JP2004254403A

JP2004254403A - Permanent magnet type motor and manufacturing method thereof

Info

Publication number: JP2004254403A
Application number: JP2003041340A
Authority: JP
Inventors: Minoru Awazu; 稔粟津; Isamu Nitta; 勇新田; Shigeya Tanimoto; 茂也谷本
Original assignee: Toshiba Corp
Current assignee: Toshiba Corp
Priority date: 2003-02-19
Filing date: 2003-02-19
Publication date: 2004-09-09

Abstract

【課題】界磁用永久磁石の磁束漏れを極力低減でき、しかも製造性も確保できるようにする。
【解決手段】回転子鉄心１２を構成する鋼板１７において、各磁石挿入孔１３の内周部側に介在部１８が存していて、各介在部１８の周方向の一端部は接続部１９を介して主体部２０と接続され、他端部に、磁石挿入孔１３と連通して固定子側に開口した開口部２１を形成している。各磁石挿入孔１３に界磁用永久磁石を挿入した後、モールド用の樹脂によりモールドする。各介在部１８における一端部に開口部２１を形成しているから、その部分で界磁用永久磁石の磁束が漏れ難くなる。開口部２１は一端部のみで、他端部は主体部２０と接続されているため、介在部が主体部から分離独立する場合とは違い、製造性を確保できる。
【選択図】図１An object of the present invention is to reduce the magnetic flux leakage of a field permanent magnet as much as possible and to ensure the manufacturability.
In a steel plate (17) constituting a rotor core (12), an interposed portion (18) is present on the inner peripheral side of each magnet insertion hole (13), and one end of each interposed portion (18) in the circumferential direction is connected to a connecting portion (19). An opening 21 which is connected to the main body 20 through the other end and communicates with the magnet insertion hole 13 and opens to the stator side is formed. After the field permanent magnets are inserted into the respective magnet insertion holes 13, they are molded with a molding resin. Since the opening 21 is formed at one end of each intervening portion 18, the magnetic flux of the field permanent magnet hardly leaks at that portion. Since the opening 21 has only one end and the other end is connected to the main body 20, the manufacturability can be ensured unlike the case where the interposed part is separated and independent from the main body.
[Selection diagram] Fig. 1

Description

【０００１】
【発明の属する技術分野】
本発明は、回転子鉄心の磁石挿入孔に界磁用永久磁石を挿入して構成される回転子を備えた永久磁石形モータ及びその製造方法に関する。
【０００２】
【従来の技術】
従来、例えばインナーロータタイプの永久磁石形モータにおいては、複数枚の鋼板を積層して構成される回転子鉄心に２ｎ（ｎは１以上の整数）個の磁石挿入孔（収納部）を形成し、各磁石挿入孔内に界磁用の永久磁石を挿入して回転子を構成し、この回転子を固定子の内部に回転可能に配設した構成のものが公知である（例えば、特許文献１参照）。
【０００３】
【特許文献１】
特開平７−９９７４４号公報（図１〜図３）
【０００４】
【発明が解決しようとする課題】
しかしながら、上記した特許文献１のような構成のものでは、回転子鉄心において、各磁石挿入孔と固定子との間に介在される各介在部の周方向の両端部は、回転子鉄心の中心側の主体部と接続されている。その介在部の両端部は永久磁石の磁束が通り易い磁路を形成するため、そこから磁束が漏れやすく、永久磁石の磁束を、回転子の回転に有効に利用することができないという欠点がある。
【０００５】
そこで、上記介在部の両端部に、磁石挿入孔と連通して固定子側に開口した開口部を設けた構成とすることが考えられる。しかしながら、このような構成とした場合には、回転子鉄心としては、各介在部が、中心側の主体部から分離独立した構成となるため、回転子として組み立てることが容易にはできず、製造性に問題がある。
【０００６】
本発明は上記事情に鑑みてなされたものであり、その第１の目的は、界磁用永久磁石の磁束漏れを極力低減でき、しかも製造性も確保できる永久磁石形モータを提供するにある。また、第２の目的は、同様な目的を達成することができる永久磁石形モータの製造方法を提供することにある。
【０００７】
【課題を解決するための手段】
上記した第１の目的を達成するために、請求項１の発明は、複数枚の鋼板を積層して環状に構成され、その周方向に磁石挿入孔を２ｎ（ｎは１以上の整数）個有する回転子鉄心と、前記磁石挿入孔に挿入される２ｎ個の界磁用永久磁石とを備えた回転子を具備した永久磁石形モータにおいて、前記回転子鉄心は、前記各磁石挿入孔と固定子との間に介在される各介在部の周方向の両端部のうちの一方の端部のみに前記磁石挿入孔と連通して固定子側に開口した開口部を形成した鋼板を積層して構成したことを特徴とする。
【０００８】
上記した手段によれば、回転子鉄心を構成する各鋼板において、各介在部における周方向の一端部に固定子側に開口した開口部が形成されているから、その開口部が形成されていない場合に比べて界磁用永久磁石の磁束が漏れ難くなり、その分磁束漏れを低減できるようになる。また、開口部は一端部のみであるから、各鋼板において、介在部の一端部は主体部と接続されているため、その介在部が主体部から分離独立する場合とは違い、製造性を確保できると共に、製作精度を向上できる。
【０００９】
請求項２の発明は、請求項１記載の永久磁石形モータにおいて、回転子鉄心は、各介在部における開口部を、軸方向の一方の端面側からみて時計回り方向側または反時計回り方向側のどちらか一方側の端部のみに形成した鋼板を積層して構成したことを特徴とする。
これによれば、１種類の鋼板を積層することで回転子鉄心を構成できるため、鋼板を加工する金型の種類を少なくすることが可能となる。
【００１０】
請求項３の発明は、請求項１記載の永久磁石形モータにおいて、回転子鉄心は、各介在部における開口部を、軸方向の一方の端面側からみて時計回り方向側の端部と反時計回り方向側の端部とに周方向に交互に形成した鋼板を積層して構成したことを特徴とする。
これによれば、請求項２の発明と同様な作用効果が得られることに加え、次のような作用効果を得ることができる。すなわち、回転子鉄心と固定子との間の空隙磁束密度の高調波成分を低減でき、コギングトルクを低減できるようになる。
【００１１】
請求項４の発明は、請求項１記載の永久磁石形モータにおいて、回転子鉄心は、各介在部における開口部を、軸方向の一方の端面側からみて時計回り方向側の端部のみに形成した第１の鋼板と、反時計回り方向側の端部のみに形成した第２の鋼板とを交互に積層して構成したことを特徴とする。
これによれば、上記請求項３の発明と同様に、回転子鉄心と固定子との間の空隙磁束密度の高調波成分を低減でき、コギングトルクを低減できるようになる。
【００１２】
請求項５の発明は、上記した第１の目的を達成するために、複数枚の鋼板を積層して環状に構成され、その周方向に磁石挿入孔を２ｎ（ｎは１以上の整数）個有する回転子鉄心と、前記磁石挿入孔に挿入される２ｎ個の界磁用永久磁石とを備えた回転子を具備した永久磁石形モータにおいて、前記回転子鉄心は、前記各磁石挿入孔と固定子との間に介在される各介在部の周方向の両端部に磁石挿入孔と連通して固定子側に開口した開口部を形成することで前記介在部が主体部から独立した第１の鋼板と、前記介在部の周方向の両端部のうち少なくとも一端部が主体部と接続された第２の鋼板とを積層する共に、これら各鋼板の前記各介在部同士及び前記各主体部同士を連結して構成したことを特徴とする。
【００１３】
