be filled from one end to the other end in the hole 20f in the axial direction. It suffices that at least one end of the region in the hole 20f in the axial direction is filled with the mold resin 23. As a result, the vibration in the motor 1 can be damped. In order to prevent deterioration of the magnetic properties of the stator core 20, the size of the hole 20f and the filling amount of the mold resin 23 are appropriately determined. As shown in FIG. 4, a part of the hole 20f in the xy plane leads to the inside of the rotor core 30, specifically, the split portion 20e, but a part of the hole 20f in the xy plane. May lead to the outside of the rotor core 30.

The structure of the rotor 3 of the electric motor 1 according to the present embodiment will be described.
FIG. 7 is a cross-sectional view schematically showing the structure of the rotor 3.

The rotor 3 is a sequential pole type rotor. For example, one or more permanent magnets are arranged in the rotor core 30 so that one of the north and south poles of the permanent magnets faces the stator 2 of the motor 1. The number of permanent magnets 36 arranged on the rotor core 30 is half the number of magnetic poles of the rotor 3. The number of magnetic poles of the sequential pole type rotor is usually an even number of 4 or more. For example, when the number of magnetic poles of the rotor 3 is 4, the number of permanent magnets 36 is 2. For example, when the north pole side of each permanent magnet 36 faces the stator 2, the region between the two permanent magnets 36 adjacent to each other in the circumferential direction functions as the south pole.

The rotor 3 has a rotor core 30, one or more permanent magnets 36, a shaft 37 fixed in the rotor core 30, and a resin 38a.

The rotor core 30 includes a plurality of iron cores (specifically, at least one iron core 31, at least one iron core 32, and at least one iron core 33), at least one slit 34, and a through hole 35.

The shaft 37 and the resin 38a are arranged in the through hole 35. Specifically, the resin 38a is filled around the shaft 37. Further, the resin 38a is filled between the inner peripheral surface of the rotor core 30 and the shaft 37, and is also filled between the inner wall of each slit 34 and each permanent magnet 36. As a result, the shaft 37 is integrated with the rotor core 30. Further, since the resin 38a is a non-magnetic resin, the magnetic flux flowing into the shaft 37 from the permanent magnet 36, that is, the leakage flux can be reduced.

At least one iron core 31, at least one iron core 32, and at least one iron core 33 are laminated in the axial direction. The iron core 31, the iron core 32, and the iron core 33 are formed with a caulking portion 39, which will be described later. That is, the iron core 31, the iron core 32, and the iron core 33 are fixed by caulking.

In the example shown in FIG. 7, the rotor core 30 includes an iron core 31 as a first core, an iron core 32 as a second core, an iron core 33 as a third core, and an iron core 32 as a fourth core. It has an iron core 31 as a fifth iron core. That is, in the example shown in FIG. 7, the structure of the first core is the same as the structure of the fifth core, and the structure of the second core is the same as the structure of the fourth core. However, the rotor core 30 may include iron cores other than the first to fifth cores.

In the example shown in FIG. 7, the first core, the second core, the third core, the fourth core, and the fifth core are the first core, the second core, the third core, the fourth core, and the fifth core in the axial direction. They are stacked in the order of the 5th iron core.

As shown in FIG. 2, a plurality of slits 34 (specifically, five slits 34) are formed in the circumferential direction in the xy plane. In the xy plane, the length of each slit 34 in the longitudinal direction is longer than the length of the permanent magnet 36 in the longitudinal direction. Each slit 34 extends in the axial direction. That is, each slit 34 passes through the iron core 31, the iron core 32, and the iron core 33.

The number of slits 34 is half the number of magnetic poles of the rotor 3. In other words, the rotor 3 has twice as many magnetic poles as the slit 34. In the present embodiment, the number of slits 34 is 5, so the number of magnetic poles of the rotor 3 is 10. That is, the rotor 3 has five north poles and five south poles. The magnetic poles are arranged at equal intervals in the circumferential direction. Therefore, the pole pitch is 360 degrees / 10 = 36 degrees.

In the example shown in FIG. 2, the rotor 3 has a plurality of permanent magnets 36 (specifically, five permanent magnets 36). The plurality of permanent magnets 36 are embedded inside the rotor core 30. Specifically, each permanent magnet 36 is arranged in each slit 34. Specifically, the permanent magnet 36 is arranged in the slit 34 formed in the iron core 32 and the iron core 33, and is not arranged in the slit 34 formed in the iron core 31. As a result, the leakage flux in the iron core 31 can be reduced.

The permanent magnet 36 is, for example, a rare earth magnet. The permanent magnet 36 is, for example, a flat plate magnet. For example, the permanent magnet 36 is a neodymium sintered magnet containing Nd (neodymium) -Fe (iron) -B (boron).

The thickness of one electrical steel sheet of the rotor core 30 (that is, the cores 31, 32, and 33) is, for example, 0, 1 mm to 0.7 mm.

The structure of the iron core 31 will be described.
FIG. 8 is a diagram schematically showing the structure of the iron core 31.
The iron core 31 has at least one slit 34 and at least one crimped portion 39. As described above, the number of slits 34 formed in the iron core 31 is half the number of magnetic poles of the rotor 3. That is, in the present embodiment, five slits 34 are formed in the iron core 31. In the xy plane, each slit 34 is surrounded by an electromagnetic steel plate of an iron core 31. In the xy plane, the length of each slit 34 formed in the iron core 31 in the longitudinal direction is longer than the length in the longitudinal direction of the permanent magnet 36.

The iron core 31 is composed of at least one electromagnetic steel plate. In the present embodiment, the iron core 31 is formed by laminating a plurality of electromagnetic steel sheets in the axial direction. One electromagnetic steel sheet forming each layer of the iron core 31 is not divided into two or more plates. That is, one electromagnetic steel sheet forming each layer of the iron core 31 is one integrated plate. Each electrical steel sheet of the iron core 31 is formed into a predetermined shape by press working. Each electrical steel sheet of the iron core 31 has the same structure. However, the iron core 31 may include an electromagnetic steel sheet having a structure other than the structure shown in FIG.

A crimped portion 39 is formed on each electrical steel sheet of the iron core 31. That is, the plurality of electromagnetic steel sheets of the iron core 31 are fixed by caulking. In the present embodiment, at least one crimping portion 39 is formed on the outside of the slit 34 in the radial direction, and at least one crimping portion 39 is formed on the inside of the slit 34 in the radial direction. Further, at least one caulking portion 39 is formed between two slits 34 adjacent to each other in the circumferential direction.

