JP7613148B2 - Magnetic wedge and rotating electric machine - Google Patents
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/64—Electric machine technologies in electromobility
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Description
本発明は回転電機に用いられる磁性楔、その磁性楔を用いた回転電機に関する。 The present invention relates to a magnetic wedge used in a rotating electric machine, and a rotating electric machine using the magnetic wedge.
一般的なラジアルギャップ型回転電機では、固定子（以下ステータ）と回転子（以下ロータ）とを同軸にして配し、ロータ周りのステータに、コイルを巻き回した複数のティースを、周方向等間隔に配している。また、ティースのロータ側先端には、隣り合うティースの先端を接続するよう、磁性楔を配することがある。なおこの場合、磁性楔は、コイル部品等とは異なり、磁性楔自体にはコイルを巻き回さずに用いられる。 In a typical radial gap type rotating electric machine, the stator (hereafter referred to as stator) and rotor (hereafter referred to as rotor) are arranged coaxially, and multiple teeth with coils wound around them are arranged at equal intervals in the circumferential direction on the stator around the rotor. Magnetic wedges may also be arranged on the rotor-side tips of the teeth to connect the tips of adjacent teeth. In this case, unlike coil components, the magnetic wedges are used without having a coil wound around them themselves.
このような磁性楔を配することで、ロータからコイルに到達する磁束を磁気シールドでき、コイルの渦電流損失を抑制することができる。また、磁性楔を配することで、ステータとロータとの間のギャップ内磁束分布（特に周方向の磁束分布）をなだらかにし、ロータの回転を滑らかにするだけでなく、ロータに生じる渦電流損失も低減することができる。このような磁性楔のメリットは、磁性楔の透磁率が高いほど、あるいは磁性楔が厚いほど顕著となる。 By arranging such magnetic wedges, it is possible to magnetically shield the magnetic flux reaching the coil from the rotor, and suppress eddy current loss in the coil. In addition, by arranging magnetic wedges, it is possible to smooth the magnetic flux distribution in the gap between the stator and rotor (especially the magnetic flux distribution in the circumferential direction), which not only makes the rotor rotate smoothly, but also reduces eddy current loss generated in the rotor. The benefits of such magnetic wedges become more pronounced the higher the magnetic permeability of the magnetic wedge, or the thicker the magnetic wedge is.
特許文献１および２には電磁鋼板の積層体もしくは強磁性金属粉末の圧粉体からなる磁性楔が開示されている。 Patent documents 1 and 2 disclose magnetic wedges made of laminated electromagnetic steel sheets or compacts of ferromagnetic metal powder.
磁性楔の存在により、ティースからロータへ流れるべき磁束の一部が、磁性楔を経由してティース間で短絡してしまい、ロータへ流れる磁束が減少して回転電機のトルクが低下するという副作用がある。このような副作用も、磁性楔の透磁率が高いほど、あるいは磁性楔が厚いほど顕著となる。つまり、磁性楔のメリット（低損失化、即ち高効率化）と副作用（トルク低下）は、磁性楔の透磁率または厚さをパラメータとするトレードオフの関係にある。このため、従来の磁性楔では比透磁率を３~５程度に抑えて過度のトルク低下を回避しつつ、ある程度の効率向上に甘んじている状態であり、その効果は限定的であった。 The presence of the magnetic wedge has the side effect that some of the magnetic flux that should flow from the teeth to the rotor is short-circuited between the teeth via the magnetic wedge, reducing the magnetic flux flowing to the rotor and reducing the torque of the rotating electric machine. The higher the magnetic permeability of the magnetic wedge is, or the thicker the magnetic wedge is, the more pronounced this side effect becomes. In other words, the benefits of the magnetic wedge (lower losses, i.e. higher efficiency) and the side effect (reduced torque) are in a trade-off relationship, with the permeability or thickness of the magnetic wedge being the parameter. For this reason, with conventional magnetic wedges, the relative permeability is kept to around 3 to 5 to avoid excessive torque reduction, while only a certain degree of efficiency improvement is achieved, and the effect is limited.
そこで本発明では、磁性楔における上記のトレードオフ関係を超えて、回転電機の効率とトルクを高いレベルで両方とも向上させ得る磁性楔を提供する。 Therefore, the present invention provides a magnetic wedge that overcomes the above trade-off relationship in magnetic wedges and can improve both the efficiency and torque of a rotating electric machine to a high level.
本発明の磁性楔は、回転電機用の磁性楔であって、互いに相対的に透磁率が異なる高透磁率部分と低透磁率部分とを有し、前記低透磁率部分の透磁率が前記高透磁率部分の透磁率よりも低く、前記高透磁率部分は前記磁性楔の幅方向の中央部に位置し、前記低透磁率部分は前記磁性楔の幅方向の両端側に位置し、
前記高透磁率部分には、軟磁性粒子と、前記軟磁性粒子の間に電気絶縁性の物質とを含み、前記軟磁性粒子が、Ｆｅよりも酸化しやすい元素Ｍを含有する複数のＦｅ基軟磁性合金粒子であって、前記高透磁率部分は、前記Ｆｅ基軟磁性合金粒子が、前記元素Ｍを含む酸化物相で結着され、
前記低透磁率部分は、Ｆｅよりも酸化しやすい元素Ｍを含有し、前記Ｆｅ基軟磁性合金粒子よりも透磁率が低い複数の金属粒子が前記元素Ｍを含む酸化物相で結着されて構成されていることを特徴とする。
The magnetic wedge of the present invention is a magnetic wedge for a rotating electric machine, and has a high permeability portion and a low permeability portion which are relatively different in magnetic permeability from each other, the magnetic permeability of the low permeability portion is lower than the magnetic permeability of the high permeability portion, the high permeability portion is located at the center in the width direction of the magnetic wedge, and the low permeability portions are located on both ends in the width direction of the magnetic wedge ,
the high magnetic permeability portion includes soft magnetic particles and an electrically insulating material between the soft magnetic particles, the soft magnetic particles being a plurality of Fe-based soft magnetic alloy particles containing an element M which is more easily oxidized than Fe, the high magnetic permeability portion includes the Fe-based soft magnetic alloy particles bound together by an oxide phase containing the element M,
The low magnetic permeability portion contains an element M which is more easily oxidized than Fe, and is characterized in that it is composed of a plurality of metal particles having a lower magnetic permeability than the Fe-based soft magnetic alloy particles bound together by an oxide phase containing the element M.
