Radial-gap-type rotary electric machine, production method for radial-gap-type rotary electric machine, production device for rotary electric machine teeth piece, and production method for rotary electric machine teeth member
11557948 · 2023-01-17
Assignee
Inventors
Cpc classification
H02K2203/12
ELECTRICITY
Y02T10/64
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
H02K1/276
ELECTRICITY
H02K1/146
ELECTRICITY
International classification
H02K1/276
ELECTRICITY
Abstract
A radial-gap-type rotary electric machine, a production method therefore, a production device for a rotary electric machine teeth piece, and a production method therefore can achieve a high efficiency and have excellent productivity. A radial-gap-type rotary electric machine includes a rotation shaft, a rotator including an inner-peripheral-side rotator iron core rotatable around the rotation shaft and an outer-peripheral-side rotator iron core arranged on an outer peripheral side of the inner-peripheral-side rotator iron core and rotatable around the rotation shaft, and a stator disposed between the inner-peripheral-side rotator iron core and the outer-peripheral-side rotator iron core. A permanent magnet is provided on at least one of an outer-peripheral-side surface of the inner-peripheral-side rotator iron core and an inner-peripheral-side surface of the outer-peripheral-side rotator iron core. The stator includes a stator iron core including teeth formed of laminated bodies where amorphous metal foil strip pieces are held with mutual friction.
Claims
1. A radial-gap-type rotary electric machine comprising: a rotation shaft; a rotator including an inner-peripheral-side rotator iron core rotatable around the rotation shaft and an outer-peripheral-side rotator iron core arranged on an outer peripheral side of the inner-peripheral-side rotator iron core and rotatable around the rotation shaft; and a stator disposed between the inner-peripheral-side rotator iron core and the outer-peripheral-side rotator iron core, wherein a permanent magnet is provided on at least one of an outer-peripheral-side surface of the inner-peripheral-side rotator iron core and an inner-peripheral-side surface of the outer-peripheral-side rotator iron core, and the stator includes a stator iron core, including: teeth formed of laminated bodies where amorphous metal foil strip pieces are held with mutual friction, and a resin-made bobbin that holds the laminated body.
2. The radial-gap-type rotary electric machine according to claim 1, wherein the stator iron core includes a teeth member, the teeth member including the teeth formed of the laminated body where the amorphous metal foil strip pieces having trapezoidal shapes in plan view are laminated in an axial direction of the rotation shaft, the resin-made bobbin, and a coil conductor wound around an outside of the resin-made bobbin along a lamination direction of the laminated body, and a plurality of the teeth members are arranged in an annular shape and molded with a resin.
3. The radial-gap-type rotary electric machine according to claim 2, wherein the coil conductor is held between resin-made bobbins that are adjacent.
4. The radial-gap-type rotary electric machine according to claim 2, wherein the teeth have end portions on a side of the rotation shaft, and the end portions project from each of the resin-made bobbins.
5. The radial-gap-type rotary electric machine according to claim 2, wherein the stator iron core has a lower end portion that is integrated with a chassis of the stator with the resin.
6. The radial-gap-type rotary electric machine according to claim 1, wherein a permanent magnet is provided on the inner-peripheral-side surface of the outer-peripheral-side rotator iron core, and the inner-peripheral-side rotator iron core and the stator iron core are integrated.
7. The radial-gap-type rotary electric machine according to claim 1, wherein a permanent magnet is provided on the outer-peripheral-side surface of the inner-peripheral-side rotator iron core, and the outer-peripheral-side rotator iron core and the stator iron core are integrated.
8. The radial-gap-type rotary electric machine according to claim 1, wherein the permanent magnet is embedded in an inside of the inner-peripheral-side rotator iron core or the outer-peripheral-side rotator iron core.
Description
BRIEF DESCRIPTION OF DRAWINGS
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DESCRIPTION OF EMBODIMENTS
(24) The following describes an embodiment of the present invention using the drawings and the like.
(25) Prior to a description of a radial-gap-type rotary electric machine of the present invention, a configuration of a conventional radial-gap-type rotary electric machine will be described.
(26) The stator iron core 11 has a slot part on which a stator coil 12, which is wound around a teeth part, is mounted. Inside this stator, a rotator including permanent magnets 13 and a rotator iron core (a magnetic core) 14 is rotatably held via bearings 18. The bearings 18, which are held by end brackets 19 disposed on both ends in the axial direction of the housing, hold the rotator in the axial direction and a gravity direction. The rotator has a center on which a rotation shaft (a shaft) 17 is installed. The rotation shaft 17 passes through a hole of a front-side end bracket 19, thus constituting an output shaft.