上記した手段によれば、回転子鉄心において、第１の鋼板部分では、介在部の両端部に開口部が形成されているから、界磁用永久磁石の磁束漏れを一層低減できるようになる。このとき、第１の鋼板の介在部は主体部から独立しているが、この第１の鋼板と積層された第２の鋼板の介在部は少なくとも一端部が主体部と接続されており、第１の鋼板の各介在部を第２の鋼板の介在部と連結すると共に、第１の鋼板の各主体部と第２の鋼板の主体部とを連結することで、第１の鋼板の介在部も他の部分と一体的に扱うことが可能となり、製造性を確保できると共に、製作精度を向上できる。
【００１４】
請求項６の発明は、上記した第１の目的を達成するために、複数枚の鋼板を積層して環状に構成され、その周方向に磁石挿入孔を２ｎ（ｎは１以上の整数）個有する回転子鉄心と、前記磁石挿入孔に挿入される２ｎ個の界磁用永久磁石とを備えた回転子を具備した永久磁石形モータにおいて、前記回転子鉄心は、前記各磁石挿入孔と固定子との間に介在される各介在部の周方向の両端部のうち少なくとも一端部に磁石挿入孔と連通して固定子側に開口した開口部を形成した第１の鋼板を複数枚積層したものと、この第１の鋼板を積層したものの軸方向の片側または両側に配置され、前記磁石挿入孔に挿入された界磁用永久磁石の脱落を防止する磁石脱落防止部を有する第２の鋼板とを連結して構成したことを特徴とする。
【００１５】
上記した手段によれば、回転子鉄心において、第１の鋼板を積層した部分では、介在部の少なくとも一端部には開口部が形成されているから、界磁用永久磁石の磁束漏れを低減できるようになる。そして、第１の鋼板の介在部及び主体部を第２の鋼板と連結することで、製造性を確保できると共に、製作精度を向上できる。さらに、第２の鋼板には磁石脱落防止部を設けているので、それにより界磁用永久磁石の脱落を防止でき、製造性を向上できる。
【００１６】
請求項７の発明は、請求項１ないし６のいずれかに記載の永久磁石形モータにおいて、回転子鉄心は、周方向に分割された複数の分割鉄心を環状に連結して構成することを特徴とする。
これによれば、素材となる鋼板から、回転子鉄心に使用する鋼板を取る加工をする際に、ロスを少なくでき、ひいてはコストを低減できるようになる。
【００１７】
請求項８の発明は、上記した第２の目的を達成するために、複数枚の鋼板を積層して環状に構成され、その周方向に磁石挿入孔を２ｎ（ｎは１以上の整数）個有する回転子鉄心と、前記磁石挿入孔に挿入される２ｎ個の界磁用永久磁石とを備えた回転子を具備した永久磁石形モータを製造する方法において、前記回転子を製造する際に、前記各磁石挿入孔に前記界磁用永久磁石を挿入した状態で樹脂によりモールドし、この後、前記回転子鉄心の各磁石挿入孔と固定子との間に介在される各介在部の周方向の両端部に、前記磁石挿入孔と連通して前記固定子側に開口する開口部を後加工により形成するようにしたことを特徴とする。
【００１８】
上記した手段によれば、最終的に、各介在部の両端部に開口部を形成するようにしているので、界磁用永久磁石の磁束漏れを低減できるようになる。また、回転子を製造する際において、磁石挿入孔へ界磁用永久磁石を挿入する際、及び樹脂によりモールドする際には、各介在部の両端部は主体部と接続されているから、製造性を確保できる。
【００１９】
請求項９の発明は、上記した第２の目的を達成するために、複数枚の鋼板を積層して環状に構成され、その周方向に磁石挿入孔を２ｎ（ｎは１以上の整数）個有する回転子鉄心と、前記磁石挿入孔に挿入される２ｎ個の界磁用永久磁石とを備えた回転子を具備した永久磁石形モータを製造する方法において、前記回転子を製造する際に、前記回転子鉄心は、前記磁石挿入孔と固定子との間に介在される各介在部の周方向の一端部のみに固定子側に開口した開口部を形成すると共に、前記磁石挿入孔が前記開口部側ほど広くなるように形成し、前記各磁石挿入孔に前記界磁用永久磁石を挿入した後、前記磁石挿入孔の前記開口部側を狭くするように前記各介在部を前記界磁用永久磁石側へ変形させた状態で樹脂によりモールドするようにしたことを特徴とする。
【００２０】
上記した手段によれば、最終的に、各介在部の一端部には開口部が形成されているから、界磁用永久磁石の磁束漏れを低減できるようになる。また、回転子を製造する際に、各介在部は、開口部とは反対側の端部は主体部と接続されているので、主体部と一体的に扱うことができ、製造性を確保できる。しかもこの場合、磁石挿入孔に界磁用永久磁石を挿入する際に、磁石挿入孔の開口部側ほど広くなるように形成しているので、その磁石挿入孔へ界磁用永久磁石を挿入しやすくなる。
【００２１】
請求項１０の発明は、請求項８または９記載の永久磁石形モータにおいて、回転子鉄心は、周方向に分割された複数の分割鉄心を環状に連結して構成することを特徴とする。
これによれば、請求項７の発明と同様な作用効果を得ることができる。
【００２２】
【発明の実施の形態】
以下、本発明を、アウターロータタイプの永久磁石形モータに適用した第１実施例について図１ないし図４を参照して説明する。まず、図３には、一部を破断したモータの破断斜視図が示されている。このモータは、例えば脱水兼用洗濯機において、洗い時に撹拌体を、脱水時に撹拌体及び回転槽を一体に回転駆動するための駆動用モータに用いられるものである。
【００２３】
図３において、固定子１は、多数個のティース２を放射状に有する固定子鉄心３と、この固定子鉄心３を覆うように成形により設けられた樹脂４と、各ティース２に巻回された固定子巻線５とから構成されている。固定子鉄心３は、複数枚の鋼板を積層すると共に、環状をなすように構成されている。この固定子１には、これを脱水兼用洗濯機の所定部位に取り付けるための取付部６が設けられている。
【００２４】
これに対して回転子１０は、図４にも示すように、容器状をなす磁性体製のフレーム１１と、このフレーム１１の外周部の開口部側に設けられた環状壁１１ａの内周部に配置された円環状をなす回転子鉄心１２と、この回転子鉄心１２の内周部側に設けられた多数個の磁石挿入孔１３に挿入された多数個の界磁用永久磁石１４と、これら回転子鉄心１２及び界磁用永久磁石１４をフレーム１１に一体化するように成形により設けられたモールド用の樹脂１５とから構成されていて、回転子鉄心１２の内周面が上記固定子鉄心３の各ティース２の先端部に対して所定の隙間を介して対向するように配置される。
【００２５】
上記回転子鉄心１２は、周方向に分割された複数個の分割鉄心を円環状となるように連結して構成されている。各分割鉄心は、図４に示すように複数枚の鋼板１７を積層して構成されている。１個の分割鉄心は、例えば磁石挿入孔１３を６個分有する大きさとなっている。
【００２６】
ここで、図１には回転子鉄心１２の鋼板１７の平面図を示し、図２には、回転子鉄心１２の各磁石挿入孔１３に界磁用永久磁石１４を挿入すると共にモールド用の樹脂１５を設けた状態での回転子１０の一部の平面図を示している。なお、図２において、界磁用永久磁石１４には、他の部分と区別するため斜線を施している。
【００２７】
図１において、鋼板１７の内周部側に、周方向に延びる長方形をなす上記磁石挿入孔１３が周方向に並べて形成されている。この鋼板１７において、各磁石挿入孔１３の内周部側には、磁石挿入孔１３と上記固定子１との間に介在される介在部１８が存していて、各介在部１８の周方向の両端部のうち一方の端部は接続部１９を介して外周部側の主体部２０と接続され、他方の端部のみに磁石挿入孔１３と連通して固定子１側に開口した開口部２１を形成している。この場合、回転子鉄心１２は、各介在部１８における開口部２１を、軸方向の一方の端面側（図１の上面側）からみて時計回り方向側（図１で右側）の端部のみに形成した鋼板１７を積層した構成となっている。
そして、図２において、モールド用の樹脂１５は、上記開口部２１に入り込んでいると共に、隣り合った両介在部１８の端部を覆った状態となっている。
【００２８】
上記した実施例によれば次のような作用効果を得ることができる。すなわち、回転子鉄心１２を構成する各鋼板１７において、各介在部１８における周方向の一端部に固定子１側に開口した開口部２１が形成されているから、その開口部２１が形成されていない場合に比べて界磁用永久磁石１４の磁束が漏れ難くなり、その分磁束漏れを低減できるようになる。また、開口部２１は一端部のみであるから、各鋼板１７において、介在部１８の一端部は主体部２０と接続部１９を介して接続されているため、その介在部１８が主体部２０から分離独立する場合とは違い、製造性を確保できると共に、製作精度を向上できる。
【００２９】
また、回転子鉄心１２は、各介在部１８における開口部２１を、軸方向の一方の端面側からみて時計回り方向側の一方側の端部のみに形成した鋼板１７を積層して構成しているので、１種類の鋼板１７を積層することで回転子鉄心１２を構成できるため、鋼板１７を加工する金型の種類を少なくすることが可能となる。
【００３０】
なお、各介在部１８における開口部２１を、この第１実施例とは反対に反時計回り方向側の一方側の端部のみに形成した鋼板１７を積層して構成する場合でも同様な効果を得ることができる。
【００３１】
さらに、回転子鉄心１２は、周方向に分割された複数の分割鉄心を環状に連結して構成するようにしているので、素材となる鋼板から、回転子鉄心１２に使用する鋼板１７を取る加工をする際に、ロスを少なくでき、ひいてはコストを低減できるようになる。
【００３２】
図５は本発明の第２実施例を示したものであり、この第２実施例は、上記した第１実施例とは次の点が異なっている。
