MAGNET STRUCTURE AND MOTOR

Abstract

Provided is a magnet structure (MS) which includes a plurality of permanent magnets (2) fixed onto a baseplate (1), and a cover structure (3) for covering the plurality of permanent magnets (2). The cover structure (3) includes a plurality of covers (3a) that is formed of a non-magnetic material and covers the plurality of permanent magnets (2). A relative position between the plurality of covers (3a) is fixed, and there is a gap (G) between the neighboring covers (3a).

Claims

1. A magnet structure comprising: a plurality of permanent magnets fixed onto a baseplate; and a cover structure configured to cover the plurality of permanent magnets, wherein the cover structure includes a plurality of covers that is formed of a non-magnetic material and covers the plurality of permanent magnets, a relative position between the plurality of covers is fixed, and there is a gap between the neighboring covers.

2. The magnet structure according to claim 1, wherein there is a gap between the permanent magnets.

3. The magnet structure according to claim 1, wherein the baseplate is a magnetic material.

4. The magnet structure according to claim 1, wherein the number of covers is smaller than the number of permanent magnets.

5. The magnet structure according to claim 1, wherein surfaces of the permanent magnets are covered with a resin.

6. The magnet structure according to claim 1, wherein: lateral surfaces of the baseplate have grooves extending in longitudinal directions thereof; and each of the covers includes bent parts fitted into the grooves.

7. The magnet structure according to claim 1, wherein holes for inserting fixing components for fixing the covers are not provided in lateral surfaces of the baseplate.

8. The magnet structure according to claim 1, wherein lateral surfaces of the covers have protrusions that protrude in a longitudinal direction of the baseplate.

9. The magnet structure according to claim 6, wherein lateral surfaces of the grooves of the baseplate which are close to the permanent magnet are inclined with respect to a surface of the baseplate to which the permanent magnets are fixed.

10. A motor having a plurality of the magnet structures defined in claim 1, wherein the plurality of magnet structures is disposed along a surface of a rotor, the motor includes coils that are disposed within a range of a magnetic field of the plurality of magnet structures, and polarities of surfaces of the magnet structures are alternately inverted in a circumferential direction of the surface of the rotor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a partially exploded perspective view of a magnet structure.

[0018] FIG. 2A is a view illustrating a longitudinal section of a magnet structure (a first embodiment) from the front, FIG. 2B is a side view thereof, and FIG. 2C is a top view thereof.

[0019] FIG. 3 is a view illustrating a longitudinal section of the magnet structure from the front.

[0020] FIG. 4 is a front view of a rotor of a rotary motor having a plurality of magnet structures.

[0021] FIG. 5 is a view illustrating a sectional configuration perpendicular to a rotational axis of the motor.

[0022] FIG. 6 is a view illustrating an area surrounded with a quadrilateral dotted line in FIG. 5.

[0023] FIG. 7 is a block diagram of an electric generation system using the motor.

[0024] FIG. 8 is a view illustrating a sectional configuration perpendicular to a rotational axis of a motor having another structure.

[0025] FIG. 9A is a view illustrating a longitudinal section of a magnet structure (a second embodiment) from the front, FIG. 9B is a side view thereof, and FIG. 9C is a top view thereof.

[0026] FIG. 10A is a view illustrating a longitudinal section of a magnet structure (a third embodiment) from the front, FIG. 10B is a side view thereof, and FIG. 10C is a top view thereof.

[0027] FIG. 11A is a view illustrating a longitudinal section of a magnet structure (a fourth embodiment) from the front, FIG. 11B is a side view thereof, and FIG. 11C is a top view thereof.

[0028] FIG. 12 is a view illustrating a longitudinal section of the magnet structure from the front.

[0029] FIG. 13 is a view illustrating a longitudinal section of the magnet structure from the front.

[0030] FIG. 14 is a view illustrating a longitudinal sectional configuration of the magnet structure and covers from the side.

[0031] FIG. 15 is a partial perspective view of the cover illustrating flows of electric currents.