また、前記磁性楔において、前記元素Ｍが、Ａｌ、Ｓｉ、Ｃｒ、Ｚｒ、Ｈｆの少なくとも一種であることが好ましい。 Furthermore, in the magnetic wedge, it is preferable that the element M is at least one of Al, Si, Cr, Zr, and Hf.
また、前記磁性楔において、前記低透磁率部分が非強磁性であることが好ましい。 Furthermore, in the magnetic wedge, it is preferable that the low permeability portion is non-ferromagnetic.
また、本発明の回転電機は、上記のいずれかの磁性楔を用いている。 The rotating electric machine of the present invention uses any one of the magnetic wedges described above.
本発明によれば、回転電機の効率とトルクを高いレベルで両立させ得る磁性楔を提供することができる。 The present invention provides a magnetic wedge that can achieve high levels of both efficiency and torque for a rotating electric machine.
以下、本発明の実施形態について、図面を参照しながら詳細に説明する。 The following describes in detail an embodiment of the present invention with reference to the drawings.
（第１実施形態）
図１に磁性楔１００の斜視図を示す。磁性楔１００は、回転電機用の磁性楔であって、互いに相対的に透磁率が異なる高透磁率部分と低透磁率部分とを有し、前記低透磁率部分の透磁率が前記高透磁率部分の透磁率よりも低く、前記高透磁率部分は前記磁性楔の幅方向の中央部に位置し、前記低透磁率部分は前記磁性楔の幅方向の両端側に位置している。、本実施形態では、全体として、長手方向に垂直な断面が凸形状となっている。そして、磁性楔１００の幅方向（隣り合うティース同士を結ぶ、磁路方向。回転電機の回転方向（固定子の周方向）） の一端から逆側の一端に向かって、第一の低透磁率部分２１、高透磁率部分１０、第二の低透磁率部分２２の順で形成されている。なお、「高透磁率部分」「低透磁率部分」の文言は、両部分の透磁率の大きさの相対的な関係を示すものである。
First Embodiment
FIG. 1 shows a perspective view of a magnetic wedge 100. The magnetic wedge 100 is a magnetic wedge for a rotating electric machine, and has a high permeability portion and a low permeability portion with relatively different magnetic permeability from each other, the magnetic permeability of the low permeability portion is lower than that of the high permeability portion, the high permeability portion is located in the center of the magnetic wedge in the width direction, and the low permeability portion is located on both ends of the magnetic wedge in the width direction. In this embodiment, the cross section perpendicular to the longitudinal direction is generally convex. Then, the first low permeability portion 21, the high permeability portion 10, and the second low permeability portion 22 are formed in this order from one end of the magnetic wedge 100 in the width direction (the magnetic path direction connecting adjacent teeth; the direction of rotation of the rotating electric machine (circumferential direction of the stator)) to the opposite end. The terms "high magnetic permeability portion" and "low magnetic permeability portion" indicate the relative relationship between the magnitude of magnetic permeability of both portions.
高透磁率部分１０は、磁性楔１００の幅方向の略中央で、凸形状の突出部分の範囲内に位置しており、磁性楔１００の長手方向に沿って細長く形成されている。また、高透磁率部分１０は、磁性楔１００を厚さ方向（幅方向（隣り合うティース同士を結ぶ方向）に垂直な方向。）に貫通するように配置されている。また、図１に示した磁性楔１００では、高透磁率部分の断面が長方形になっているが、これに限らず、台形などの種々の形状を適用することができる。なお、磁性楔１００の概略寸法は、例えば、長手方向が１０ｍｍから３００ｍｍ、幅方向が２ｍｍから２０ｍｍ、厚みが１から５ｍｍである。 The high permeability portion 10 is located in the approximate center of the width of the magnetic wedge 100, within the range of the protruding portion of the convex shape, and is elongated along the longitudinal direction of the magnetic wedge 100. The high permeability portion 10 is arranged so as to penetrate the magnetic wedge 100 in the thickness direction (perpendicular to the width direction (direction connecting adjacent teeth)). In the magnetic wedge 100 shown in FIG. 1, the cross section of the high permeability portion is rectangular, but this is not limited to this, and various shapes such as a trapezoid can be applied. The approximate dimensions of the magnetic wedge 100 are, for example, 10 mm to 300 mm in the longitudinal direction, 2 mm to 20 mm in the width direction, and 1 to 5 mm in thickness.
高透磁率部分１０は、軟磁性粒子、例えば、鉄粉またはＦｅ基軟磁性合金粉末のいずれか、あるいはその両方と、電気絶縁性の物質からなる複合材（コンポジット材）とすることができる。コンポジット材は、軟磁性粒子間に電気絶縁性の物質を存在させて、軟磁性粒子同士を結着させるとともに、粒子間を電気的に隔絶したものであり、磁性楔１００の電気抵抗を高めることによって、磁性楔１００に生じる渦電流損失を抑制することができる。 The high permeability portion 10 can be a composite material made of soft magnetic particles, for example, either iron powder or Fe-based soft magnetic alloy powder, or both, and an electrically insulating material. The composite material has an electrically insulating material between the soft magnetic particles, which bonds the soft magnetic particles together and electrically isolates the particles. By increasing the electrical resistance of the magnetic wedge 100, the eddy current loss that occurs in the magnetic wedge 100 can be suppressed.