The structure of the iron core 32 will be described.
FIG. 9 is a diagram schematically showing the structure of the iron core 32.
The iron core 32 has an inner core portion 32a, at least one outer core portion 32b, and at least one slit 34. Similar to the iron core 31, the number of slits 34 formed in the iron core 32 is half the number of magnetic poles of the rotor 3. That is, in the present embodiment, five slits 34 are formed in the iron core 32. In the xy plane, the length of each slit 34 in the longitudinal direction is longer than the length of the permanent magnet 36 in the longitudinal direction.

In the present embodiment, the inner core portion 32a of the iron core 32 as the second core is also referred to as the first inner core portion, the inner core portion 32a of the iron core 32 as the fourth core is also referred to as the third inner core portion, and the second The outer core portion 32b of the iron core 32 as an iron core is also referred to as a first outer core portion, and the outer core portion 32b of the iron core 32 as a fourth iron core is also referred to as a third outer core portion.

The inner iron core portion 32a is located inside the slit 34 in the radial direction. The inner core portion 32a is separated from the outer core portion 32b. The inner core portion 32a has at least one concave portion 321 and at least one convex portion 322 forming the outer edge of the inner iron core portion 32a in the xy plane. In the example shown in FIG. 9, a plurality of concave portions 321 and a plurality of convex portions 322 are alternately formed in the circumferential direction. Each slit 34 is formed between the recess 321 of the inner iron core portion 32a and the outer iron core portion 32b. Therefore, the outer core portion 32b faces the inner iron core portion 32a.

The outer iron core portion 32b is located outside the slit 34 in the radial direction. In other words, the outer core portion 32b is separated from the inner core portion 32a.

The iron core 32 is composed of at least one electromagnetic steel plate. In the present embodiment, the iron core 32 is formed by laminating a plurality of electromagnetic steel sheets in the axial direction. Each electrical steel sheet of the iron core 32 is formed into a predetermined shape by press working. Each electrical steel sheet forming each layer of the iron core 32 has the same structure. However, the iron core 32 may include an electromagnetic steel sheet having a structure other than the structure shown in FIG.

At least one of the inner core portion 32a and the outer core portion 32b has at least one protrusion 32c facing the permanent magnet 36 in the circumferential direction.

In the example shown in FIG. 9, protrusions 32c are formed on both the inner core portion 32a and the outer core portion 32b. Specifically, in the xy plane, protrusions 32c are formed at both ends of each outer core portion 32b in the circumferential direction, and protrusions 32c are formed at both ends of the recess 321. In other words, in the xy plane, protrusions 32c are formed at both ends of the slit 34 in the longitudinal direction.

It is desirable that each protrusion 32c is in contact with the permanent magnet 36. As a result, the position of the permanent magnet 36 is firmly fixed in the slit 34.

In the xy plane, the height of each protrusion 32c is less than half the thickness of the permanent magnet 36 in the lateral direction. As a result, the outer core portion 32b does not come into contact with the inner core portion 32a, and the outer core portion 32b can be separated from the inner core portion 32a. The height of each protrusion 32c is the height of the permanent magnet 36 in the lateral direction in the xy plane.

The structure of the iron core 33 will be described.
FIG. 10 is a diagram schematically showing the structure of the iron core 33.
The iron core 33 has an inner core portion 33a (also referred to as a second inner core portion), at least one outer core portion 33b (also referred to as a second outer core portion), and at least one slit 34. Similar to the iron core 31 and the iron core 32, the number of slits 34 formed in the iron core 33 is half the number of magnetic poles of the rotor 3. That is, in the present embodiment, five slits 34 are formed in the iron core 33. In the xy plane, the length of each slit 34 in the longitudinal direction is longer than the length of the permanent magnet 36 in the longitudinal direction.

The inner iron core portion 33a is located inside the slit 34 in the radial direction. The inner core portion 33a is separated from the outer core portion 33b. The inner core portion 33a has at least one concave portion 331 and at least one convex portion 332 that form the outer edge of the inner iron core portion 33a in the xy plane. In the example shown in FIG. 10, a plurality of concave portions 331 and a plurality of convex portions 332 are formed alternately in the circumferential direction. Each slit 34 is formed between the recess of the inner iron core portion 33a and the outer iron core portion 33b. Therefore, the outer core portion 33b faces the inner core portion 33a.

The above-mentioned protrusion 32c is not formed on the iron core 33. In the xy plane, each slit 34 formed in the iron core 33 leads to the outside of the rotor 3. In the xy plane, both ends of each permanent magnet 36 arranged in each slit 34 formed in the iron core 33 in the longitudinal direction also communicate with the outside of the rotor 3.

The outer iron core portion 33b is located outside the slit 34 in the radial direction. In other words, the outer core portion 33b is separated from the inner core portion 33a.

The iron core 33 is composed of at least one electromagnetic steel plate. In the present embodiment, the iron core 33 is formed by laminating a plurality of electromagnetic steel sheets in the axial direction. Each electrical steel sheet of the iron core 33 is formed into a predetermined shape by press working. Each electrical steel sheet forming each layer of the iron core 33 has the same structure. However, the iron core 33 may include an electromagnetic steel sheet having a structure other than the structure shown in FIG.

In the example shown in FIG. 7, the rotor 3 has two iron cores 31, two iron cores 32, and one iron core 33. In the example shown in FIG. 7, the iron core 31, the iron core 32, and the iron core 33 are laminated in the order of the iron core 31, the iron core 32, and the iron core 33 in the axial direction. Specifically, the iron core 31, the iron core 32, and the iron core 33 are laminated in the order of the iron core 31, the iron core 32, the iron core 33, the iron core 32, and the iron core 31. Therefore, the iron core 32 is arranged between the iron core 31 and the iron core 33, and the iron core 33 is arranged between the two iron cores 32. When the permanent magnet 36 is inserted into the slit 34, the protrusion 32c of each iron core 32 acts as a guide, so that the permanent magnet 36 can be easily inserted into the slit 34.

The thickness of each iron core 31 in the axial direction is indicated by La, the thickness of each iron core 32 in the axial direction is indicated by Lb, and the thickness of the iron core 33 in the axial direction is indicated by Lc. The total thickness L1 of the iron core 31 in the axial direction is 2 × La. The total thickness L2 of the iron core 32 in the axial direction is 2 × Lb. The total thickness L3 of the iron core 33 in the axial direction is Lc. In this case, the rotor 3 satisfies L1 ≦ L2 <L3. As a result, the leakage flux in the rotor 3 can be effectively reduced.

In the axial direction, the rotor core 30 is longer than the stator core 20. In the axial direction, the iron core 31 is arranged at the end of the rotor core 30. Further, in the radial direction, the iron core 31 does not face the stator core 20. As a result, the magnetic flux from the permanent magnets 36 arranged on the iron core 32 and the iron core 33 can efficiently pass through the stator core 20. As a result, the efficiency of the motor 1 can be improved.