[0032] FIG. 16 is a partial perspective view of the cover illustrating flows of electric currents.

[0033] FIG. 17 is a partial perspective view of the cover illustrating flows of electric currents.

[0034] FIG. 18 is a partial perspective view of the cover illustrating flows of electric currents.

[0035] FIG. 19 is a partial perspective view of the cover illustrating flows of electric currents.

DETAILED DESCRIPTION

[0036] Hereinafter, a magnet structure according to an embodiment and a motor using the same will be described. The same elements will be given the same reference signs, and duplicate description thereof will be omitted.

[0037] FIG. 1 is a partially exploded perspective view of a magnet structure. FIG. 2A is a view illustrating a longitudinal section of a magnet structure (a first embodiment) from the front, FIG. 9B is a side view thereof, and FIG. 2C is a top view thereof.

[0038] A magnet structure MS includes a plurality of permanent magnets 2 that is aligned and fixed on a baseplate 1, and a cover structure 3 for covering the plurality of permanent magnets 2. The cover structure 3 includes a plurality of covers 3a that is formed of a non-magnetic material and covers the plurality of permanent magnets 2. A relative position between the plurality of covers 3a is fixed, and there is a gap G between the neighboring covers 3a. A gas (air) is interposed in the gap G In this figure, a longitudinal direction of the magnet structure MS is defined as a Z-axis direction, a width direction of the magnet structure MS, that is, a longitudinal direction of one permanent magnet 2 (one permanent magnet bar), is defined as a Y-axis direction, and a direction perpendicular to both of them is defined as an X-axis direction. The X-axis direction is identical to a thickness direction of the baseplate 1.

[0039] In FIG. 1, 12 permanent magnets 2 (12 permanent magnet bars) and 10 covers 3a are illustrated. After the permanent magnets 2 are fixed onto the baseplate 1, the covers 3a slide in the Z-axis direction and cover the permanent magnets 2.

[0040] Due to the presence of the covers 3a, corrosion, falling, etc. of the permanent magnets 2 are suppressed. Meanwhile, because the gap G is between the covers 3a, eddy currents occurring at the covers 3a can be reduced, and efficiency of a motor is increased. Due to the gap, deformation associated with thermal expansion can also be suppressed. Especially, upper surface sides of the covers 3a are preferably open in view of suppression of the occurrence of the eddy currents, and heat dissipation.

[0041] There is also a gap G2 between the permanent magnets 2 (the permanent magnet bars). A gas (air) is interposed in the gap G2. In a case in which the baseplate 1 (for instance, iron) is expanded and contracted by heat, the gap G2 between the permanent magnets 2 can absorb stress applied to the permanent magnets 2. Therefore, the permanent magnets 2 are not easily removed from the baseplate 1. The permanent magnets 2 are fixed to the baseplate 1 by a bond.

[0042] The baseplate 1 may be a magnetic material. A laminated steel sheet (iron), a silicon steel sheet, or an iron sheet can be used as the magnetic material for the baseplate 1. A material such as stainless steel, aluminum, or carbon fiber can also be used as a non-magnetic material. If the baseplate 1 is the magnetic material, magnetic lines of force generated from the permanent magnets 2 can pass through the baseplate 1, and thus magnetic properties can be enhanced.

[0043] The number of covers 3a may be smaller than the number of permanent magnets 2 (permanent magnet bars). In this case, the number of components for fixing the covers may be small, and productivity is improved. Especially when the permanent magnets 2 are fixed to the baseplate 1, strength of the baseplate 1 is important. As the number of components for fixture becomes few, the baseplate is neither reduced in volume nor becomes a complicated shape. Thus, the strength of the baseplate 1 is increased.

[0044] Here, the number of covers 3a and the number of permanent magnets 2 will be described.