軟磁性粒子の平均粒径は、粒径を小さくすることで電気抵抗を高め、渦電流損失の低減することができ、粒径を大きくすることで、高透磁率部分の透磁率が高くなって磁性楔の効果を強めることが可能となる。これらの観点から、軟磁性粒子の平均粒径は、２００μm以下が好ましく、１００μｍ以下がより好ましく、５０μm以下がさらに好ましく、２μｍ以上が好ましく、５μｍ以上がより好ましく、１０μｍ以上がさらに好ましい。 By decreasing the average particle size of the soft magnetic particles, it is possible to increase the electrical resistance and reduce eddy current loss, and by increasing the particle size, it is possible to increase the permeability of the high permeability portion and strengthen the effect of the magnetic wedge. From these viewpoints, the average particle size of the soft magnetic particles is preferably 200 μm or less, more preferably 100 μm or less, even more preferably 50 μm or less, preferably 2 μm or more, more preferably 5 μm or more, and even more preferably 10 μm or more.
電気絶縁性の物質としては、有機物、無機物のいずれも使用可能であり、例えば、エポキシ樹脂、フェノール樹脂、ポリイミド、ポリフェニレンサルファイド、ポリアミド、ポリアミドイミド、シリコン樹脂、コロイダルシリカ、低融点ガラスなどが使用可能である。これらを使用した場合、強磁性粉末とこれらの電気絶縁性物質を混合後、トランスファー成形、射出成形、ホットプレス等の方法で作製できる。 As the electrically insulating material, either organic or inorganic substances can be used, such as epoxy resin, phenol resin, polyimide, polyphenylene sulfide, polyamide, polyamideimide, silicone resin, colloidal silica, and low-melting glass. When using these, the ferromagnetic powder and the electrically insulating material can be mixed, and then the product can be manufactured by transfer molding, injection molding, hot pressing, or other methods.
また、高透磁率部分１０の一形態として、上記強磁性粒子がＦｅより酸化しやすい元素Ｍを含むＦｅ基合金であり、軟磁性粒子間に元素Ｍの酸化物相を生成させて粒子同士を結着した形態とすることも可能である。この形態の高透磁率部分１０の作製方法としては、軟磁性粒子をプレス成形後、酸素が存在する雰囲気で熱処理することにより、元素Ｍの酸化物相を粒界に成長させることができる、この形態であれば、粒界の電気絶縁性物質の割合を最小化することができ、高密度となるので、高強度、高透磁率となって、より好適である。元素Ｍとしては、Ａｌ、Ｓｉ、Ｃｒ、Ｚｒ、Ｈｆなどの一種あるは二種以上を使用することができる。ここで、「Ｆｅよりも酸化しやすい元素Ｍ」とは、酸化物の標準生成ギブズエネルギーが、Ｆｅ２Ｏ３よりも低い元素を意味している。 In addition, as one form of the high permeability portion 10, the ferromagnetic particles may be an Fe-based alloy containing element M, which is more easily oxidized than Fe, and an oxide phase of element M may be generated between soft magnetic particles to bond the particles together. As a method for producing the high permeability portion 10 of this form, the soft magnetic particles may be press-molded and then heat-treated in an atmosphere containing oxygen, so that the oxide phase of element M can grow at the grain boundaries. In this form, the proportion of electrically insulating material at the grain boundaries can be minimized, and the density is increased, resulting in high strength and high permeability, which is more preferable. As the element M, one or more of Al, Si, Cr, Zr, Hf , etc. may be used. Here, "element M, which is more easily oxidized than Fe" means an element whose standard Gibbs energy of oxide formation is lower than that of Fe2O3 .
低透磁率部分２１，２２は、上記の電気絶縁性物質を使用して形成することができる。低透磁率部分と高透磁率部分を別々に作製して、それらを図１の形態になるように、接着や溶着等で一体化させることができる。また、二色成形法などで低透磁率材料と高透磁率材料を一体成形することも可能である。高透磁率部分１０に含まれる電気絶縁性物質と、低透磁率部分を形成する電気絶縁性物質が同じであっても良いし、別材料であっても良い。また、磁性楔１００の強度を向上させるために、ガラスファイバーやガラスクロスをその内部に埋め込むことも可能である。 The low permeability portions 21 and 22 can be formed using the above-mentioned electrically insulating material. The low permeability portion and the high permeability portion can be produced separately and integrated by gluing, welding, or the like to form the configuration shown in FIG. 1. It is also possible to integrally mold the low permeability material and the high permeability material using a two-color molding method or the like. The electrically insulating material contained in the high permeability portion 10 and the electrically insulating material forming the low permeability portion may be the same or different materials. It is also possible to embed glass fiber or glass cloth inside the magnetic wedge 100 to improve its strength.
また、高透磁率部分１０として、Ｆｅより酸化しやすい元素Ｍを含むＦｅ基合金粒子を使用し、その粒子間に元素Ｍの酸化物相を成長させた場合は、低透磁率部分２１，２２を以下のようにして形成しても良い。すなわち、低透磁率部分２１，２２は、上記のＦｅ基合金より透磁率が低い低透磁率金属粒子で構成される。ここで低透磁率金属粒子は、Ｆｅよりも酸化しやすい元素Ｍを含有する。当該低透磁率金属粒子は元素Ｍの単体であっても、Ｍ主体の合金であっても、上記Ｆｅ基合金と同じ合金系であっても良い。同じ合金系の場合は、上記高透磁率部分を構成するＦｅ基合金粒子のＦｅ組成量よりも、Ｆｅ組成量を減らすなどして、低透磁率の合金粒子を得ることができる。ここまで低透磁率部分２１，２２が、上記のＦｅ基合金より透磁率が低い低透磁率金属粒子で構成される場合について記載したが、非磁性であっても構わない。
これらの高透磁率部分と低透磁率部分を金型内にセットしてプレス（サイジング）することにより、一体化した成形体を作製し、これを酸素存在下で熱処理することにより、粒子間に元素Ｍの酸化物相を生成させ、粒子間と、低透磁率部と高透磁率部の境界部をも強固に結着することができる。
In addition, when Fe-based alloy particles containing element M, which is more easily oxidized than Fe, are used as the high permeability portion 10, and an oxide phase of element M is grown between the particles, the low permeability portions 21 and 22 may be formed as follows. That is, the low permeability portions 21 and 22 are composed of low permeability metal particles having a lower permeability than the above-mentioned Fe-based alloy. Here, the low permeability metal particles contain element M, which is more easily oxidized than Fe. The low permeability metal particles may be a single element of element M, an alloy mainly composed of M, or the same alloy system as the above-mentioned Fe-based alloy. In the case of the same alloy system, alloy particles with low permeability can be obtained by reducing the Fe composition amount compared to the Fe composition amount of the Fe-based alloy particles constituting the high permeability portion. Up to this point, the low permeability portions 21 and 22 have been described as being composed of low permeability metal particles having a lower permeability than the above-mentioned Fe-based alloy, but they may be non-magnetic.