Another example of the iron core 31 will be described.
FIG. 11 is a diagram showing another example of the iron core 31.
One of the two iron cores 31 shown in FIG. 7 may have at least one protrusion 31a, as shown in FIG. In the example shown in FIG. 11, the protrusion 31a is formed so as to project in the radial direction on the inner wall of the slit 34 formed in the iron core 31 as the first iron core. The protrusion 31a faces the permanent magnet 36 in the axial direction. As a result, for example, in the manufacturing process of the rotor 3, when the permanent magnet 36 is inserted into the rotor core 30 from the slit 34 of the iron core 31 as the fifth iron core, the permanent magnet 36 becomes the iron core 31 as the first iron core. It is possible to prevent the magnet from falling from the slit 34 of the magnet.

The protrusion 31a may be in contact with the permanent magnet 36 in the axial direction, or may be separated from the permanent magnet 36. When the protrusion 31a is in contact with the permanent magnet 36 in the axial direction, the permanent magnet 36 can be firmly fixed in the slit 34, and the vibration and noise in the motor 1 caused by the vibration of the permanent magnet 36 can be reduced. can. On the other hand, when the protrusion 31a is separated from the permanent magnet 36, the leakage flux can be reduced.

Another example of the iron core 32 will be described.
FIG. 12 is a diagram showing another example of the iron core 32. In the example shown in FIG. 12, each outer core portion 32b has at least one protrusion 32c facing the permanent magnet 36 in the circumferential direction. It is desirable that each protrusion 32c is in contact with the permanent magnet 36. As a result, the position of the permanent magnet 36 is firmly fixed in the slit 34. On the other hand, no protrusion 32c is formed in each recess 321 of the inner iron core portion 32a.

Yet another example of the iron core 32 will be described.
FIG. 13 is a diagram showing still another example of the iron core 32. In the example shown in FIG. 13, the inner core portion 32a has at least one protrusion 32c facing the permanent magnet 36 in the circumferential direction. It is desirable that each protrusion 32c is in contact with the permanent magnet 36. As a result, the position of the permanent magnet 36 is firmly fixed in the slit 34. On the other hand, the protrusion 32c is not formed on the outer iron core portion 32b.

14 and 15 are cross-sectional views schematically showing another example of rotor 3. Specifically, FIG. 14 is a cross-sectional view taken along the line C14-C14 in FIG. 15, and FIG. 15 is a cross-sectional view taken along the line C15-C15 in FIG.

The rotor 3 shown in FIGS. 14 and 15 has resins 38b and 38c in addition to the resin 38a. In the rotor 3 shown in FIGS. 14 and 15, the resin 38a is also referred to as a first resin, the resin 38b is also referred to as a second resin, and the resin 38c is also referred to as a third resin. As shown in FIG. 15, when the resins 38a, 38b, and 38c are integrated, the resins 38a, 38b, and 38c are shown as one resin 38.

As shown in FIG. 15, the rotor core 30 has a first end 30a and a second end 30b in the axial direction.

The resin 38a is formed inside the rotor core 30 in the radial direction. Specifically, the resin 38a is formed around the shaft 37 in the through hole 35.

The resin 38b is arranged in the slit 34. Specifically, the resin 38b is arranged in a space adjacent to both ends of each permanent magnet 36 in the longitudinal direction in the xy plane. As shown in FIGS. 14 and 15, it is desirable that the resin 38b be adjacent to each permanent magnet 36 so as to be in contact with at least one of the plurality of outer surfaces of each permanent magnet 36. The resin 38b may be adjacent to each permanent magnet 36 so as to abut all of the outer surfaces of the plurality of outer surfaces of each permanent magnet 36.

The resin 38c is formed at the first end portion 30a of the rotor core 30. The broken line shown in FIG. 15 indicates the boundary between the region where the resin 38c is formed and the region where the resins 38a and 38b are formed. The resins 38a, 38b, and 38c are integrally formed of the same resin material. That is, the resins 38a, 38b, and 38c are a single structure (resin body) formed by integral molding. Therefore, the resins 38a, 38b, and 38c are not structurally separated from each other.

The resins 38a, 38b, and 38c are resins containing a non-magnetic material as a main component, that is, non-magnetic resins. The resins 38a, 38b, and 38c are thermoplastic resins such as PBT (polybutylene terephthalate) resin and PPS (polyphenylene sulfide) resin. A glass filler may be blended in the resins 38a, 38b, and 38c. Further, the resins 38a, 38b, and 38c may be thermosetting resins formed by BMC (Bulk Molding Compound).

The length of the resin 38a in the radial direction is preferably three times or more the gap between the stator 2 and the rotor 3. In particular, the length of the resin 38a in the radial direction is preferably three times or more the maximum value of the gap between the rotor core 30 (specifically, the iron core 32 or 33) and the stator 2. Thereby, the magnetic flux flowing into the shaft 37 from the permanent magnet 36, that is, the leakage flux can be reduced.

Since the permanent magnet 36 is not arranged in the slit 34 of the iron core 31, the length L4 of the rotor core 30 is longer than the length L5 of the permanent magnet 36 in the axial direction. Thereby, the end portion of the permanent magnet 36 in the axial direction can be covered with the resin 38b. The length L4 is equal to the length from the first end 30a to the second end 30b of the rotor core 30.

Modification example 1.
FIG. 16 is a cross-sectional view showing another example of the rotor core 30.
In the first modification, the arrangement of the plurality of iron cores of the rotor core 30 is different from that of the rotor core 30 described in the first embodiment. The rotor core 30 shown in FIG. 16 can be applied to the rotor 3 instead of the rotor core 30 shown in FIG. 7.

In the first modification, the rotor core 30 includes an iron core 31 as a first iron core, an iron core 32 as a second iron core, an iron core 33 as a third iron core, an iron core 32 as a fourth iron core, and a fifth iron core. 33, a sixth core 32, and a seventh core 31. That is, in the first modification, the structure of the first core is the same as that of the seventh core, the structure of the second core is the same as that of the fourth and sixth cores, and the structure of the third core is the same. 5 The structure of the iron core is the same. However, in the first modification, the rotor core 30 may include iron cores other than the first to seventh cores.

In the first modification, the first core, the second core, the third core, the fourth core, the fifth core, the sixth core, and the seventh core are the first core, the second core, and the third core in the axial direction. The 4th core, the 5th core, the 6th core, and the 7th core are laminated in this order.