[0045] FIG. 14 is a view illustrating a longitudinal sectional configuration of the magnet structure and the covers from the side. The twelve permanent magnets 2 are arranged in a longitudinal direction. Since the number of covers 3a is smaller than the number of permanent magnets 2, a degree to which the gap G2 between the permanent magnets 2 is covered by the covers 3a becomes high, and the gap G2 is not easily exposed directly. Therefore, water or dust becomes less likely to enter the gap G2, and an anticorrosive effect and an antirust effect are expected at a portion that is in contact with the gap G2. In addition, protection of the gap position between the permanent magnets 2 due to the cover 3a is enhanced, and thereby fracturing and cracking of the permanent magnet 2 are reduced. When there is the least common multiple of a least unit obtained by dividing a length of the magnet structure in the Z-axis direction by the number of covers 3a and a least unit obtained by dividing the length of the magnet structure by the number of permanent magnets 2, there is a possibility of the gap G2 being exposed at that position (a position where G=G(*) in FIG. 14). In this case, a protective function of the gap G2 is reduced, but the exposure of the gap G2(G(*)) is confirmed. Thereby, it can be confirmed whether or not mounting positions of the covers are as specified. In addition, the numbers of covers and permanent magnets, and the lengths of the covers and the permanent magnets in the Z-axis direction or widths of the gaps thereof are appropriately adjusted, and thereby the gap between the permanent magnets can also be located at a position at which it is exposed from the gap between the covers.

[0046] FIG. 3 is a view illustrating a longitudinal section of the magnet structure from the front.

[0047] Reference signs 3a1 to 3a6 denote parts of the cover 3a. There is a gap G3 between the cover 3a and the permanent magnet 2. A bond can be applied to the gap G3, and can fix the cover 3a and the permanent magnet 2. The bond is a resin, coats the permanent magnet 2, is not in contact with the cover 3a, and also enables a mode without a bonding function between the permanent magnet 2 and the cover 3a. In any case, a surface of the permanent magnet is covered with a resin. Thereby, the magnet surface is cut off from open air, and corrosion and deterioration of the permanent magnet can be prevented. Further, when the resin is a bond, the cover and the permanent magnet are fixed, and strength of the magnet structure can be increased.

[0048] In this case, fixing components (screws B) for fixing the cover 3a to the baseplate 1 can be omitted, and the strength of the baseplate 1 can be increased. In the case of the structure of FIG. 3, the baseplate 1 has threaded holes, and the screws B (or bolts) pass through holes of lower bent parts of the cover 3a and the threaded holes of the baseplate 1, and fix the cover 3a to the baseplate 1. A bond G4 is interposed in a gap between the permanent magnet 2 and the baseplate 1, and firmly fixes them. The screws B are male screws, and the threaded holes have female threads. The bolt is a type of male screw. A method of preparing a pin without threaded grooves instead of the male screw, preparing a non-threaded hole instead of the threaded hole, inserting the pin into the hole, and then fixedly welding the pin to the baseplate 1 is also conceivable. The fixing component such as the screw, the bolt, or the pin is inserted into the hole of the baseplate 1, and thereby the cover 3a can be fixed to the baseplate 1. The cover 3a can be fixed in contact with the permanent magnet 2 without providing the gap G3.

[0049] The permanent magnet 2 is formed into a bar shape by disposing a plurality of permanent magnet blocks 2B along a Y axis with no gap. The permanent magnet blocks 2B are fixed onto the baseplate 1 by the bond G4.

[0050] When viewed from the front, the baseplate 1 has two holes H. A jig for transportation of the magnet structure can be inserted into the holes H.

[0051] The cover 3a includes a top part 3a1, lateral parts 3a2, and bent parts 3a3 to 3a6. The top part 3a1 is a plate parallel to an YZ plane, and the lateral parts 3a2 are plates parallel to an XZ plane. An upper bent part 3a3 constituting each bent part is a plate parallel to the YZ plane, and an intermediate bent part 3a4 constituting each bent part is a plate parallel to the XZ plane. A lower bent part 3a5 constituting each bent part is a plate parallel to the YZ plane. A skirt bent part 3a6 constituting each bent part is a plate parallel to the XZ plane.