(27) As illustrated in
(28) The stator iron core is made of a soft magnetic material. Generally, the stator iron core is configured such that an electromagnetic steel plate is used and punched out with a press die to be laminated. The amorphous metal is a material that has a loss substantially smaller than that of the electromagnetic steel plate to ensure contribution to a high efficiency of a motor. However, as described above, its hardness is very high, thus having difficulty punching it into a slot-type motor core as illustrated in the drawing with a press for lamination. Therefore, it is difficult to apply the amorphous metal to a rotary electric machine having the structure illustrated in
(29)
(30) The stator iron core is made of a soft magnetic material. Generally, the stator iron core is configured such that an electromagnetic steel plate is used and punched out with a press die to be laminated. The amorphous metal is a material that has a loss substantially smaller than that of the electromagnetic steel plate to ensure contribution to a high efficiency of a motor. However, as described above, its hardness is very high, thus having difficulty punching it into a slot-type motor core as illustrated in the drawing with a press for lamination. Therefore, it is difficult to apply the amorphous metal to a rotary electric machine having the structure illustrated in
(31) [Radial-Gap-Type Rotary Electric Machine]
(32) Subsequently, a description will be given of the radial-gap-type rotary electric machine of the present invention. The radial-gap-type rotary electric machine of the present invention has a configuration to which the amorphous metal is applicable.
(33) A rotation shaft (a shaft) 37 is rotatably held by a bearing 38. The rotator 102 has a configuration rotatable around the rotation shaft 37 while having a clearance (a gap) with the stator 101. The following describes the configurations of the stator 101 and the rotator 102 in detail.
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(36) As illustrated in
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(38) As illustrated in
(39) As illustrated in
(40) A material of the amorphous metal is not especially limited, but it is preferable to use, for example, Metglas 2605HB1M (composition: Fe—Si—B), Metglas 2605SA1 (composition: Fe—Si—B), Metglas 2605S3A (composition: Fe—Si—B—Cr), and Metglas 2705M (composition: Co—Fe—Ni—Si—B—Mo) manufactured by Hitachi Metals, Ltd. The above-described “Metglas” is a registered trademark of Metglas Incorporated, which is a group company of Hitachi Metals, Ltd.
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(42) As illustrated in
(43) The rotator 102 having the cup shape internally includes a ring-shaped holding member 32 for holding the inner-peripheral-side rotator iron core 31a. The inner-peripheral-side rotator iron core 31a includes a soft magnetic material 21 and a permanent magnet (a rotator magnet) 22 that are mounted on the ring-shaped holding member 32. The outer-peripheral-side rotator iron core 31b includes a soft magnetic material 24 and a permanent magnet (a rotator magnet) 23 that are mounted outside the soft magnetic material 21 and the permanent magnet 22. Furthermore, it is a structure where the rotation shaft 37 is arranged at a center of the cup-shaped rotator 102. The respective members can be fixed by fastening using a screw or the like, bonding, and welding, and depending on the part, with a way such as press-fitting and shrink fitting. The soft magnetic materials 21, 24 arranged on the rotator 102 may be laminated bodies of the electromagnetic steel plates or the like and may be lumps of iron such as shafts since they are yoke of a DC magnetic field source.
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(45) Conventionally, there has been a technique to apply the amorphous metal to a two-rotor-type axial gap motor. This two-rotor-type axial gap motor has a structure where gaps are axially opposed. Thus, a very large axial absorbing force is generated when one side rotor is assembled. After the second rotor is assembled, the absorbing force is balanced. However, depending on an error in gap dimensions or the like, a case where the absorbing force is left on one side occurs. It is the structure also having difficulty assembling while equally managing the gaps. It is the structure also having difficulty holding a magnet mounted on a rotator with respect to a centrifugal force because the rotator has a large diameter.
(46) In the radial-gap-type rotary electric machine of the present invention illustrated in
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(50) [Production Device and Production Method for Rotary Electric Machine Teeth]
(51) The following describes a device and a method that can efficiently produce the above-described laminated body of the trapezoidal-shaped amorphous metal foil strip pieces.