すなわち、回転子鉄心２３を構成する鋼板２４は、各介在部１８における開口部２１を、軸方向の一方側の端面からみて時計回り方向側の端部と反時計回り方向の端部とに周方向に交互に形成した構成となっていて、回転子鉄心２３は、このような構成の鋼板２４を複数枚積層して構成する。そして、このような構成の回転子鉄心２３においても、第１実施例と同様に、各磁石挿入孔１３に界磁用永久磁石１４が挿入されると共に、モールド用の樹脂１５が設けられる。
【００３３】
このような構成とした第２実施例においては、特に次のような作用効果を得ることができる。すなわち、各介在部１８における開口部２１を、時計回り方向側の端部と反時計回り方向の端部とに周方向に交互に形成した構成としているので、回転子鉄心２３と固定子１との間の空隙磁束密度の高調波成分を低減でき、コギングトルクを低減できるようになる。
【００３４】
図６は本発明の第３実施例を示したものであり、この第３実施例は、上記した第１実施例とは次の点が異なっている。
すなわち、図６（ａ）に示す第１の鋼板２６は、第１実施例の鋼板１７と同一の構成であり、各介在部１８における開口部２１は、軸方向の一方の端面側からみて時計回り方向側の端部のみに形成した構成となっている。図６（ｂ）に示す第２の鋼板２７は、各介在部１８における開口部２１は、軸方向の一方の端面側からみて反時計回り方向側の端部のみに形成した構成となっている。そして、回転子鉄心は、図６（ａ）に示す第１の鋼板２６と、図６（ｂ）に示す第２の鋼板２７とを、磁石挿入孔１３の位置を一致させた状態で軸方向に交互に積層した構成とする。そして、このような構成の回転子鉄心においても、第１実施例と同様に、各磁石挿入孔１３に界磁用永久磁石１４が挿入されると共に、モールド用の樹脂１５が設けられる。
【００３５】
このような構成とした第３実施例においては、各介在部１８において、開口部２１の位置が、時計回り方向側と反時計回り方向側と軸方向で交互に配置されるようになるため、上記した第２実施例と同様に、回転子鉄心と固定子１との間の空隙磁束密度の高調波成分を低減でき、コギングトルクを低減できるようになる。
【００３６】
図７及び図８は本発明の第４実施例を示したものであり、この第４実施例は、上記した第１実施例とは次の点が異なっている。
すなわち、図８（ｂ）に示す第１の鋼板２９は、各介在部１８における周方向の両端部に開口部２１を形成していて、各介在部１８は、主体部２０から独立している。図８（ａ）に示す第２の鋼板３０は、各介在部１８における周方向の両端部がそれぞれ接続部１９を介して主体部２０と接続された構成となっている。
【００３７】
そして、図７に示すように、回転子鉄心３１は、第１の鋼板２９を複数枚積層した第１の鋼板積層群３２と、この第１の鋼板積層群３２の軸方向の両側（上下両側）に配置した第２の鋼板３０とから構成している。そして、各主体部２０はかしめ部３３によりかしめることで連結し、また、各介在部１８もかしめ部３４によりかしめることで連結している。そして、このような構成の回転子鉄心３１においても、第１実施例と同様に、各磁石挿入孔１３に界磁用永久磁石１４が挿入されると共に、モールド用の樹脂１５が設けられる。
【００３８】
このような構成とした第４実施例においては、特に次のような作用効果を得ることができる。すなわち、回転子鉄心３１において、第１の鋼板２９を積層した部分では、介在部１８の両端部には開口部２１が形成されているから、界磁用永久磁石１４の磁束漏れを一層低減できるようになる。このとき、第１の鋼板２９の介在部１８は主体部２０から独立しているが、この第１の鋼板積層群３２の軸方向の両側に配置された第２の鋼板３０の介在部１８は両端部が主体部２０と接続されており、第１の鋼板２９の各介在部１８を第２の鋼板３０の介在部１８と連結すると共に、第１の鋼板２９の各主体部２０と第２の鋼板３０の主体部２０とを連結することで、第１の鋼板２９の介在部１８も他の部分と一体的に扱うことが可能となり、製造性を確保できると共に、製作精度を向上できる。
なお、上記した実施例において、第２の鋼板３０は、介在部１８の一端部に開口部２１を形成したものを用いるようにしても良い。
【００３９】
図９は本発明の第５実施例を示したものであり、この第５実施例は、上記した第４実施例とは次の点が異なっている。図９において、右側には、第１の鋼板３６を打ち抜き加工する工程を示し、左側には、第２の鋼板３７を打ち抜き加工する工程を示している。なお、各工程において、斜線を施した部分は、金型の刃物の形状を示している。また、各工程とも、１個の磁石挿入孔１３の周辺部分のみを示している。
【００４０】
第２の鋼板３７は、（ａ−１）〜（ａ−５）の工程を経て形成されたもので、介在部１８と主体部２０との間に磁石脱落防止部３８が設けられていて、介在部１８と主体部２０とはその磁石脱落防止部３８を介して接続されている。
第１の鋼板３６は、（ｂ−１）〜（ｂ−５）の工程を経て形成されたもので、介在部１８の両端部に開口部２１が形成されていて、介在部１８は主体部２０から分離独立している。なお、第１及び第２の鋼板３６，３７において、３９は主体部２０におけるかしめ部、４０は介在部１８におけるかしめ部である。
【００４１】
この場合、回転子鉄心は次のようにして形成される。まず、左側の工程で形成された第２の鋼板３７の上に、右側の工程で形成された第１の鋼板３６を順次重ねると共に、かしめ部３９，４０にてかしめることにより各主体部２０と各介在部１８を連結する。これにより回転子鉄心が形成される。この後、第１の鋼板３６を積層した部分の各磁石挿入孔１３に界磁用永久磁石１４を挿入し、モールド用の樹脂１５を設けてモールドする。このとき、各界磁用永久磁石１４は、最下部の第２の鋼板３７の磁石脱落防止部３８にて受けられた状態となる。
【００４２】
このような構成とした第５実施例においては、上記した第４実施例とほぼ同様な作用効果を得ることでき、加えて次のような利点もある。すなわち、最下部に位置される第２の鋼板３７に磁石脱落防止部３８を設けているので、組立時において界磁用永久磁石１４の脱落を防止でき、製造性を一層向上できる。
なお、第２の鋼板３７は、最下部と最上部の両側に設けることもできる。また、第１の鋼板３６の開口部２１は、どちらか一方のみに設けるようにしても良い。
【００４３】
図１０は本発明の第６実施例を示したものであり、この第６実施例は上記した第１〜第５実施例とは次の点が異なっている。
すなわち、回転子鉄心４０を構成する各鋼板４１は、（ａ）に示すように、第４実施例における図８（ａ）の第２の鋼板３０と同様に、各介在部１８における周方向の両端部がそれぞれ接続部１９を介して主体部２０と接続された構成となっている。回転子鉄心４０は、このような構成の鋼板４１を積層して連結した構成となっている。
【００４４】
そして、（ｂ）に示すように、回転子鉄心４０における各磁石挿入孔１３に界磁用永久磁石１４を挿入し、モールド用の樹脂１５によりモールドする。この後、（ｃ）に示すように、各介在部１８の両端部の接続部１９を、レーザー加工などの後加工により取り除くことにより、介在部１８の両端部に、磁石挿入孔１３と連通して内周部側（固定子１側）に開口する開口部４２を形成した構成とする。この場合、各介在部１８は、モールド用の樹脂１５により永久磁石１４、主体部２０、及びフレーム１１（図３及び図４参照）と一体化されている。
【００４５】
このような第６実施例によれば、次のような作用効果を得ることができる。すなわち、最終的に、回転子鉄心４０における各介在部１８の両端部に開口部４２を形成するようにしているので、界磁用永久磁石１４の磁束漏れを低減できるようになる。また、回転子を製造する際において、磁石挿入孔１３へ界磁用永久磁石１４を挿入する際、及び樹脂１５によりモールドする際には、各介在部１８の両端部は接続部１９を介して主体部２０と接続されているから、製造性を確保できる。
【００４６】
図１１は本発明の第７実施例を示したものであり、この第７実施例は上記した第１〜第６実施例とは次の点が異なっている。
すなわち、回転子鉄心４５を構成する各鋼板４６は、（ａ）に示すように、各介在部１８の一端部は接続部１９を介して主体部２０と接続され、他端部には磁石挿入孔１３と連通して内周部側（固定子１側）に開口した開口部２１が形成されている。この場合、介在部１８は、磁石挿入孔１３が開口部２１側ほど広くなるように内周部側（固定子１側）へ突出している。そして、（ｂ）に示すように、各磁石挿入孔１３へ界磁用永久磁石１４を挿入した後、各介在部１８の開口部２１側の端部を、開口部２１を狭くするように界磁用永久磁石１４側へ変形させ、この状態で、モールド用の樹脂１５によりモールドする。これにより、各介在部１８は、（ｂ）の状態が保持されるようになる。
【００４７】
このような第７実施例によれば、次のような作用効果を得ることができる。すなわち、最終的に、回転子鉄心４５における各介在部１８の一端部には開口部２１が形成されているから、界磁用永久磁石１４の磁束漏れを低減できるようになる。また、回転子を製造する際に、各介在部１８は、開口部２１とは反対側の端部は主体部２０と接続されているので、主体部２０と一体的に扱うことができ、製造性を確保できる。しかもこの場合、磁石挿入孔１３に界磁用永久磁石１４を挿入する際に、磁石挿入孔１３の開口部２１側ほど広くなるように形成しているので、その磁石挿入孔１３へ界磁用永久磁石１４を挿入しやすくなる利点がある。
なお、第２〜第７実施例においても、回転子鉄心を、周方向に分割した複数個の分割鉄心を環状に連結して構成することが好ましい。
【００４８】
本発明は、上記した各実施例にのみ限定されるものではなく、次のように変形または拡張できる。