In the first modification, the inner core portion 32a of the iron core 32 as the second core is also referred to as the first inner core portion, the inner core portion 33a of the iron core 33 as the third core is also referred to as the second inner core portion, and the fourth iron core is also referred to. The inner core portion 32a of the iron core 32 is also referred to as the third inner core portion, the inner core portion 33a of the iron core 33 as the fifth core is also referred to as the fourth inner core portion, and the inner core portion of the iron core 32 as the sixth core 32. 32a is also referred to as a fifth inner iron core portion.

In the first modification, the outer core portion 32b of the iron core 32 as the second core is also referred to as the first outer core portion, the outer core portion 33b of the iron core 33 as the third core is also referred to as the second outer core portion, and the fourth iron core is also referred to. The outer core portion 32b of the iron core 32 is also referred to as the third outer core portion, the outer core portion 33b of the iron core 33 as the fifth core is also referred to as the fourth outer core portion, and the outer core portion of the iron core 32 as the sixth core 32. 32b is also referred to as a fifth outer core portion.

In the first modification, the rotor core 30 includes at least three cores 32. In other words, the plurality of iron cores 32 are arranged apart from each other. As a result, since each iron core 32 has a protrusion 32c, the permanent magnet 36 can be inserted into an appropriate position in the slit 34 even when the rotor core 30 is long in the axial direction, and the position of the permanent magnet 36 can be inserted. Can be defined in the slit 34. It is desirable that each protrusion 32c is in contact with the permanent magnet 36. As a result, the position of the permanent magnet 36 is firmly fixed in the slit 34. As a result, vibration and noise in the motor 1 can be reduced.

Modification example 2.
FIG. 17 is a cross-sectional view showing still another example of the rotor core 30.
In the second modification, the arrangement of the plurality of iron cores of the rotor core 30 is different from that of the rotor core 30 described in the first embodiment. The rotor core 30 shown in FIG. 17 can be applied to the rotor 3 instead of the rotor core 30 shown in FIG.

In the second modification, the rotor core 30 includes an iron core 31 as a first iron core, an iron core 32 as a second iron core, an iron core 33 as a third iron core, an iron core 31 as a fourth iron core, and a fifth iron core. 33, a sixth core 32, and a seventh core 31. That is, in the second modification, the structure of the first core is the same as that of the fourth and seventh cores, the structure of the second core is the same as that of the sixth core, and the structure of the third core is the same. 5 The structure of the iron core is the same. However, in the second modification, the rotor core 30 may include iron cores other than the first to seventh cores.

In the second modification, the first core, the second core, the third core, the fourth core, the fifth core, the sixth core, and the seventh core are the first core, the second core, and the third core in the axial direction. The 4th core, the 5th core, the 6th core, and the 7th core are laminated in this order.

In the second modification, the inner core portion 32a of the iron core 32 as the second core is also referred to as the first inner core portion, the inner core portion 33a of the iron core 33 as the third core is also referred to as the second inner core portion, and the fifth iron core is also referred to. The inner core portion 33a of the iron core 33 is also referred to as a third inner core portion, and the inner core portion 32a of the iron core 32 as the sixth core is also referred to as a fourth inner core portion.

In the second modification, the outer core portion 32b of the iron core 32 as the second core is also referred to as the first outer core portion, the outer core portion 33b of the iron core 33 as the third core is also referred to as the second outer core portion, and the fifth iron core is also referred to. The outer core portion 33b of the iron core 33 is also referred to as a third outer core portion, and the outer core portion 32b of the iron core 32 as the sixth core is also referred to as a fourth outer core portion.

In the second modification, the rotor core 30 includes at least three cores 31, and at least one core 31 is arranged between the two cores 33. As a result, even when the rotor core 30 is long in the axial direction, the permanent magnet 36 can be inserted into an appropriate position in the slit 34, and the position of the permanent magnet 36 can be determined in the slit 34.

Further, a plurality of iron cores 31 are arranged apart from each other. The electromagnetic steel sheets forming each layer of the iron core 31 are one integrated plate. As a result, the rigidity of the rotor core 30 can be increased even when the rotor core 30 (particularly the iron core 33) is long in the axial direction. As a result, vibration and noise in the motor 1 can be reduced.

A method of manufacturing the rotor 3 will be described.
FIG. 18 is a flowchart showing an example of the manufacturing process of the rotor 3.

In step S1, the iron core 31 as the first iron core having the above-mentioned structure is produced. Specifically, at least one slit 34 and a through hole 35 are formed in at least one electrical steel sheet by press working (for example, punching). When at least one slit 34 and a through hole 35 are formed in each of the plurality of electrical steel sheets, these electrical steel sheets are laminated in the axial direction while being fixed by caulking in the press die. .. As a result, at least one crimped portion 39 is formed on each electrical steel sheet of the iron core 31. In step S1, the iron core 31 as the fifth iron core may be produced at the same time as the iron core 31 as the first iron core is produced.

In step S2, an iron core 32 as a second iron core having the above-mentioned structure is produced. Specifically, by press working (for example, punching), an inner core portion 32a and at least one outer core portion 32b are formed on at least one electrical steel sheet. At the same time, a through hole 35 is formed in the inner iron core portion 32a. When the inner core portion 32a and at least one outer core portion 32b are formed on each of the plurality of electrical steel sheets, the electrical steel sheets are axially fixed while being crimped in the press die. Stack. In step S2, the iron core 32 as the fourth iron core may be produced at the same time as the iron core 32 as the second iron core is produced.

In step S3, the iron core 32 as the second iron core is laminated on the iron core 31 as the first iron core.

In step S4, the iron core 32 as the second iron core is fixed to the iron core 31 as the first iron core by caulking. Specifically, the inner core portion 32a and at least one outer core portion 32b are fixed to the iron core 31 by caulking. As a result, at least one crimped portion 39 is formed on each of the electrical steel sheets of the iron core 31 and the iron core 32. In this case, each outer core portion 32b is arranged outside the inner core portion 32a in the radial direction so that a slit 34 is formed between the inner core portion 32a and each outer core portion 32b. As a result, each outer iron core portion 32b is arranged outside the slit 34 in the radial direction.

In step S5, an iron core 33 as a third iron core having the above-mentioned structure is produced. Specifically, by press working (for example, punching), an inner core portion 33a and at least one outer core portion 33b are formed on at least one electrical steel sheet. At the same time, a through hole 35 is formed in the inner iron core portion 33a. When the inner core portion 33a and at least one outer core portion 33b are formed on each of the plurality of electrical steel sheets, the electrical steel sheets are axially fixed while being crimped in the press die. Stack.

In step S6, the iron core 33 as the third iron core is laminated on the iron core 32 as the second iron core.