These high and low permeability parts are set in a mold and pressed (sized) to produce an integrated molded body, which is then heat-treated in the presence of oxygen to generate an oxide phase of element M between the particles, thereby firmly bonding the particles and the boundaries between the low and high permeability parts.
図２は、この構成における高透磁率部分１０と、低透磁率部分２１（２２）の境界を拡大して示した模式図である。高透磁率部分１０は、複数のＦｅ基軟磁性合金粒子で構成され、より具体的には、Ｆｅよりも酸化しやすい元素Ｍを含有する複数のＦｅ基軟磁性合金粒子１の圧密体である。そして、圧密体の粒子間に、空隙２と、Ｆｅ基軟磁性合金粒子１同士を結着するＦｅ基軟磁性合金粒子の表面酸化物相３とを有している。かかる表面酸化物相は元素Ｍを含む酸化物相である。
また、低透磁率部分２１または２２は、Ｆｅ基軟磁性合金粒子１より透磁率が低い複数の低透磁率金属粒子４で構成される。ここで低透磁率金属粒子４は、Ｆｅよりも酸化しやすい元素Ｍを含有することを特徴とする。そして、低透磁率金属粒子４の粒子間に空隙２と、低透磁率金属粒子４同士を結着する表面酸化物相５とを有している。かかる表面酸化物相は元素Ｍを含む酸化物相である。
さらに、Ｆｅ基軟磁性合金粒子１と低透磁率金属粒子４とが隣接する場所においては、表面酸化物相６が形成されている。表面酸化物相６は、Ｆｅ基軟磁性合金粒子１の表面酸化物相３と低透磁率金属粒子４の表面酸化物相５が接合して一体化したものであって、隣接する粒子により成分が異なる相となる。ただし、Ｆｅ基軟磁性合金粒子１と低透磁率金属粒子４に、同じ元素Ｍを含有することで、表面酸化物相６を、元素Ｍを主体とする、より均質な表面酸化物相６にすることができる。これにより、Ｆｅ基軟磁性合金粒子１および低透磁率金属粒子４の粒子間を強固に結着することができる。
2 is a schematic diagram showing an enlarged view of the boundary between the high magnetic permeability portion 10 and the low magnetic permeability portion 21 (22) in this configuration. The high magnetic permeability portion 10 is composed of a plurality of Fe-based soft magnetic alloy grains, and more specifically, is a compact of a plurality of Fe-based soft magnetic alloy grains 1 containing element M, which is more easily oxidized than Fe. Between the grains of the compact, there are voids 2, and a surface oxide phase 3 of the Fe-based soft magnetic alloy grains that binds the Fe-based soft magnetic alloy grains 1 together. This surface oxide phase is an oxide phase containing element M.
The low permeability portion 21 or 22 is composed of a plurality of low permeability metal grains 4 having a lower magnetic permeability than the Fe-based soft magnetic alloy grains 1. The low permeability metal grains 4 are characterized in that they contain an element M which is more easily oxidized than Fe. The low permeability metal grains 4 have gaps 2 between them and a surface oxide phase 5 which bonds the low permeability metal grains 4 together. The surface oxide phase is an oxide phase containing the element M.
Furthermore, where the Fe-based soft magnetic alloy particles 1 and the low magnetic permeability metal particles 4 are adjacent to each other, a surface oxide phase 6 is formed. The surface oxide phase 6 is formed by bonding and integrating the surface oxide phase 3 of the Fe-based soft magnetic alloy particles 1 and the surface oxide phase 5 of the low magnetic permeability metal particles 4, and the components of the adjacent particles are different. However, by containing the same element M in the Fe-based soft magnetic alloy particles 1 and the low magnetic permeability metal particles 4, the surface oxide phase 6 can be made to be a more homogeneous surface oxide phase 6 mainly composed of element M. This allows the Fe-based soft magnetic alloy particles 1 and the low magnetic permeability metal particles 4 to be firmly bonded to each other.
（第２実施形態）
次に、本発明の第２実施形態の磁性楔２００について説明する。本実施形態の磁性楔２００と第１実施形態の磁性楔１００とは、形状だけが異なる。また、第１実施形態と同じ構成は、作用効果が同じなので、同じ記号を付して説明を省略する。
Second Embodiment
Next, a magnetic wedge 200 according to a second embodiment of the present invention will be described. The magnetic wedge 200 according to this embodiment differs from the magnetic wedge 100 according to the first embodiment only in shape. In addition, since the same configurations as those in the first embodiment have the same effects, the same symbols are used and the description is omitted.