アウターロータタイプに限られず、インナーロータタイプにも適用できる。また、本発明のモータは、脱水兼用洗濯機以外の用途にも用いることができる。
【００４９】
【発明の効果】
請求項１の永久磁石形モータによれば、回転子鉄心を構成する各鋼板において、各介在部における周方向の一端部に固定子側に開口した開口部が形成されているから、その開口部が形成されていない場合に比べて界磁用永久磁石の磁束が漏れ難くなり、その分磁束漏れを低減できるようになる。また、開口部は一端部のみであるから、各鋼板において、介在部の一端部は主体部と接続されているため、その介在部が主体部から分離独立する場合とは違い、製造性を確保できると共に、製作精度を向上できる。
【００５０】
請求項５の永久磁石形モータによれば、回転子鉄心において、第１の鋼板部分では、介在部の両端部には開口部が形成されているから、界磁用永久磁石の磁束漏れを一層低減できるようになる。このとき、第１の鋼板の介在部は主体部から独立しているが、この第１の鋼板と積層された第２の鋼板の介在部は少なくとも一端部が主体部と接続されており、第１の鋼板の各介在部を第２の鋼板の介在部と連結すると共に、第１の鋼板の各主体部と第２の鋼板の主体部とを連結することで、第１の鋼板の介在部も他の部分と一体的に扱うことが可能となり、製造性を確保できると共に、製作精度を向上できる。
【００５１】
請求項８の永久磁石形モータの製造方法によれば、最終的に、各介在部の両端部に開口部を形成するようにしているので、界磁用永久磁石の磁束漏れを低減できるようになる。また、回転子を製造する際において、磁石挿入孔へ界磁用永久磁石を挿入する際、及び樹脂によりモールドする際には、各介在部の両端部は主体部と接続されているから、製造性を確保できる。
【図面の簡単な説明】
【図１】本発明の第１実施例を示すもので、回転子鉄心の鋼板の一部を示す平面図
【図２】モールドされた回転子の一部を示す平面図
【図３】モータの破断斜視図
【図４】回転子の一部を示す破断斜視図
【図５】本発明の第２実施例を示す図１相当図
【図６】本発明の第３実施例を示すもので、（ａ）は第１の鋼板の平面図、（ｂ）は第２の鋼板の平面図
【図７】本発明の第４実施例を示すもので、回転子鉄心の一部を示す破断斜視図
【図８】（ａ）は第２の鋼板の平面図、（ｂ）は第１の鋼板の平面図
【図９】本発明の第５実施例を示すもので、（ａ−１）〜（ａ−５）は第２の鋼板を製造する工程を示す図、（ｂ−１）〜（ｂ−５）は第１の鋼板を製造する工程を示す図
【図１０】（ａ）〜（ｃ）は本発明の第６実施例の製造方法を示す平面図
【図１１】（ａ），（ｂ）は本発明の第７実施例の製造方法を示す平面図
【符号の説明】
１は固定子、１０は回転子、１２は回転子鉄心、１３は磁石挿入孔、１４は界磁用永久磁石、１５は樹脂、１７は鋼板、１８は介在部、１９は接続部、２０は主体部、２１は開口部、２３は回転子鉄心、２４は鋼板、２６は第１の鋼板、２７は第２の鋼板、２９は第１の鋼板、３０は第２の鋼板、３１は回転子鉄心、３２は第１の鋼板積層群、３３，３４はかしめ部、３６は第１の鋼板、３７は第２の鋼板、３８は磁石脱落防止部、４０は回転子鉄心、４１は鋼板、４２は開口部、４５は回転子鉄心、４６は鋼板を示す。[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a permanent magnet type motor having a rotor configured by inserting a permanent magnet for field into a magnet insertion hole of a rotor core, and a method of manufacturing the same.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, for example, in a permanent magnet type motor of an inner rotor type, 2n (n is an integer of 1 or more) magnet insertion holes (housing portions) are formed in a rotor core formed by laminating a plurality of steel plates. There is known a configuration in which a permanent magnet for a field is inserted into each magnet insertion hole to form a rotor, and the rotor is rotatably disposed inside a stator (for example, Patent Document 1). 1).
[0003]
[Patent Document 1]
JP-A-7-99744 (FIGS. 1 to 3)
[0004]
[Problems to be solved by the invention]
However, in the configuration as in Patent Document 1 described above, in the rotor core, both ends in the circumferential direction of each interposed portion interposed between each magnet insertion hole and the stator are positioned at the center of the rotor core. It is connected to the main part on the side. Since both ends of the interposed portion form a magnetic path through which the magnetic flux of the permanent magnet easily passes, there is a disadvantage that the magnetic flux easily leaks therefrom, and the magnetic flux of the permanent magnet cannot be effectively used for rotating the rotor. .
[0005]
Therefore, it is conceivable to adopt a configuration in which openings are provided at both ends of the intervening portion and open to the stator side in communication with the magnet insertion holes. However, in the case of such a configuration, as the rotor core, each interposed portion is configured to be separated and independent from the main body on the center side, so that it is not easy to assemble the rotor, and There is a problem with sex.
[0006]
SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and a first object of the present invention is to provide a permanent magnet type motor capable of minimizing magnetic flux leakage of a field permanent magnet and securing manufacturability. A second object is to provide a method for manufacturing a permanent magnet motor that can achieve the same object.
[0007]
[Means for Solving the Problems]
In order to achieve the first object, the invention according to claim 1 is configured such that a plurality of steel plates are laminated to form an annular shape, and 2n (n is an integer of 1 or more) magnet insertion holes in the circumferential direction. A permanent magnet type motor having a rotor having a rotor core having the rotor core and 2n field permanent magnets inserted into the magnet insertion holes, wherein the rotor core is fixed to each of the magnet insertion holes. A steel sheet having an opening that opens to the stator side in communication with the magnet insertion hole only at one end of both ends in the circumferential direction of each interposed portion interposed between the stator and the stator is laminated. It is characterized by comprising.