In step S7, the iron core 33 as the third iron core is fixed to the iron core 32 as the second iron core by caulking. Specifically, the inner core portion 33a and at least one outer core portion 33b are fixed to the iron core 32 by caulking. As a result, at least one crimped portion 39 is formed on each of the electrical steel sheets of the iron core 32 and the iron core 33. In this case, each outer core portion 33b is arranged outside the inner core portion 33a in the radial direction so that a slit 34 is formed between the inner core portion 33a and each outer core portion 33b. As a result, each outer iron core portion 33b is arranged outside the slit 34 in the radial direction.

In step S8, the iron core 32 as the fourth iron core is laminated on the iron core 33 as the third iron core. The iron core 32 as the fourth iron core laminated on the iron core 33 may be produced in step S2 or may be produced in step S8.

In step S9, the iron core 32 as the fourth iron core is fixed to the iron core 33 as the third iron core by caulking.

In step S10, the iron core 31 as the fifth iron core is laminated on the iron core 32 as the fourth iron core. The iron core 31 as the fifth iron core laminated on the iron core 32 may be produced in step S1 or may be produced in step S10.

In step S11, the iron core 31 as the fifth iron core is fixed to the iron core 32 as the fourth iron core by caulking.

As a result of the processes from steps S1 to S11, the rotor core 30 shown in FIG. 7 is produced. However, the order of processing from steps S1 to S11 is not limited to the above example. For example, after the iron core 31, the iron core 32, and the iron core 33 are manufactured, these iron cores 31, the iron core 32, and the iron core 33 may be laminated in the axial direction.

In step S12, the permanent magnet 36 is inserted into the slit 34.

In step S13, the shaft 37 is inserted into the through hole 35.

19 and 20 are views showing an example of a resin 38 molding step (specifically, step S14).
In step S14, the resin 38 (that is, the resins 38a, 38b, and 38c) is molded. Specifically, as shown in FIG. 19, the resin 40 is injected into the rotor core 30 from one end side of the rotor core 30. In the examples shown in FIGS. 19 and 20, the resin 40 is injected into the through hole 35 from the resin injection port 41. When injecting the resin 40, it is desirable to strongly eject the resin 40 from one end side to the other end side of the rotor core 30. As a result, it is possible to suppress the generation of voids between the electromagnetic steel sheets of the rotor core 30.

The resin injection port 41 is provided in, for example, a mold formed so as to cover the rotor core 30. The resin injection port 41 is provided, for example, at a position facing the through hole 35. In the example shown in FIGS. 19 and 20, the resin injection port 41 is provided above the through hole 35. By filling the through hole 35 with the resin 40, the resin 38a is first formed in the through hole 35. As a result, the shaft 37 is fixed by the resin 38a.

As shown in FIG. 20, by further injecting the resin 40 from the resin injection port 41, the resin 40 gradually overflows from the through hole 35, and the resin 38c is formed at the first end portion 30a of the rotor core 30. At the same time as being formed, the resin 40 is filled in the slit 34. As a result, the space around the permanent magnet 36 in the slit 34 is filled with the resin 40, and the resin 38b is formed.

By further injecting the resin 40 from the resin injection port 41, the resin 38c is also formed on the first end portion 30a and the upper portion of the slit 34. As a result, the resins 38a, 38b, and 38c are integrally formed of the same resin material (that is, the resin 40). Although the resins 38a, 38b, and 38c are formed of the same resin material, they may be formed of a material other than the resin material, for example, a material containing a non-magnetic material.

The rotor 3 can be manufactured by the above-mentioned process.

The effect of the rotor 3 will be described.
FIG. 21 is a diagram schematically showing the structure of the rotor 70, which is a sequential pole type rotor as a comparative example.
FIG. 22 is an enlarged view showing a part of the structure of the rotor shown in FIG.
“N” shown in FIGS. 21 and 22 indicates an N pole, and “S” indicates an S pole.

The rotor core 71 of the rotor 70 has a bridge 72 and a bridge 73. The bridge 72 is formed between the slit 75 in which the permanent magnet 74 is arranged and the outer peripheral surface of the rotor core 71, and the bridge 73 is a region (that is, a salient pole) between two adjacent slits 75. Is. In the rotor 70 according to the comparative example, the outer magnetic pole of each permanent magnet 74 is the north pole. That is, the north pole of each permanent magnet 74 faces the stator. Therefore, the bridge 73 serves as the south pole of the rotor 70.

In the rotor 70 according to the comparative example, a part of the magnetic flux from the north pole of each permanent magnet 74, that is, the leakage flux B1 easily flows through the bridge 72 toward the south pole of the permanent magnet 74. That is, in the rotor 70 according to the comparative example, the leakage flux B1 is likely to occur.

It is possible to reduce the leakage flux by reducing the radial width of the bridge 72, but if the width is too small, it becomes difficult to press the electromagnetic steel plate. Therefore, in general, as the size of the motor and the rotor becomes smaller, the ratio of the size of the bridge 72 to the size of the permanent magnet becomes larger, and as a result, the influence of the leakage flux becomes larger. As a result, the current for increasing the torque of the motor is increased, and the efficiency of the motor is lowered.

On the other hand, in the iron core 33 of the rotor 3 according to the present embodiment, since each outer core portion 33b is separated from the inner core portion 33a, the iron core 33 has a structure corresponding to the above-mentioned bridge 72. Not done. Therefore, in the xy plane, each slit 34 formed in the iron core 33 leads to the outside of the rotor 3. Further, in the xy plane, both ends of each permanent magnet 36 arranged in each slit 34 formed in the iron core 33 in the longitudinal direction also communicate with the outside of the rotor 3. Therefore, both ends of each permanent magnet 36 in the longitudinal direction do not abut on the iron core 33 (specifically, the electromagnetic steel plate).

As a result, in the iron core 33, it is possible to block the path through which the magnetic flux from both ends in the longitudinal direction of each permanent magnet 36 passes. As a result, the leakage flux in the rotor 3 can be reduced, and the torque of the motor 1 can be increased.

Further, the iron core 32 also does not have a structure corresponding to the above-mentioned bridge 72 because each outer core portion 32b is separated from the inner core portion 32a. Therefore, in the xy plane, each slit 34 formed in the iron core 32 leads to the outside of the rotor 3. Further, in the iron core 32, both end portions of the permanent magnets 36 in the longitudinal direction, specifically, a part of each end portion do not abut on the iron core 32 (specifically, the electromagnetic steel plate).

As a result, in the iron core 32, it is possible to block the path through which the magnetic flux from both ends in the longitudinal direction of each permanent magnet 36 passes. As a result, the leakage flux in the rotor 3 can be reduced, and the torque of the motor 1 can be increased.