[0052] The bent parts of the cover 3a are fitted into grooves of the baseplate 1, and the grooves extend in the Z-axis direction. A width of the groove (in the X-axis direction) is constant in a depth direction, but the width can be changed to be able to prevent the bent part from coming out of the groove. In this way, lateral surfaces of the baseplate 1 are provided with the grooves extending in longitudinal directions thereof, and each cover 3a includes the bent parts fitted into the grooves. The bent parts are fitted into the grooves, and thereby the cover 3a can be fixed to the baseplate. In this case, the components (the screws) for fixing the cover 3a to the baseplate 1 can be omitted, and the strength of the baseplate 1 can be increased. When this structure is combined with the bond, fixing strength can be further increased.

[0053] FIG. 4 is a front view of a rotor of a motor having a plurality of magnet structures.

[0054] The magnet structures MS are fixed to a cylindrical rotor C such that the longitudinal directions thereof are parallel to the Z axis that is a rotational axis. For example, the number of the magnet structures MS arranged in a circumferential direction is 128. In the same figure, two-tier magnet structures MS are disposed in an axial direction, and a total of 256 magnet structures MS are used.

[0055] FIG. 5 is a view illustrating a sectional configuration perpendicular to a rotational axis of the motor. FIG. 6 is a view illustrating an area surrounded with a quadrilateral dotted line in FIG. 5.

[0056] In the motor, the rotor C is fixed around a shaft AX, and the plurality of magnet structures MS is disposed along a surface of the rotor C. The motor includes coils 10 that are disposed within a range of a magnetic field of the plurality of magnet structures MS. Polarities of surfaces of the magnet structures MS are alternately inverted in the circumferential direction of the rotor C. The magnet structure itself can also be used for a motor that performs linear driving.

[0057] FIG. 7 is a block diagram of an electric generation system using the motor.

[0058] To be specific, an example applied to a wind turbine generator will be described. The wind turbine generator includes a plurality of blades 20, which receive a fluid F (wind) and rotate about a hub 21. Rotation of the hub 21 is amplified by a gearbox 22 (a speed increaser), and rotates the shaft AX of the aforementioned motor 23. The blades can constitute a turbine, and the fluid F may be a liquid.

[0059] FIG. 8 is a view illustrating a sectional configuration perpendicular to a rotational axis of a motor having another structure.

[0060] The magnet structures MS are each made up of a plurality of rectangular parallelepiped permanent magnets stacked in a depth direction of each slot S of the rotor C.

[0061] The permanent magnet is formed of a rare earth sintered magnet, and is preferably, for example, an R-T-B sintered magnet. The R-T-B sintered magnet has particles (crystal grains) and grain boundaries composed of R.sub.2T.sub.14B crystals.

[0062] R in the R-T-B sintered magnet represents at least one rare earth element. The rare earth elements are Sc, Y, and lanthanoid elements that belong to group III in the long-period type periodic table. The lanthanoid elements include, for example, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and Lu. T in the R-T-B sintered magnet represents Fe, or Fe and Co. Further, T in the R-T-B sintered magnet may contain one or more selected from other transition metal elements. B in the R-T-B sintered magnet represents boron (B), or boron (B) and carbon (C).

[0063] The R-T-B sintered magnet according to the present embodiment may contain Cu or Al. Due to the addition of these elements, higher coercive force, higher corrosion resistance, or an improvement in a temperature characteristic is made possible.

[0064] Further, the R-T-B sintered magnet according to the present embodiment may contain Dy, Tb, or both of them as a heavy rare earth element. The heavy rare earth element may be contained in a crystal grain and a grain boundary. When the heavy rare earth element is not substantially contained in the crystal grain, it is preferably contained in the grain boundary. The heavy rare earth element in the grain boundary preferably has a higher concentration than that in the crystal grain. The R-T-B sintered magnet according to the present embodiment may be an R-T-B sintered magnet in which the heavy rare earth element is subjected to grain boundary diffusion. The R-T-B sintered magnet in which the heavy rare earth element is subjected to grain boundary diffusion can improve a residual magnetic flux density and a coercive force with a smaller amount of the heavy rare earth element, compared to an R-T-B sintered magnet in which the heavy rare earth element is not subjected to grain boundary diffusion.