[0008]
According to the above-described means, in each of the steel plates constituting the rotor core, the opening that opens toward the stator is formed at one end in the circumferential direction of each interposed portion, so that the opening is not formed. As compared with the case, the magnetic flux of the field permanent magnet is less likely to leak, and the magnetic flux leakage can be reduced accordingly. Also, since the opening is only at one end, in each steel plate, one end of the interposed part is connected to the main part, so that unlike the case where the interposed part is separated and independent from the main part, manufacturability is secured. Production accuracy can be improved.
[0009]
According to a second aspect of the present invention, in the permanent magnet type motor according to the first aspect, the rotor core is provided such that the opening in each of the interposed portions is clockwise or counterclockwise as viewed from one end face in the axial direction. Characterized in that they are formed by laminating steel sheets formed only on either one end.
According to this, the rotor core can be configured by laminating one type of steel sheet, and thus it is possible to reduce the number of types of dies for processing the steel sheet.
[0010]
According to a third aspect of the present invention, in the permanent magnet type motor according to the first aspect, the rotor core has an opening in each of the interposed portions that is counterclockwise when viewed from one end face side in the axial direction. The steel plate is formed by laminating steel plates alternately formed in the circumferential direction on the end on the rotation direction side.
According to this, the following operation and effect can be obtained in addition to the operation and effect similar to those of the second aspect of the invention. That is, harmonic components of the air gap magnetic flux density between the rotor core and the stator can be reduced, and the cogging torque can be reduced.
[0011]
According to a fourth aspect of the present invention, in the permanent magnet type motor according to the first aspect, the rotor core has an opening in each of the interposed portions formed only at an end on the clockwise direction when viewed from one end face in the axial direction. The first steel plate and the second steel plate formed only at the end in the counterclockwise direction are alternately stacked.
According to this, the harmonic component of the air gap magnetic flux density between the rotor core and the stator can be reduced, and the cogging torque can be reduced, as in the third aspect of the present invention.
[0012]
According to a fifth aspect of the present invention, in order to achieve the first object, a plurality of steel plates are laminated to form an annular shape, and 2n (n is an integer of 1 or more) magnet insertion holes are provided in the circumferential direction. A permanent magnet type motor having a rotor having a rotor core having the rotor core and 2n field permanent magnets inserted into the magnet insertion holes, wherein the rotor core is fixed to each of the magnet insertion holes. A first opening independent of the main body is formed by forming an opening communicating with the magnet insertion hole and opening toward the stator at both ends in the circumferential direction of each of the intervening parts interposed between the main part. A steel plate and a second steel plate, at least one end of which is connected to the main portion at both ends in the circumferential direction of the interposed portion, are laminated, and the interposed portions of the steel plates and the main portions are connected to each other. It is characterized by being configured by being connected.