At least one of the inner core portion 32a and the outer core portion 32b of the iron core 32 has at least one protrusion 32c facing the permanent magnet 36 in the circumferential direction. As a result, the position of the permanent magnet 36 is firmly fixed in the slit 34, and vibration and noise in the motor 1 can be reduced.

An iron core 31 is arranged at the end of the rotor 3 in the axial direction. The electromagnetic steel sheets forming each layer of the iron core 31 are one integrated plate. Therefore, since the iron core 31, the iron core 32, and the iron core 33 are fixed by caulking, the rigidity of the rotor 3 can be maintained. In particular, the iron core 31 contributes to maintaining the rigidity of the entire rotor core 30. When the iron cores 31 are arranged on both sides of the iron core 32 and the iron core 33 in the axial direction, the rigidity of the rotor 3 can be further increased.

Since the iron core 31, the iron core 32, and the iron core 33 are fixed by caulking, the assembly accuracy of the rotor core 30 can be improved, and the strength of the rotor core 30 can be increased. As a result, vibration and noise in the motor 1 due to assembly errors can be reduced.

Further, since the rotor core 30 is integrally formed by laminating a plurality of iron cores, productivity can be improved.

As described above, the leakage flux can be effectively reduced in the iron core 33. Further, the rotor 3 satisfies L1 ≦ L2 <L3. Therefore, since the ratio of the thickness of the iron core 33 in the axial direction is the largest in the rotor core 30, the leakage flux in the rotor 3 can be effectively reduced. Further, as described above, since the demagnetization of each permanent magnet 36 can be improved in the iron core 33, the rotor core 30 has the largest ratio of the thickness of the iron core 33 in the axial direction in the rotor core 30. By forming the above, the demagnetization of each permanent magnet 36 in the rotor 3 can be effectively improved. As a result, the output of the motor 1 can be increased.

In the example shown in FIG. 7, the iron core 31, the iron core 32, and the iron core 33 are laminated in the order of the iron core 31, the iron core 32, and the iron core 33 in the axial direction. Specifically, the iron core 31, the iron core 32, and the iron core 33 are laminated in the order of the iron core 31, the iron core 32, the iron core 33, the iron core 32, and the iron core 31. That is, two iron cores 32 are arranged apart from each other in the axial direction. When the permanent magnet 36 is inserted into the slit 34, the protrusion 32c of each iron core 32 serves as a guide. As a result, the permanent magnet 36 can be easily inserted into the slit 34, and the position accuracy of the permanent magnet 36 in the slit 34 can be improved. As a result, the vibration and noise of the electric motor 1 caused by the vibration of the permanent magnet 36 can be reduced.

Each slit 34 formed in the iron core 31 is surrounded by an electromagnetic steel plate of the iron core 31, but the permanent magnet 36 is not arranged in the slit 34 formed in the iron core 31. Therefore, the leakage flux in the iron core 31 can be reduced.

In the xy plane, the length of each slit 34 formed in the iron core 31 in the longitudinal direction is longer than the length in the longitudinal direction of the permanent magnet 36. Therefore, it is possible to prevent the magnetic flux from each permanent magnet 36 (specifically, each permanent magnet 36 arranged in the iron core 32) from passing through the iron core 31. As a result, the leakage flux in the iron core 31 can be further reduced, and the torque of the motor 1 can be further increased.

As shown in FIG. 11, when the protrusion 31a is formed on the inner wall of the slit 34 formed in the iron core 31 as the first iron core so as to face the permanent magnet 36 in the axial direction, the permanent magnet 36 is formed. It is possible to prevent the rotor core 30 (specifically, the slit 34) from coming off.

Further, the protrusion 31a of the iron core 31 can determine the position of the permanent magnet 36 in the axial direction. This makes it possible to facilitate the assembly of the rotor 3 in the manufacturing process of the rotor 3. When the protrusion 31a is in contact with the permanent magnet 36 in the axial direction, the permanent magnet 36 can be firmly fixed in the slit 34, and the vibration and noise in the motor 1 caused by the vibration of the permanent magnet 36 can be reduced. can. On the other hand, when the protrusion 31a is not in contact with the permanent magnet 36, the leakage flux can be reduced.

Further, the resin 38a is filled between the inner peripheral surface of the rotor core 30 and the shaft 37, and is also filled between the inner wall of each slit 34 and each permanent magnet 36. As a result, the shaft 37 is integrated with the rotor core 30. Since the resin 38a is a non-magnetic resin, the magnetic flux flowing into the shaft 37 from the permanent magnet 36, that is, the leakage flux can be effectively reduced.

Since the integrated resin 38 (that is, the resins 38a, 38b, and 38c) covers the rotor core 30 and the permanent magnet 36, the strength of the rotor core 30 can be increased. Further, even when the shaft 37 is a magnetic material, it is possible to prevent the magnetic flux from the permanent magnet 36 from leaking to the shaft 37.

Since the electric motor 1 has the rotor 3, it has the effect of the rotor 3 described above.

In the axial direction, the rotor core 30 is longer than the stator core 20. In the axial direction, the iron core 31 is arranged at the end of the rotor core 30. Further, in the radial direction, the iron core 31 does not face the stator core 20. Therefore, since the permanent magnet 36 is not arranged on the iron core 31, the magnetic flux from the permanent magnets 36 arranged on the iron core 32 and the iron core 33 can efficiently pass through the stator core 20. That is, the magnetic force of the permanent magnet 36 can be effectively used, and the efficiency of the motor 1 can be improved. Further, since the magnetic flux flowing from the stator 2 to the iron core 31 can be reduced, the efficiency of the motor 1 can be further improved.

According to the method for manufacturing the rotor 3, the rotor 3 having the above-mentioned effect can be manufactured.

Further, according to the method for manufacturing the rotor 3, the resins 38a, 38b, and 38c can be integrally formed, so that the strength of the rotor core 30 can be increased.

Further, according to the method for manufacturing the rotor 3, since the iron core 31, the iron core 32, and the iron core 33 are fixed by caulking, the assembly accuracy of the rotor core 30 can be improved, and the strength of the rotor core 30 is increased. be able to. As a result, the rotor 3 capable of reducing vibration and noise can be manufactured.

Further, according to the method for manufacturing the rotor 3, the rotor core 30 is manufactured by laminating the iron core 31, the iron core 32, and the iron core 33 in the axial direction, so that the productivity can be improved.