磁性楔は後述のようにステータのティースに形成された突起や溝に嵌合されて取り付けられる。したがって、この嵌合形態によって、磁性楔の断面は種々の形状をとることができる。第一の実施形態では磁性楔の両端に段差を設けた形状で説明したが、例えば図３に示したように、磁性楔２００の両端がテーパー状になっていても良い。このような形状であれば、ステータに形成された溝の角部への応力集中を緩和できるので好適である。また、図３に示した磁性楔２００では、高透磁率部分の断面が長方形になっているが、これに限らず、台形などの種々の形状を適用することができる。 The magnetic wedge is attached by fitting into protrusions and grooves formed on the teeth of the stator as described below. Therefore, depending on the fitting form, the cross section of the magnetic wedge can have various shapes. In the first embodiment, the magnetic wedge is described as having a shape with steps on both ends, but for example, as shown in Figure 3, both ends of the magnetic wedge 200 may be tapered. This shape is preferable because it can reduce stress concentration at the corners of the grooves formed in the stator. Also, in the magnetic wedge 200 shown in Figure 3, the cross section of the high permeability part is rectangular, but this is not limited to this, and various shapes such as a trapezoid can be applied.
（第３実施形態）
次に、本発明の第３実施形態である、回転電機３００について説明する。
図４は、回転電機３００の模式図であり、回転電機３００の回転軸に垂直な断面構造を示している。回転電機３００は、ラジアルギャップ型回転電機であり、ステータ３５とロータ３２を同軸にして配している。そして、ステータ３５には、コイル３３を巻き回した複数のティース３４を、周方向に等間隔に配している。
Third Embodiment
Next, a rotating electric machine 300 according to a third embodiment of the present invention will be described.
4 is a schematic diagram of the rotating electric machine 300, showing a cross-sectional structure perpendicular to the rotation axis of the rotating electric machine 300. The rotating electric machine 300 is a radial gap type rotating electric machine, in which a stator 35 and a rotor 32 are arranged coaxially. The stator 35 has a plurality of teeth 34 around which coils 33 are wound, which are arranged at equal intervals in the circumferential direction.
本実施形態の回転電機３００では、ティース３４のロータ３２側先端に、隣り合うティース３４の先端を接続するよう、第１実施形態の磁気楔１００、あるいは、第２実施形態の磁気楔２００を配している。 In the rotating electric machine 300 of this embodiment, the magnetic wedge 100 of the first embodiment or the magnetic wedge 200 of the second embodiment is arranged at the rotor 32 side end of the teeth 34 so as to connect the ends of adjacent teeth 34.
ここで、ティース３４の比透磁率と飽和磁束密度は、通常、磁性楔１００または２００のそれらよりも高く設計される。これにより、磁性楔１００または２００に達したロータ３２からの磁束は、磁性楔１００または２００を経由してティース３４に流入し、コイルに達する磁束が抑制されて、コイルに生じる渦電流損失を低減することができる。また、回転電機の駆動時において、コイル電流により生じたティース３４内の磁束は、大部分がギャップを隔ててロータ３２に流入するものの、一部は磁性楔に誘引されて周方向に広がるようになる。これにより、ステータ３５とロータ３２との間のギャップ内磁束分布がなだらかになり、例えばロータ３２に永久磁石を配置した回転電機では、コギングを抑制することができ、さらにロータ３２に発生する渦電流損を低減することができる。また、例えばロータ３２にかご形導体を配置した誘導型回転電機では、二次銅損を低減することができる。以上のように本発明による磁性楔１００または２００を回転電機に配することで、損失を低減し、高効率・高性能の回転電機３００にすることができる。 Here, the relative permeability and saturation magnetic flux density of the teeth 34 are usually designed to be higher than those of the magnetic wedge 100 or 200. As a result, the magnetic flux from the rotor 32 that reaches the magnetic wedge 100 or 200 flows into the teeth 34 via the magnetic wedge 100 or 200, and the magnetic flux that reaches the coil is suppressed, thereby reducing the eddy current loss generated in the coil. In addition, when the rotating electric machine is driven, most of the magnetic flux in the teeth 34 generated by the coil current flows into the rotor 32 across the gap, but a part of it is attracted to the magnetic wedge and spreads in the circumferential direction. As a result, the magnetic flux distribution in the gap between the stator 35 and the rotor 32 becomes gentle, and for example, in a rotating electric machine in which a permanent magnet is arranged in the rotor 32, cogging can be suppressed and the eddy current loss generated in the rotor 32 can be reduced. In addition, for example, in an induction type rotating electric machine in which a cage conductor is arranged in the rotor 32, secondary copper loss can be reduced. As described above, by arranging the magnetic wedge 100 or 200 according to the present invention in a rotating electric machine, it is possible to reduce losses and create a highly efficient and high-performance rotating electric machine 300.
（高透磁率部分の磁気特性）
高透磁率部分に、Ｆｅより酸化しやすい元素であるＡｌおよびＣｒを含むＦｅ－Ａｌ－Ｃｒ合金粒子を用いた場合の第１実施形態の実施例を以下に示す。
(Magnetic properties of high permeability parts)
An example of the first embodiment in which the high magnetic permeability portion uses Fe-Al-Cr alloy particles containing Al and Cr, which are elements that are more easily oxidized than Fe, will be described below.