[0013]
According to the above-described means, in the rotor core, since the openings are formed at both ends of the interposed portion in the first steel plate portion, the magnetic flux leakage of the field permanent magnet can be further reduced. At this time, the interposed part of the first steel sheet is independent of the main part, but the interposed part of the second steel sheet laminated with the first steel sheet has at least one end connected to the main part. By connecting each interposed part of the first steel sheet to the interposed part of the second steel sheet and connecting each main part of the first steel sheet to the main part of the second steel sheet, the interposed part of the first steel sheet is connected. Can also be handled integrally with other parts, so that manufacturability can be ensured and manufacturing accuracy can be improved.
[0014]
According to a sixth aspect of the present invention, in order to achieve the first object, a plurality of steel plates are stacked to form an annular shape, and 2n (n is an integer of 1 or more) magnet insertion holes are provided in the circumferential direction. A permanent magnet type motor having a rotor having a rotor core having the rotor core and 2n field permanent magnets inserted into the magnet insertion holes, wherein the rotor core is fixed to each of the magnet insertion holes. A plurality of first steel plates each having an opening communicating with the magnet insertion hole and opening on the stator side are formed at least at one end of both ends in the circumferential direction of each of the interposed portions interposed between the stator and the stator. And a second steel plate, which is disposed on one or both sides in the axial direction of the laminated first steel plate, and has a magnet falling-off preventing portion for preventing the field permanent magnet inserted into the magnet insertion hole from falling off. Are connected to each other.
[0015]
According to the above-described means, in the portion where the first steel sheet is laminated in the rotor core, the opening is formed at at least one end of the interposed portion, so that the magnetic flux leakage of the field permanent magnet can be reduced. Become like Then, by connecting the interposed part and the main part of the first steel plate to the second steel plate, manufacturability can be ensured and manufacturing accuracy can be improved. Further, since the second steel plate is provided with the magnet falling preventing portion, the falling of the field permanent magnet can be prevented, and the productivity can be improved.
[0016]
According to a seventh aspect of the present invention, in the permanent magnet motor according to any one of the first to sixth aspects, the rotor core is formed by connecting a plurality of circumferentially divided cores in a ring shape. And
According to this, the loss can be reduced when the steel sheet used for the rotor core is processed from the steel sheet as the material, and the cost can be reduced.
[0017]
According to an eighth aspect of the present invention, in order to achieve the above-mentioned second object, a plurality of steel plates are laminated to form an annular shape, and 2n (n is an integer of 1 or more) magnet insertion holes in the circumferential direction. In a method of manufacturing a permanent magnet type motor having a rotor having a rotor iron core and 2n number of field permanent magnets inserted into the magnet insertion holes, when manufacturing the rotor, In the state where the field permanent magnets are inserted into the respective magnet insertion holes, molding is performed with resin, and thereafter, the circumferential direction of each interposed portion interposed between each magnet insertion hole of the rotor core and the stator. An opening which opens to the side of the stator in communication with the magnet insertion hole is formed at both ends by post-processing.
[0018]
According to the above-described means, since the openings are formed at both ends of each intervening portion, the magnetic flux leakage of the field permanent magnet can be reduced. Also, when manufacturing the rotor, when inserting the permanent magnet for field into the magnet insertion hole, and when molding with resin, both ends of each interposed part are connected to the main part, Nature can be secured.
[0019]
According to a ninth aspect of the present invention, in order to achieve the second object, a plurality of steel plates are stacked to form an annular shape, and 2n (n is an integer of 1 or more) magnet insertion holes are provided in the circumferential direction. In a method of manufacturing a permanent magnet type motor having a rotor having a rotor iron core and 2n number of field permanent magnets inserted into the magnet insertion holes, when manufacturing the rotor, The rotor core has an opening that opens to the stator only at one circumferential end of each of the interposed portions interposed between the magnet insertion hole and the stator. After the field permanent magnet is inserted into each of the magnet insertion holes, the respective intervening portions are formed so as to be narrower on the opening side of the magnet insertion hole. Mold with resin while deforming to the permanent magnet side. The features.
[0020]
According to the above-described means, since the opening is formed at one end of each intervening portion, it is possible to reduce the magnetic flux leakage of the field permanent magnet. Further, when manufacturing the rotor, each interposed portion is connected to the main portion at the end opposite to the opening, so that it can be handled integrally with the main portion, and manufacturability can be secured. . Moreover, in this case, when the field permanent magnet is inserted into the magnet insertion hole, the field permanent magnet is formed so as to be wider toward the opening side of the magnet insertion hole, so that the field permanent magnet is inserted into the magnet insertion hole. It will be easier.
[0021]
According to a tenth aspect of the present invention, in the permanent magnet type motor according to the eighth or ninth aspect, the rotor core is configured by annularly connecting a plurality of circumferentially divided cores.
According to this, the same function and effect as the invention of claim 7 can be obtained.
[0022]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, a first embodiment in which the present invention is applied to an outer rotor type permanent magnet motor will be described with reference to FIGS. First, FIG. 3 shows a cutaway perspective view of the motor with a part cut away. This motor is used, for example, as a drive motor for rotating the stirrer at the time of washing and the stirrer and the rotary tub integrally at the time of dehydration in a washing machine for both dehydration.
[0023]
In FIG. 3, the stator 1 is wound around each of the teeth 2, a stator core 3 having a large number of teeth 2 radially, a resin 4 provided by molding so as to cover the stator core 3. And a stator winding 5. The stator core 3 is configured such that a plurality of steel plates are laminated and has an annular shape. The stator 1 is provided with an attachment portion 6 for attaching the stator 1 to a predetermined portion of the washing machine for both dehydration.
[0024]
On the other hand, as shown in FIG. 4, the rotor 10 includes a frame 11 made of a magnetic material in a container shape and an inner peripheral portion of an annular wall 11 a provided on the opening side of the outer peripheral portion of the frame 11. And a plurality of field permanent magnets 14 inserted into a plurality of magnet insertion holes 13 provided on the inner peripheral side of the rotor core 12, The rotor core 12 and the permanent magnet for field magnet 14 are formed by molding so as to be integrated with the frame 11, and the inner peripheral surface of the rotor core 12 is fixed to the stator. The iron core 3 is disposed so as to face the tip of each tooth 2 via a predetermined gap.
[0025]
The rotor core 12 is configured by connecting a plurality of divided cores circumferentially divided so as to form an annular shape. Each split core is configured by laminating a plurality of steel plates 17 as shown in FIG. One divided core has a size having, for example, six magnet insertion holes 13.
[0026]
Here, FIG. 1 shows a plan view of a steel plate 17 of the rotor core 12, and FIG. 2 shows that a field permanent magnet 14 is inserted into each magnet insertion hole 13 of the rotor core 12 and a resin for molding is used. 15 is a plan view of a part of the rotor 10 in a state where the rotor 15 is provided. In FIG. 2, the field permanent magnets 14 are hatched to distinguish them from other parts.
[0027]
In FIG. 1, the rectangular magnet insertion holes 13 extending in the circumferential direction are formed on the inner circumferential side of the steel plate 17 so as to be arranged in the circumferential direction. In the steel plate 17, on the inner peripheral side of each magnet insertion hole 13, an intervening portion 18 interposed between the magnet insertion hole 13 and the stator 1 exists. One end of the two ends is connected to the main body 20 on the outer peripheral side through the connecting portion 19, and only the other end communicates with the magnet insertion hole 13 and opens to the stator 1 side. 21 are formed. In this case, the rotor core 12 has the opening 21 in each of the interposed portions 18 only at the end on the clockwise side (the right side in FIG. 1) when viewed from one end face side (the upper side in FIG. 1) in the axial direction. The formed steel plates 17 are stacked.