Embodiment 2.
FIG. 23 is a diagram schematically showing the structure of the fan 60 according to the second embodiment of the present invention.
The fan 60 has a blade 61 and an electric motor 62 that rotates the blade 61. The fan 60 is also called a blower. The electric motor 62 is the electric motor 1 according to the first embodiment. The blades 61 are fixed to the shaft of the motor 62 (for example, the shaft 37 in the first embodiment). The blade 61 is driven by the electric motor 62. When the motor 62 is driven, the blades 61 rotate to generate an air flow. As a result, the fan 60 can blow air.

According to the fan 60 according to the second embodiment, since the electric motor 1 described in the first embodiment is applied to the electric motor 62, the same effect as that described in the first embodiment can be obtained. As a result, the vibration and noise of the fan 60 can be reduced.

Embodiment 3.
The air conditioner 50 (also referred to as a refrigerating air conditioner or a refrigerating cycle device) according to the third embodiment of the present invention will be described.
FIG. 24 is a diagram schematically showing the configuration of the air conditioner 50 according to the third embodiment.

The air conditioner 50 according to the third embodiment is an indoor unit 51 as a blower (first blower), a refrigerant pipe 52, and a blower (second blower) connected to the indoor unit 51 via the refrigerant pipe 52. ) As an outdoor unit 53.

The indoor unit 51 has an electric motor 51a (for example, the electric motor 1 according to the first embodiment), a blower portion 51b that blows air by being driven by the electric motor 51a, and a housing 51c that covers the electric motor 51a and the blower portion 51b. .. The blower portion 51b has, for example, blades 51d driven by an electric motor 51a. For example, the blades 51d are fixed to the shaft of the motor 51a (for example, the shaft 37) and generate an air flow.

The outdoor unit 53 includes an electric motor 53a (for example, the electric motor 1 according to the first embodiment), a blower 53b, a compressor 54, and a heat exchanger (not shown). The blower unit 53b blows air by being driven by the electric motor 53a. The blower portion 53b has, for example, a blade 53d driven by an electric motor 53a. For example, the blades 53d are fixed to the shaft of the motor 53a (for example, the shaft 37) and generate an air flow. The compressor 54 includes an electric motor 54a (for example, the electric motor 1 according to the first embodiment), a compression mechanism 54b (for example, a refrigerant circuit) driven by the electric motor 54a, and a housing 54c that covers the electric motor 54a and the compression mechanism 54b. Have.

In the air conditioner 50, at least one of the indoor unit 51 and the outdoor unit 53 has the electric motor 1 described in the first embodiment. Specifically, as the drive source of the blower unit, the motor 1 described in the first embodiment is applied to at least one of the motors 51a and 53a. Further, as the motor 54a of the compressor 54, the motor 1 described in the first embodiment may be used.

The air conditioner 50 can perform an operation such as a cooling operation in which cold air is blown from the indoor unit 51 or a heating operation in which warm air is blown from the indoor unit 51, for example. In the indoor unit 51, the motor 51a is a drive source for driving the blower portion 51b. The blower portion 51b can blow the adjusted air.

According to the air conditioner 50 according to the third embodiment, the motor 1 described in the first embodiment is applied to at least one of the motors 51a and 53a, so that the same effect as that described in the first embodiment can be obtained. Obtainable. As a result, the vibration and noise of the air conditioner 50 can be reduced.

Further, by using the motor 1 according to the first embodiment as a drive source of the blower (for example, the indoor unit 51), the same effect as that described in the first embodiment can be obtained. This makes it possible to reduce the vibration and noise of the blower. The blower having the motor 1 according to the first embodiment and the blades (for example, blades 51d or 53d) driven by the motor 1 can be used alone as a blower device. This blower can be applied to equipment other than the air conditioner 50.

Further, by using the motor 1 according to the first embodiment as the drive source of the compressor 54, the same effect as that described in the first embodiment can be obtained. As a result, the vibration and noise of the compressor 54 can be improved.

The electric motor 1 described in the first embodiment can be applied to a drive source in equipment such as a blower, a ventilation fan, a home electric appliance, or a machine tool, in addition to the fan 60, the compressor 54, and the air conditioner 50.

The example shown in the above-described embodiment shows an example of the content of the present invention, can be combined with another known technique, and has a configuration without departing from the gist of the present invention. It is also possible to omit or change the part.

1,51a, 53a, 54a, 62 Motor, 2 Stator, 3 Rotor, 30 Rotor core, 31 Core (1st core), 32 Core (2nd core), 32a, 33a Inner core, 32b, 33b Outer iron core, 32c protrusion, 33 iron core (third iron core), 34 slit, 36 permanent magnet, 38, 38a, 38b, 38c resin, 50 air conditioner (refrigeration air conditioner), 51 indoor unit (blower), 53 outdoor Machine (blower), 60 fans (blower).

Claims (24)