（磁気特性測定用試料の作製）
高圧水アトマイズ法により、Ｆｅ－５％Ａｌ－４％Ｃｒ（質量％）の合金粉末（Ｆｅ基軟磁性粉末）を作製した。作製した粉末の平均粒径（メジアン径）は１２μｍであった。この合金粉末にポリビニルアルコール（ＰＶＡ）とイオン交換水を加えてスラリーを作製し、スプレードライヤーで噴霧乾燥を行って造粒粉を得た。原料粉末を１００質量部とするとＰＶＡ添加量は０．７５質量部である。得られた造粒粉に０．４質量部の割合でステアリン酸亜鉛を添加し、混合した。得られた混合粉を金型に充填し、室温にて成形圧力０．９ＧＰａでプレス成形した。作製した成形体に、大気中７５０℃×１時間の熱処理を施して磁気特性評価用試料を得た。作製した磁気測定用試料の形状は、直流磁化曲線測定用として１０ｍｍ×１０ｍｍ×厚さ１．５ｍｍの平板形状、および、鉄損測定用試料として外径１３．４ｍｍ×内径７．７ｍｍ×厚さ２．０ｍｍのリング形状である。
(Preparation of samples for measuring magnetic properties)
An alloy powder (Fe-based soft magnetic powder) of Fe-5%Al-4%Cr (mass%) was prepared by high-pressure water atomization. The average particle size (median diameter) of the prepared powder was 12 μm. Polyvinyl alcohol (PVA) and ion-exchanged water were added to this alloy powder to prepare a slurry, which was spray-dried with a spray dryer to obtain a granulated powder. The amount of PVA added was 0.75 parts by mass when the raw material powder was 100 parts by mass. Zinc stearate was added to the obtained granulated powder at a ratio of 0.4 parts by mass and mixed. The obtained mixed powder was filled into a mold and press-molded at room temperature with a molding pressure of 0.9 GPa. The produced molded body was subjected to a heat treatment at 750 ° C. × 1 hour in air to obtain a sample for magnetic property evaluation. The magnetic measurement samples were prepared in the form of a flat plate measuring 10 mm×10 mm×1.5 mm thick for DC magnetization curve measurement, and in the form of a ring measuring 13.4 mm outer diameter×7.7 mm inner diameter×2.0 mm thick for iron loss measurement.
（高透磁率部分の断面組織）
上記のように作製した高透磁率部分について、走査電子顕微鏡（ＳＥＭ／ＥＤＸ）を用いて断面観察を行い、同時に各構成元素の分布を調べた。結果を図４に示す。図５（ａ）はＳＥＭ像であり、図５（ｂ）～（ｅ）はそれぞれ、Ｆｅ（鉄）、Ａｌ（アルミニウム）、Ｃｒ（クロム）、Ｏ（酸素）の分布を示すマッピング像である。明るい色調ほど対象元素が多いことを示す。図５から、Ｆｅ基軟磁性粒子間の粒界にはアルミニウムと酸素が多く、酸化物相が形成されていることがわかる。さらに、各軟磁性粒子同士がこの酸化物相を介して結合している様子がわかる。
(Cross-sectional structure of high permeability part)
The cross-section of the high permeability portion prepared as described above was observed using a scanning electron microscope (SEM/EDX), and the distribution of each constituent element was examined at the same time. The results are shown in Figure 4. Figure 5(a) is an SEM image, and Figures 5(b) to (e) are mapping images showing the distribution of Fe (iron), Al (aluminum), Cr (chromium), and O (oxygen), respectively. The brighter the color tone, the more the target element is present. From Figure 5, it can be seen that there is a lot of aluminum and oxygen at the grain boundaries between the Fe-based soft magnetic particles, and an oxide phase is formed. Furthermore, it can be seen that the soft magnetic particles are bonded to each other via this oxide phase.
（直流磁化曲線）
試料の直流磁化曲線（Ｂ－Ｈ曲線）は直流自記磁束計（東栄工業製ＴＲＦ－５ＡＨ）を用いて、上記の１０ｍｍ角試料を電磁石の磁極に挟み、最大印加磁界５００ｋＡ／ｍで測定した。室温での測定結果を図６に示す。印加磁界１６０ｋＡ／ｍにおける磁束密度の値は１．６０Ｔ、比透磁率μは８．０であった。後述のモータ特性シミュレーションでは、高透磁率部分のＢ－Ｈ曲線としてこの実測値を用いた。
(DC magnetization curve)
The DC magnetization curve (BH curve) of the sample was measured using a DC magnetic flux meter (TRF-5AH manufactured by Toei Kogyo Co., Ltd.) by clamping the above 10 mm square sample between the magnetic poles of an electromagnet and applying a maximum magnetic field of 500 kA/m. The measurement results at room temperature are shown in Figure 6. The magnetic flux density value at an applied magnetic field of 160 kA/m was 1.60 T, and the relative permeability μ was 8.0. In the motor characteristic simulation described below, this actual measured value was used as the BH curve of the high permeability portion.
（鉄損）
上記のリング試料に、ポリウレタン被覆銅線を用いて一次巻線と二次巻線を施した。巻き回数は一次側、二次側とも５０ターンとした。この試料を、大電流バイポーラ電源を備えたＢ－Ｈアナライザ（ＩＦＧ社製ＢＨ－５５０）に接続して鉄損Ｐｃｖを測定した。測定条件は、周波数ｆ＝５０Ｈｚ～１ｋＨｚ、最大磁束密度Ｂｍ＝０．０５～１．５５Ｔである。なお、一次巻線のジュール熱による試料温度上昇を防ぐために、冷媒温度を２３℃に維持した冷却槽に試料を浸漬して鉄損を測定した。冷媒にはシリコンオイルを使用した。測定結果を図７に示す。図中の白丸が測定値である。図のようにＢｍの高い領域では磁気飽和に近づくためＰｃｖが徐々に飽和する傾向を示している。次項のモータ特性評価では、高透磁率部分の鉄損としてこの実測値を用いた。なお、実測で測定できたのはＢｍ＝１．５５Ｔまでであったが、モータ内部で磁性楔は電磁鋼板の飽和磁束密度に相当する２Ｔ程度まで磁化される可能性がある。そこで、１．５５Ｔを超える高Ｂｍ側のＰｃｖ値については、測定結果を最小二乗法で以下の式に当てはめ、この式の外挿値を使用した。
Ｐｃｖ＝６．９ｆ／（１＋（１．２８／Ｂｍ）２）
ここでＰｃｖの単位はｋＷ／ｍ３、Ｂｍの単位はＴ、ｆの単位はＨｚである。図６中の実線がこの式の計算値である。
(iron loss)
The above ring sample was wound with a primary winding and a secondary winding using polyurethane-coated copper wire. The number of turns was 50 turns on both the primary and secondary sides. The sample was connected to a B-H analyzer (IFG BH-550) equipped with a large current bipolar power supply to measure the iron loss Pcv. The measurement conditions were frequency f = 50 Hz to 1 kHz, and maximum magnetic flux density Bm = 0.05 to 1.55 T. In order to prevent the sample temperature from increasing due to Joule heat from the primary winding, the sample was immersed in a cooling tank with a refrigerant temperature maintained at 23°C to measure the iron loss. Silicone oil was used as the refrigerant. The measurement results are shown in Figure 7. The white circles in the figure are the measured values. As shown in the figure, in the high Bm region, magnetic saturation is approached, and Pcv shows a tendency to gradually saturate. In the motor characteristic evaluation in the next section, this measured value was used as the iron loss of the high magnetic permeability part. Although actual measurements were only possible up to Bm = 1.55 T, the magnetic wedge inside the motor may be magnetized up to about 2 T, which corresponds to the saturation magnetic flux density of the electromagnetic steel sheet. Therefore, for Pcv values on the high Bm side exceeding 1.55 T, the measurement results were applied to the following formula using the least squares method, and the extrapolated value of this formula was used.