In FIG. 2, the molding resin 15 enters the opening 21 and covers the ends of the adjacent intervening portions 18.
[0028]
According to the above-described embodiment, the following operational effects can be obtained. That is, in each of the steel plates 17 constituting the rotor core 12, the opening 21 that opens toward the stator 1 is formed at one end in the circumferential direction of each of the intervening portions 18, so that the opening 21 is formed. The magnetic flux of the field permanent magnet 14 is less liable to leak than in the case where the magnetic field is not present, and the magnetic flux leakage can be reduced accordingly. Further, since the opening 21 is only at one end, the one end of the interposition part 18 is connected to the main part 20 via the connection part 19 in each steel plate 17. Unlike the case of being separated and independent, manufacturability can be ensured and manufacturing accuracy can be improved.
[0029]
Further, the rotor core 12 is configured by laminating the steel plates 17 formed on the opening 21 in each of the intervening portions 18 only at one end on the clockwise side when viewed from one end face side in the axial direction. Since the rotor iron core 12 can be configured by laminating one type of the steel plates 17, it is possible to reduce the types of dies for processing the steel plates 17.
[0030]
The same effect can be obtained even when the opening 21 in each of the intervening portions 18 is formed by laminating the steel plates 17 formed only at one end on the counterclockwise direction side, contrary to the first embodiment. Obtainable.
[0031]
Further, since the rotor core 12 is configured by connecting a plurality of divided cores divided in the circumferential direction in a ring shape, a process of removing a steel plate 17 used for the rotor core 12 from a steel plate as a material. In this case, the loss can be reduced, and the cost can be reduced.
[0032]
FIG. 5 shows a second embodiment of the present invention. The second embodiment differs from the first embodiment in the following points.
That is, the steel plate 24 constituting the rotor core 23 surrounds the opening 21 in each of the intervening portions 18 with a clockwise end and a counterclockwise end as viewed from one axial end surface. The rotor core 23 is formed by laminating a plurality of steel plates 24 having such a configuration. Also in the rotor core 23 having such a configuration, similarly to the first embodiment, the field permanent magnets 14 are inserted into the respective magnet insertion holes 13 and the molding resin 15 is provided.
[0033]
In the second embodiment having such a configuration, the following operation and effects can be obtained. That is, since the openings 21 in each of the intervening portions 18 are formed alternately in the circumferential direction at the clockwise end and the counterclockwise end, the rotor core 23 and the stator 1 , The harmonic component of the air gap magnetic flux density can be reduced, and the cogging torque can be reduced.
[0034]
FIG. 6 shows a third embodiment of the present invention. The third embodiment differs from the first embodiment in the following points.
That is, the first steel plate 26 shown in FIG. 6A has the same configuration as the steel plate 17 of the first embodiment, and the opening 21 in each intervening portion 18 is a clock as viewed from one end face side in the axial direction. It is configured to be formed only at the end on the rotation direction side. The second steel plate 27 shown in FIG. 6B has a configuration in which the opening 21 in each of the intervening portions 18 is formed only at the end on the counterclockwise direction side when viewed from one end surface side in the axial direction. . Then, the rotor core moves the first steel plate 26 shown in FIG. 6A and the second steel plate 27 shown in FIG. 6B in the axial direction with the positions of the magnet insertion holes 13 matched. Are alternately laminated. Also in the rotor core having such a configuration, the field permanent magnets 14 are inserted into the respective magnet insertion holes 13 and the molding resin 15 is provided as in the first embodiment.
[0035]
In the third embodiment having such a configuration, in each of the intervening portions 18, the positions of the openings 21 are alternately arranged in the clockwise direction and the counterclockwise direction in the axial direction. As in the second embodiment, the harmonic component of the air gap magnetic flux density between the rotor core and the stator 1 can be reduced, and the cogging torque can be reduced.
[0036]
7 and 8 show a fourth embodiment of the present invention. The fourth embodiment differs from the first embodiment in the following points.
That is, the first steel plate 29 shown in FIG. 8B has openings 21 at both ends in the circumferential direction of each interposed portion 18, and each interposed portion 18 is independent of the main portion 20. . The second steel plate 30 shown in FIG. 8A has a configuration in which both ends of each intervening portion 18 in the circumferential direction are connected to the main portion 20 via the connecting portions 19, respectively.
[0037]
As shown in FIG. 7, the rotor core 31 includes a first steel sheet stacking group 32 in which a plurality of first steel sheets 29 are stacked, and both sides (upper and lower sides) of the first steel sheet stacking group 32 in the axial direction. ), And the second steel plate 30 arranged in (2). The respective main portions 20 are connected by caulking by the caulking portion 33, and the respective intervening portions 18 are also connected by caulking by the caulking portion 34. Also in the rotor core 31 having such a configuration, similarly to the first embodiment, the field permanent magnets 14 are inserted into the respective magnet insertion holes 13 and the molding resin 15 is provided.
[0038]
In the fourth embodiment having such a configuration, the following operation and effect can be obtained. That is, in the portion where the first steel plate 29 is laminated in the rotor core 31, the openings 21 are formed at both ends of the interposition portion 18, so that the magnetic flux leakage of the field permanent magnet 14 can be further reduced. Become like At this time, the interposed part 18 of the first steel sheet 29 is independent of the main part 20, but the interposed part 18 of the second steel sheet 30 arranged on both axial sides of the first steel sheet stack 32 is Both ends are connected to the main portion 20, and each intervening portion 18 of the first steel plate 29 is connected to the intervening portion 18 of the second steel plate 30, and each main portion 20 of the first steel plate 29 is connected to the second main portion 20. By connecting the main portion 20 of the first steel plate 30 to the main portion 20, the intervening portion 18 of the first steel plate 29 can also be handled integrally with other portions, so that manufacturability can be ensured and manufacturing accuracy can be improved.
In the above-described embodiment, the second steel plate 30 having the opening 21 formed at one end of the interposition part 18 may be used.
[0039]
FIG. 9 shows a fifth embodiment of the present invention. The fifth embodiment differs from the fourth embodiment in the following points. In FIG. 9, the step of punching the first steel plate 36 is shown on the right side, and the step of punching the second steel plate 37 is shown on the left side. In each step, the hatched portion indicates the shape of the blade of the mold. In each step, only the peripheral portion of one magnet insertion hole 13 is shown.
[0040]
The second steel plate 37 is formed through the steps (a-1) to (a-5), and is provided with a magnet drop prevention portion 38 between the interposition portion 18 and the main portion 20, The interposed part 18 and the main part 20 are connected via the magnet falling-off preventing part 38.
The first steel plate 36 is formed through the steps (b-1) to (b-5), and the openings 21 are formed at both ends of the interposed portion 18, and the interposed portion 18 is a main portion. 20 and independent. In the first and second steel plates 36 and 37, reference numeral 39 denotes a caulked portion in the main portion 20, and reference numeral 40 denotes a caulked portion in the interposition portion 18.