(52) The amorphous-metal-foil-strip material sheet 121 is supplied to the cutting stage 123 by the feed roller 122 at equal intervals. The amorphous-metal-foil-strip material sheet fed to the cutting stage 123 has legs that are shear-cut by the upper blade 124a and the lower blade 124b to be the amorphous metal foil strip piece, and then, the amorphous metal foil strip pieces are sequentially continuously laminated on the base plate 126 to produce a laminated body 1. In such a system, the cutting blade has a simple shape, thus facilitating installing on and removing from the die, which reduces the cost, and facilitating maintenance such as repolishing. In view of this, efficient production is ensured by sufficiently reducing the production cost with respect to disadvantage in production due to the hardness and the thinness of the amorphous metal.
(53) However, when the cutting is evenly performed by one set of cutting blades, a parallelogram amorphous metal foil strip piece is formed. Therefore, in the production device and method of the present invention, as indicated by a solid line and a dotted line in
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(55) It is also possible to cut the amorphous foil strip while making angles by moving the cutting stage 123 using a mechanical cam or the like. Furthermore, a sufficient production speed can be expected as well in a method that intermittently feeds the amorphous metal foil strip with the feed roller 122 and operates the upper blade 124a and the lower blade 124b by electric slide in synchronization with the intermittent feed operation. A cutting speed can be expected at around 200 SPM. Furthermore, supplying a plurality of laminated amorphous-foil-strip material sheets 121 ensures the production at a production speed that can be expected to have an effect commercially.
(56) The laminated body 1 laminated on the base plate 126 is managed and arrayed to have a predetermined axial length (height) in a method such as a number management or a weight management of the amorphous metal foil strip pieces that constitute the laminated body 1. Then, the laminated body 1 is inserted into the resin-made bobbin to complete a teeth block.
(57) As described above, it has been proven that the present invention can provide the radial-gap-type rotary electric machine, the production method for the radial-gap-type rotary electric machine, the production device for the rotary electric machine teeth piece, and the production method for the rotary electric machine teeth member using the amorphous metal that can achieve the high efficiency and have the excellent productivity.
(58) The present invention is not limited to the above-described embodiments but includes various modifications. For example, the above-described embodiments have been described in detail in order to easily describe the present invention, and therefore, it is not necessarily limited to include all the described configurations. It is possible to replace a part of the configuration of one embodiment with a configuration of another embodiment, and it is possible to add a configuration of one embodiment to a configuration of another embodiment. Some of the configurations of each embodiment can be added to, deleted from, or replaced by other configurations.
REFERENCE SIGNS LIST
(59) 10 . . . housing,
(60) 11 . . . stator iron core,
(61) 12 . . . stator coil,
(62) 13 . . . permanent magnet,
(63) 14 . . . rotator iron core,
(64) 15 . . . chassis,
(65) 17, 37 . . . shaft,
(66) 18 . . . bearing,
(67) 19 . . . end bracket,
(68) 100 . . . radial-gap-type rotary electric machine,
(69) 101 . . . stator,
(70) 102 . . . rotator,
(71) 1 . . . tooth (laminated body of amorphous metal foil strip pieces),
(72) 3 . . . resin-made bobbin,
(73) 4 . . . coil conductor,
(74) 20 . . . stator base,
(75) 21, 24 . . . soft magnetic material,
(76) 22, 23 . . . permanent magnet,
(77) 25 . . . stator iron core,
(78) 26 . . . bearing holding portion,
(79) 27 . . . bearing holding plate,
(80) 31 . . . rotator iron core,
(81) 31a . . . inner-peripheral-side rotator iron core,
(82) 31b . . . outer-peripheral-side rotator iron core,
(83) 32 . . . ring-shaped holding member,
(84) 37 . . . rotation shaft (shaft),
(85) 38 . . . bearing,
(86) 50 . . . teeth member,
(87) 60 . . . embedded magnet,
(88) 61 . . . embedded magnet holding member,
(89) 120 . . . cutting apparatus,
(90) 121 . . . amorphous-metal-foil-strip material sheet,
(91) 122 . . . feed roller,
(92) 123 . . . cutting stage,
(93) 124a . . . upper blade,
(94) 124b . . . lower blade,
(95) 125 . . . upper plate,
(96) 126 . . . base plate,
(97) 130 . . . amorphous metal foil strip,
(98) 301 . . . protrusion