Pcv=6.9f/(1+(1.28/Bm) 2 )
Here, the unit of Pcv is kW/m 3 , the unit of Bm is T, and the unit of f is Hz. The solid line in Fig. 6 is the calculated value of this formula.
（回転電機特性評価）
誘導型回転電機に実施例もしくは比較例の磁性楔を設置した場合の特性（効率とトルク）を有限要素法による二次元電磁界シミュレーションを用いて算出した。その際、各磁性楔の高透磁率部分の磁気特性として上述のＢ－Ｈ曲線と鉄損値を計算に取り入れた。
電磁界シミュレーションに供した誘導型回転電機の諸元は以下の通りである。
ステータ：直径４５０ｍｍ×高さ１６２ｍｍ
極数：４
スロット数：３６
ロータおよびステータ材質：電磁鋼板（５０Ａ１０００）
回転電機出力：１５０ｋＷ
回転数：１４２５ｒｐｍ
(Evaluation of rotating electrical machine characteristics)
The characteristics (efficiency and torque) of an induction type rotating electric machine in which the magnetic wedge of the embodiment or the comparative example is installed were calculated using a two-dimensional electromagnetic field simulation using the finite element method. At that time, the above-mentioned BH curve and iron loss value were incorporated into the calculation as the magnetic characteristics of the high permeability part of each magnetic wedge.
The specifications of the induction type rotating electric machine used in the electromagnetic field simulation are as follows:
Stator: diameter 450mm x height 162mm
Number of poles: 4
Number of slots: 36
Rotor and stator material: Electromagnetic steel sheet (50A1000)
Rotating motor output: 150kW
Rotational speed: 1425 rpm
図８に、本評価で使用した磁性楔１００の設置位置を示す。磁性楔１００の断面はT字型であり、磁性楔１００の幅（回転電機の周方向の長さ）は、コイル３３側で１２．０ｍｍ、ロータ３２側で７．０ｍｍである。磁性楔１００の幅方向中央における厚さ（回転電機の径方向の長さ）は３．０ｍｍであり、段差部の厚さは１．５ｍｍである。 Figure 8 shows the installation position of the magnetic wedge 100 used in this evaluation. The cross section of the magnetic wedge 100 is T-shaped, and the width of the magnetic wedge 100 (the length in the circumferential direction of the rotating electric machine) is 12.0 mm on the coil 33 side and 7.0 mm on the rotor 32 side. The thickness of the magnetic wedge 100 at the center in the width direction (the length in the radial direction of the rotating electric machine) is 3.0 mm, and the thickness of the step portion is 1.5 mm.
（実施例）
実施例の磁性楔１００の断面模式図を図９に示す。実施例は、幅方向中央部に位置する高透磁率部分１０と、その両側に位置する低透磁率部分２１、２２からなる。高透磁率部分１０の磁気特性は上述の通りであり、高透磁率部分の幅ｘは０＜ｘ＜１２ｍｍの範囲にある。また、低透磁率部分２１、２２は非磁性として、比透磁率を１に固定した。
(Example)
A schematic cross-sectional view of a magnetic wedge 100 according to an embodiment is shown in Fig. 9. This embodiment is composed of a high permeability portion 10 located in the center in the width direction, and low permeability portions 21 and 22 located on either side of it. The magnetic properties of the high permeability portion 10 are as described above, and the width x of the high permeability portion is in the range of 0<x<12 mm. The low permeability portions 21 and 22 are non-magnetic, and the relative permeability is fixed to 1.
（比較例）
比較例の磁性楔１００の断面模式図を図１０に示す。比較例は、ロータ側に位置する高透磁率部分１０と、コイル側に位置する低透磁率部分２１からなる。高透磁率部分１０の磁気特性は上述の通りであり、高透磁率部分の厚さｙは０≦ｙ≦３ｍｍの範囲にある。また、低透磁率部分２１は非磁性として、比透磁率を１に固定した。この比較例において、ｙ＝０は磁性楔１００の全体が非磁性体となり、ｙ＝３ｍｍのときは磁性楔１００の全体が高透磁率部分となる。
(Comparative Example)
A schematic cross-sectional view of a magnetic wedge 100 of a comparative example is shown in Figure 10. The comparative example is composed of a high permeability portion 10 located on the rotor side and a low permeability portion 21 located on the coil side. The magnetic characteristics of the high permeability portion 10 are as described above, and the thickness y of the high permeability portion is in the range of 0 < y < 3 mm. The low permeability portion 21 is non-magnetic, and has a fixed relative permeability of 1. In this comparative example, when y = 0, the entire magnetic wedge 100 is non-magnetic, and when y = 3 mm, the entire magnetic wedge 100 is a high permeability portion.