[0065] Every permanent magnet is designed to have the same dimensions. For example, a length of a long side ranges from 3 to 70 mm, a length of a short side ranges from 3 to 30 mm, and a height ranges from 3 to 70 mm. As an example, every permanent magnet has a long side length of 21 mm, a short side length of 4 mm, and a height of 6 mm. If necessary, predetermined polishing (for example, barrel polishing) may be performed to chamfer the permanent magnet. All the permanent magnets are magnetized in the same direction, and are magnetized in a direction parallel to a short-side direction.

[0066] FIG. 9A is a view illustrating a longitudinal section of a magnet structure (a second embodiment) from the front, FIG. 9B is a side view thereof, and FIG. 9C is a top view thereof.

[0067] In a second embodiment, the screws B and threaded holes are removed from the first embodiment, and moreover, shapes of the covers 3a are changed. The other configurations and applications are as described above. That is, the threaded holes for fixing the covers 3a may not be provided in the lateral surfaces of the baseplate 1. The screws are omitted so that the strength of the baseplate 1 can be kept high.

[0068] The lateral surfaces of each cover 3a have protrusions P that protrude in the longitudinal direction (the Z-axis direction) of the baseplate 1. Each protrusion P comes into contact with the neighboring covers 3a so that movement of the covers 3a in the longitudinal direction can be regulated and a gap between the covers 3a can be secured. Thereby, eddy currents can be reduced. It is illustrated in FIGS. 9A, 9B and 9C that the portions of the skirt bent parts 3a6 of the covers 3a in FIG. 3 extend in the Z-axis direction. The sectional configuration in which the screws and threaded holes are removed from FIG. 3 is illustrated in FIG. 12.

[0069] FIG. 10A is a view illustrating a longitudinal section of a magnet structure (a third embodiment) from the front, FIG. 10B is a side view thereof, and FIG. 10C is a top view thereof.

[0070] When a third embodiment is compared with the second embodiment, only shapes of the lateral surfaces of each cover 3a are different, and the other configurations and applications are as described above. The covers 3a have protrusions P that protrude in the longitudinal direction (the Z-axis direction) of the baseplate 1. Each protrusion P comes into contact with the neighboring covers 3a, so that movement of the covers 3a in the longitudinal direction can be regulated, and a gap between the covers 3a can be secured. Thereby, eddy currents can be reduced. It is illustrated in FIGS. 10A, 10B and 10C that the portions of the intermediate bent parts 3a4 of each cover 3a in FIG. 3 extend in the Z-axis direction. Like the second embodiment, the sectional configuration in which the screws and threaded holes are removed from FIG. 3 is illustrated in FIG. 12.

[0071] FIG. 11A is a view illustrating a longitudinal section of a magnet structure (a fourth embodiment) from the front, FIG. 11B is a side view thereof, and FIG. 11C is a top view thereof.

[0072] When a fourth embodiment is compared with the second embodiment, only shapes of the lateral surfaces of each cover 3a are different, and the other configurations and applications are as described above. The covers 3a have protrusions P that protrude in the longitudinal direction (the Z-axis direction) of the baseplate 1. Each protrusion P comes into contact with the neighboring covers 3a, so that movement of the covers 3a in the longitudinal direction can be regulated, and a gap between the covers 3a can be secured. Thereby, eddy currents can be reduced. It is illustrated in FIGS. 11A, 11B and 11C that the portions of the lateral parts 3a2 of each cover 3a in FIG. 3 extend in the Z-axis direction. Like the second and third embodiments, the sectional configuration in which the screws and threaded holes are removed from FIG. 3 is illustrated in FIG. 12.

[0073] In any of the aforementioned configurations, shapes of the bent parts of each cover 3a can be variously deformed.