A sequential pole type rotor having a plurality of iron cores having slits extending in the axial direction and permanent magnets arranged in the slits.
The first iron core among the plurality of iron cores having the slit,
The slit, the first inner core portion located inside the slit in the radial direction, and the first outer core portion separated from the first inner core portion and located outside the slit in the radial direction. The second iron core among the plurality of iron cores having
The slit, a second inner core portion located inside the slit in the radial direction, and a second outer core portion separated from the second inner core portion and located outside the slit in the radial direction. With a third iron core among the plurality of iron cores having
The first core, the second core, and the third core are laminated in the axial direction.
At least one of the first inner core portion and the first outer core portion is a sequential pole type rotor having protrusions facing the permanent magnet in the circumferential direction. The consequential pole type rotor according to claim 1, wherein the slit formed in the third iron core in a plane orthogonal to the axial direction is connected to the outside of the consequential pole type rotor. Claim 1 Or the sequential pole type rotor according to 2. When the total thickness of the first core in the axial direction is L1, the total thickness of the second core in the axial direction is L2, and the total thickness of the third core in the axial direction is L3. The sequential pole type rotor according to any one of claims 1 to 3, which satisfies L1 ≦ L2 <L3. Any one of claims 1 to 4, wherein the first core, the second core, and the third core are laminated in the order of the first core, the second core, and the third core in the axial direction. The sequential pole type rotor according to item 1. The sequential pole type rotor according to any one of claims 1 to 5, wherein the second core is arranged between the first core and the third core. The permanent magnet is arranged in the slit formed in the second iron core and the third iron core, and is not arranged in the slit formed in the first iron core. Any one of claims 1 to 6. The sequential pole type rotor described in the section. The slit, a third inner core portion located inside the slit in the radial direction, and a third outer core portion separated from the third inner core portion and located outside the slit in the radial direction. The fourth iron core among the plurality of iron cores having
Further including a fifth iron core among the plurality of iron cores having the slit,
The first core, the second core, the third core, the fourth core, and the fifth core are the first core, the second core, the third core, and the fourth core in the axial direction. , And the 5th iron core are stacked in this order.
The sequential pole type rotor according to any one of claims 1 to 7, wherein at least one of the third inner core portion and the third outer core portion has a protrusion facing the permanent magnet in the circumferential direction. .. The slit, a third inner core portion located inside the slit in the radial direction, and a third outer core portion separated from the third inner core portion and located outside the slit in the radial direction. The fourth iron core among the plurality of iron cores having
The slit, the fourth inner core portion located inside the slit in the radial direction, and the fourth outer core portion separated from the fourth inner core portion and located outside the slit in the radial direction. The fifth iron core among the plurality of iron cores having
The slit, the fifth inner core portion located inside the slit in the radial direction, and the fifth outer core portion separated from the fifth inner core portion and located outside the slit in the radial direction. The sixth iron core among the plurality of iron cores having
Further including a seventh iron core among the plurality of iron cores having the slit,
The first core, the second core, the third core, the fourth core, the fifth core, the sixth core, and the seventh core are the first core and the second core in the axial direction. , The third core, the fourth core, the fifth core, the sixth core, and the seventh core are laminated in this order.
At least one of the third inner core portion and the third outer core portion has a protrusion facing the permanent magnet in the circumferential direction.
The sequential pole type rotor according to any one of claims 1 to 7, wherein at least one of the fifth inner core portion and the fifth outer core portion has a protrusion facing the permanent magnet in the circumferential direction. .. A fourth iron core among the plurality of iron cores having the slit,
The slit, a third inner core portion located inside the slit in the radial direction, and a third outer core portion separated from the third inner core portion and located outside the slit in the radial direction. The fifth iron core among the plurality of iron cores having
The slit, the fourth inner core portion located inside the slit in the radial direction, and the fourth outer core portion separated from the fourth inner core portion and located outside the slit in the radial direction. The sixth iron core among the plurality of iron cores having
Further including a seventh iron core among the plurality of iron cores having the slit,
The first core, the second core, the third core, the fourth core, the fifth core, the sixth core, and the seventh core are the first core and the second core in the axial direction. , The third core, the fourth core, the fifth core, the sixth core, and the seventh core are laminated in this order.
The sequential pole type rotor according to any one of claims 1 to 7, wherein at least one of the fourth inner core portion and the fourth outer core portion has a protrusion facing the permanent magnet in the circumferential direction. .. Any one of claims 1 to 10 in which the length of the slit formed in the first iron core in the longitudinal direction in the plane orthogonal to the axial direction is longer than the length in the longitudinal direction of the permanent magnet in the plane. The sequential pole type rotor described in the section. The sequential pole type rotor according to any one of claims 1 to 11, wherein a protrusion facing the permanent magnet in the axial direction is formed on the inner wall of the slit formed in the first iron core. The first core, the second core, and the rotor core including the third core,
The shaft fixed in the rotor core and
Any of claims 1 to 12, further comprising a resin filled between the inner peripheral surface of the rotor core and the shaft and further filled between the inner wall of the slit and the permanent magnet. Or the sequential pole type rotor according to item 1. The sequential pole type rotor according to any one of claims 1 to 12, which has a rotor core including the first core, the second core, and the third core. Stator iron core and
An electric motor provided with a sequential pole type rotor according to any one of claims 1 to 14, which is rotatably arranged inside the stator core. Stator iron core and
The stator pole type rotor according to claim 14, which is rotatably arranged inside the stator core, is provided.
In the axial direction, the rotor core is longer than the stator core.
In the axial direction, the first core is arranged at the end of the rotor core.
An electric motor in which the first core does not face the stator core in the radial direction. The electric motor according to claim 15 or 16.
A blower with blades driven by the motor. Indoor unit and
It is equipped with an outdoor unit connected to the indoor unit.
The refrigerating and air-conditioning apparatus having the electric motor according to claim 15 or 16, wherein at least one of the indoor unit and the outdoor unit has the electric motor. A method for manufacturing a sequential pole type rotor having a plurality of iron cores having slits extending in the axial direction and permanent magnets arranged in the slits.
A step of producing a first core among the plurality of iron cores having the slit, and
The slit, the first inner core portion located inside the slit in the radial direction, and the first outer core portion separated from the first inner core portion and located outside the slit in the radial direction. The step of producing the second iron core among the plurality of iron cores having the same.
The step of laminating the second core on the first core, and
The step of fixing the second core to the first core by caulking,
The slit, a second inner core portion located inside the slit in the radial direction, and a second outer core portion separated from the second inner core portion and located outside the slit in the radial direction. The step of producing the third iron core among the plurality of iron cores having the above.
The step of laminating the third core on the second core, and
The step of fixing the third core to the second core by caulking,
A method of manufacturing a sequential pole type rotor including a step of inserting a permanent magnet into the slit. A rotor having a plurality of iron cores having slits extending in the axial direction and permanent magnets arranged in the slits.
The first iron core among the plurality of iron cores having the slit,
The slit, the first inner core portion located inside the slit in the radial direction, and the first outer core portion separated from the first inner core portion and located outside the slit in the radial direction. The second iron core among the plurality of iron cores having
The slit, a second inner core portion located inside the slit in the radial direction, and a second outer core portion separated from the second inner core portion and located outside the slit in the radial direction. With the third iron core among the plurality of iron cores having
With
The first core, the second core, and the third core are laminated in the axial direction.
At least one of the first inner core portion and the first outer core portion has a protrusion facing the permanent magnet in the circumferential direction.
Rotor. Stator iron core and
The rotor according to claim 20, which is rotatably arranged inside the stator core.
Motor equipped with. The motor according to claim 21 and
With the blades driven by the motor
Blower equipped with. Indoor unit and
With the outdoor unit connected to the indoor unit
With
At least one of the indoor unit and the outdoor unit has the electric motor according to claim 21.
Refrigeration air conditioner. A method for manufacturing a rotor having a plurality of iron cores having slits extending in the axial direction and permanent magnets arranged in the slits.
A step of producing a first core among the plurality of iron cores having the slit, and
The slit, the first inner core portion located inside the slit in the radial direction, and the first outer core portion separated from the first inner core portion and located outside the slit in the radial direction. The step of producing the second iron core among the plurality of iron cores having the same.
The step of laminating the second core on the first core, and
The step of fixing the second core to the first core by caulking,
The slit, a second inner core portion located inside the slit in the radial direction, and a second outer core portion separated from the second inner core portion and located outside the slit in the radial direction. The step of producing the third iron core among the plurality of iron cores having the above.
The step of laminating the third core on the second core, and
The step of fixing the third core to the second core by caulking,
With the step of inserting a permanent magnet into the slit
A method of manufacturing a rotor comprising.

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