（回転電機特性評価結果）
実施例の磁性楔を用いた回転電機の効率とトルクを表１に、比較例の磁性楔を用いた場合の回転電機の効率とトルクを表２にそれぞれ示す。また、図１１は横軸に回転電機の効率、縦軸にトルクをとって表1および表２の結果を図示したものである。図１１においては、グラフ上で右上に位置するものほど、効率もトルクも高く、良好な特性と言うことができる。
まず比較例の磁性楔の結果に着目すると、全体が非磁性の比較例１が最もトルクが高い一方、効率は最低である。高透磁率部分を増やしていくと（比較例２~４）、効率は向上してくもののトルクは低下していく。全体が高透磁率部分の比較例５で、比較例の中では最高効率が得られるものの、トルクは最低となる。比較例における以上のようなトレードオフの関係を図１１中に点線で示した。
一方、実施例の計算結果のプロット点は、いずれも上記点線の右上に位置しており、比較例に比べて高トルクと高効率を両立した優れた特性を示した。従来から使用されている磁性楔は比較例５のような全体が高透磁率部分からなる磁性楔である。この比較例５と比較すると、実施例はトルクと効率の両方とも上回っていることから、従来の磁性楔では実現できなかった優れた特性の回転電機を提供することができる。
(Evaluation results of rotating electrical machine characteristics)
Table 1 shows the efficiency and torque of a rotating electric machine using the magnetic wedge of the embodiment, and Table 2 shows the efficiency and torque of a rotating electric machine using the magnetic wedge of the comparative example. Fig. 11 shows the results of Tables 1 and 2, with the efficiency of the rotating electric machine on the horizontal axis and the torque on the vertical axis. In Fig. 11, the further to the upper right on the graph the higher the efficiency and torque, and the better the characteristics can be said to be.
First, looking at the results of the magnetic wedges of the comparative examples, Comparative Example 1, which is entirely non-magnetic, has the highest torque but the lowest efficiency. As the number of high permeability parts is increased (Comparative Examples 2 to 4), the efficiency improves but the torque decreases. Comparative Example 5, which is entirely high permeability, has the highest efficiency among the comparative examples but the lowest torque. The above trade-off relationship in the comparative examples is shown by the dotted line in Figure 11.
On the other hand, all of the plot points of the calculation results for the working example are located to the upper right of the dotted line, and show superior characteristics that combine high torque and high efficiency compared to the comparative example. Conventionally used magnetic wedges are magnetic wedges made entirely of high permeability parts, as in comparative example 5. Compared to comparative example 5, the working example is superior in both torque and efficiency, making it possible to provide a rotating electric machine with superior characteristics that could not be achieved with conventional magnetic wedges.
以上、本発明について、上記実施形態を用いて説明してきたが、本発明の技術範囲は、上記実施形態に限定されない。特許請求の範囲に記載されている技術範囲にて、内容を変更できるものである。 The present invention has been described above using the above embodiment, but the technical scope of the present invention is not limited to the above embodiment. The content can be modified within the technical scope described in the claims.
１：Ｆｅ基軟磁性粒子
２：空隙
３：表面酸化物相
４：低透磁率金属粒子
５：表面酸化物相
６：表面酸化物相
１０：高透磁率部分
２１、２２：低透磁率部分
３１：ギャップ
３２：ロータ
３３：コイル
３４：ティース
３５：ステータ
１００、２００：磁性楔
３００：回転電機
1: Fe-based soft magnetic particle 2: Gap 3: Surface oxide phase 4: Low magnetic permeability metal particle 5: Surface oxide phase 6: Surface oxide phase 10: High magnetic permeability portion 21, 22: Low magnetic permeability portion 31: Gap 32: Rotor 33: Coil 34: Teeth 35: Stator 100, 200: Magnetic wedge 300: Rotating electric machine
Claims (4)
互いに相対的に透磁率が異なる高透磁率部分と低透磁率部分とを有し、
前記低透磁率部分の透磁率が前記高透磁率部分の透磁率よりも低く、
前記高透磁率部分は前記磁性楔の幅方向の中央部に位置し、
前記低透磁率部分は前記磁性楔の幅方向の両端側に位置し、
前記高透磁率部分には、軟磁性粒子と、前記軟磁性粒子の間に電気絶縁性の物質とを含み、前記軟磁性粒子が、Ｆｅよりも酸化しやすい元素Ｍを含有する複数のＦｅ基軟磁性合金粒子であって、前記高透磁率部分は、前記Ｆｅ基軟磁性合金粒子が、前記元素Ｍを含む酸化物相で結着され、
前記低透磁率部分は、Ｆｅよりも酸化しやすい元素Ｍを含有し、前記Ｆｅ基軟磁性合金粒子よりも透磁率が低い複数の金属粒子が前記元素Ｍを含む酸化物相で結着されて構成されていること
を特徴とする磁性楔。 A magnetic wedge for a rotating electric machine, comprising:
The magnetic flux has a high magnetic permeability portion and a low magnetic permeability portion, the permeability of which is relatively different from each other,
the permeability of the low permeability portion is lower than the permeability of the high permeability portion,
the high permeability portion is located at a center portion in a width direction of the magnetic wedge,
The low magnetic permeability portions are located on both ends of the magnetic wedge in a width direction ,
the high magnetic permeability portion includes soft magnetic particles and an electrically insulating material between the soft magnetic particles, the soft magnetic particles being a plurality of Fe-based soft magnetic alloy particles containing an element M which is more easily oxidized than Fe, the high magnetic permeability portion includes the Fe-based soft magnetic alloy particles bound together by an oxide phase containing the element M,
The low magnetic permeability portion contains an element M which is more easily oxidized than Fe, and is configured by binding a plurality of metal particles having a lower magnetic permeability than the Fe-based soft magnetic alloy particles with an oxide phase containing the element M.
A magnetic wedge characterized by:
A rotating electric machine comprising the magnetic wedge according to any one of claims 1 to 3 .
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