[0074] FIG. 13 is a view illustrating a longitudinal section of the magnet structure from the front, and illustrates an example in which the shapes of the bent parts of each cover 3a are deformed. In FIG. 13, a shape of the upper bent part 3a3 constituting each bent part is different from that of FIG. 12 (FIG. 3). As the upper bent part 3a3 proceeds in a depth direction, a width (a length in the X-axis direction) is increased, and each bent part has a wedge shape. Each groove of the baseplate 1 has the same shape as each bent part.

[0075] That is, in the magnet structure, a width of the groove of the baseplate 1 includes a first width (a width in the X-axis direction) at a shallow position in a depth direction of the groove, and a second width (a width in the X-axis direction) at a deep position in the depth direction of the groove. The first width is smaller than the second width. In other words, a lateral surface (the upper bent part 3a3) of the groove of the baseplate 1 which is close to the permanent magnet 2 is inclined with respect to a surface of the baseplate 1 (a surface of the bond G4) to which the permanent magnet 2 is fixed. In this case, the second width located at the deep position is wide, and the first width located at the shallow position is narrow. Thus, when the aforementioned bent part is fitted into the groove, it does not easily come out. A longitudinal section of the groove may take a wedge form.

[0076] FIG. 15 is a partial perspective view of the covers illustrating flows of electric currents.

[0077] The covers act as a model (A). In the case of a structure of the model (A), an eddy current loss is highest, and a fluctuation range of the eddy current loss is also great. In FIGS. 15 to 19, directions in which an electric current flows are denoted by small arrows. It is illustrated in FIG. 15 that the aforementioned plurality of covers 3a is integrally formed and, in short, the covers are not divided. In this case, many induced currents (eddy currents) flows on top surfaces (YZ planes) of the covers.

[0078] FIG. 16 is a partial perspective view of the covers illustrating flows of electric currents.

[0079] The covers act as a model (B). In comparison with the covers of FIG. 15, the covers of FIG. 16 are configured such that only top surfaces (YZ planes) of the neighboring covers 3a are separated by 1 mm. Lateral surfaces (XZ planes) are not divided. Due to this separation, eddy currents do not flow across the top surfaces of the neighboring covers 3a, but the eddy currents still flow on the lateral surfaces.

[0080] FIG. 17 is a partial perspective view of the covers illustrating flows of electric currents.

[0081] The covers act as a model (C). In comparison with the covers of FIG. 16, the covers of FIG. 17 are configured such that parts of lateral surfaces (XZ planes) of the neighboring covers 3a (from the top of the lateral part 3a2 to the vicinity of the middle in FIG. 3) are separated by 1 mm. Of course, eddy currents do not flow across the separated portion.

[0082] FIG. 18 is a partial perspective view of the covers illustrating flows of electric currents.

[0083] The covers act as a model (D). In comparison with the covers of FIG. 17, the covers of FIG. 18 are configured such that parts of lateral surfaces (XZ planes) of the neighboring covers 3a (from the top to the bottom of the lateral part 3a2 in FIG. 3) are separated by 1 mm. Of course, eddy currents do not flow across the separated portion.

[0084] FIG. 19 is a partial perspective view of the covers illustrating flows of electric currents.

[0085] The covers act as a model (E). In comparison with the covers of FIG. 18, the covers of FIG. 19 are configured such that whole lateral surfaces (XZ planes) of the neighboring covers 3a (the lateral parts 3a2 and the bent parts 3a3 to 3a6 in FIG. 3) are separated by 1 mm. Of course, eddy currents do not flow across the separated portion.

[0086] Table 1 is a table that indicates a loss [W] and a rate [%] of the eddy current. This table represents data obtained when the covers of the models (A) to (E) were used.

TABLE-US-00001 TABLE 1 (A) (B) (C) (D) (E) Loss [W] 119.5 37.8 36.1 35.1 33.7 Rate [%] 100.0 31.6 30.2 29.4 28.2

[0087] The loss of the model (A) was 119.5 W. In this case, the rate was 100%. When the losses of the models (B) to (E) were normalized, the rates thereof were 31.6%, 30.2%, 29.4%, and 28.2%, respectively.