[0041]
In this case, the rotor core is formed as follows. First, the first steel plate 36 formed in the right process is sequentially stacked on the second steel plate 37 formed in the left process, and the main portions 20 are crimped by the caulking portions 39 and 40. And each intervening part 18 is connected. As a result, a rotor core is formed. Thereafter, the field permanent magnets 14 are inserted into the respective magnet insertion holes 13 where the first steel plates 36 are stacked, and the molding resin 15 is provided and molded. At this time, each field permanent magnet 14 is in a state of being received by the magnet falling-off preventing portion 38 of the lowermost second steel plate 37.
[0042]
In the fifth embodiment having such a configuration, substantially the same functions and effects as those of the above-described fourth embodiment can be obtained, and in addition, there are the following advantages. That is, since the magnet falling prevention portion 38 is provided on the second steel plate 37 located at the lowermost portion, the falling of the field permanent magnet 14 can be prevented at the time of assembly, and the productivity can be further improved.
Note that the second steel plate 37 can be provided on both sides of the lowermost portion and the uppermost portion. Further, the opening 21 of the first steel plate 36 may be provided in only one of them.
[0043]
FIG. 10 shows a sixth embodiment of the present invention. The sixth embodiment differs from the first to fifth embodiments in the following points.
That is, as shown in FIG. 8A, each steel plate 41 constituting the rotor iron core 40 has a circumferential direction in each interposed portion 18 similarly to the second steel plate 30 of FIG. 8A in the fourth embodiment. Both ends are connected to the main body 20 via the connection portions 19, respectively. The rotor core 40 has a configuration in which steel plates 41 having such a configuration are stacked and connected.
[0044]
Then, as shown in (b), the field permanent magnets 14 are inserted into the respective magnet insertion holes 13 in the rotor core 40 and are molded with the molding resin 15. Thereafter, as shown in FIG. 3C, the connecting portions 19 at both ends of each interposed portion 18 are removed by post-processing such as laser processing, so that the two end portions of the interposed portion 18 communicate with the magnet insertion holes 13. The opening 42 is formed on the inner peripheral side (stator 1 side). In this case, each intervening portion 18 is integrated with the permanent magnet 14, the main portion 20, and the frame 11 (see FIGS. 3 and 4) by the resin 15 for molding.
[0045]
According to the sixth embodiment, the following operation and effect can be obtained. That is, since the openings 42 are finally formed at both ends of each interposed portion 18 in the rotor core 40, the magnetic flux leakage of the field permanent magnet 14 can be reduced. When manufacturing the rotor, when inserting the permanent magnet for field into the magnet insertion hole 13 and when molding with the resin 15, both ends of each intervening portion 18 are connected via the connecting portion 19. Since it is connected to the main body 20, productivity can be ensured.
[0046]
FIG. 11 shows a seventh embodiment of the present invention. The seventh embodiment differs from the first to sixth embodiments in the following points.
That is, as shown in (a), each steel plate 46 constituting the rotor core 45 has one end of each intervening portion 18 connected to the main body 20 via the connecting portion 19, and the other end has a magnet inserted therein. An opening 21 communicating with the hole 13 and opening on the inner peripheral side (stator 1 side) is formed. In this case, the interposition part 18 protrudes toward the inner peripheral part (the stator 1 side) so that the magnet insertion hole 13 becomes wider toward the opening 21. Then, as shown in (b), after the field permanent magnets 14 are inserted into the respective magnet insertion holes 13, the ends of the intervening portions 18 on the opening 21 side are narrowed so that the openings 21 are narrowed. It is deformed to the permanent magnet for magnet 14 side, and in this state, it is molded with the molding resin 15. As a result, the state of FIG.
[0047]
According to the seventh embodiment, the following operation and effect can be obtained. That is, since the opening 21 is formed at one end of each of the intervening portions 18 in the rotor core 45, the magnetic flux leakage of the field permanent magnet 14 can be reduced. Further, when manufacturing the rotor, each end of the interposed portion 18 opposite to the opening 21 is connected to the main body 20, so that it can be handled integrally with the main body 20. Nature can be secured. Moreover, in this case, when the field permanent magnet 14 is inserted into the magnet insertion hole 13, it is formed so as to be wider toward the opening 21 side of the magnet insertion hole 13. There is an advantage that the permanent magnet 14 can be easily inserted.
In the second to seventh embodiments as well, it is preferable that the rotor core is formed by connecting a plurality of divided cores circumferentially divided in a ring shape.
[0048]
The present invention is not limited to the above embodiments, but can be modified or expanded as follows.
The invention can be applied not only to the outer rotor type but also to the inner rotor type. In addition, the motor of the present invention can be used for applications other than the washing machine for both dehydration.
[0049]
【The invention's effect】
According to the permanent magnet type motor of the first aspect, in each of the steel plates constituting the rotor core, an opening that opens toward the stator is formed at one end in the circumferential direction of each interposed portion. , The magnetic flux of the field permanent magnet is less likely to leak than in the case where no magnetic field is formed, and the magnetic flux leakage can be reduced accordingly. Also, since the opening is only at one end, in each steel plate, one end of the interposed part is connected to the main part, so that unlike the case where the interposed part is separated and independent from the main part, manufacturability is secured. Production accuracy can be improved.
[0050]
According to the permanent magnet type motor of the fifth aspect, in the rotor core, since the openings are formed at both ends of the interposed portion in the first steel plate portion, the magnetic flux leakage of the field permanent magnet is further reduced. It can be reduced. At this time, the interposed part of the first steel sheet is independent of the main part, but the interposed part of the second steel sheet laminated with the first steel sheet has at least one end connected to the main part. By connecting each interposed part of the first steel sheet to the interposed part of the second steel sheet and connecting each main part of the first steel sheet to the main part of the second steel sheet, the interposed part of the first steel sheet is connected. Can also be handled integrally with other parts, so that manufacturability can be ensured and manufacturing accuracy can be improved.
[0051]
According to the manufacturing method of the permanent magnet type motor of the eighth aspect, since the openings are finally formed at both ends of each interposed portion, the magnetic flux leakage of the field permanent magnet can be reduced. Become. Also, when manufacturing the rotor, when inserting the permanent magnet for field into the magnet insertion hole, and when molding with resin, both ends of each interposed part are connected to the main part, Nature can be secured.
[Brief description of the drawings]
FIG. 1 shows a first embodiment of the present invention and is a plan view showing a part of a steel plate of a rotor core.
FIG. 2 is a plan view showing a part of a molded rotor.
FIG. 3 is a cutaway perspective view of a motor.
FIG. 4 is a cutaway perspective view showing a part of a rotor.
FIG. 5 is a view corresponding to FIG. 1, showing a second embodiment of the present invention;
6 (a) is a plan view of a first steel plate, and FIG. 6 (b) is a plan view of a second steel plate according to a third embodiment of the present invention.
FIG. 7 shows a fourth embodiment of the present invention and is a cutaway perspective view showing a part of a rotor core.
8A is a plan view of a second steel sheet, and FIG. 8B is a plan view of a first steel sheet.
FIG. 9 is a view showing a fifth embodiment of the present invention, in which (a-1) to (a-5) show steps of manufacturing a second steel sheet, and (b-1) to (b-5). ) Is a diagram showing a process of manufacturing the first steel sheet.
FIGS. 10A to 10C are plan views showing a manufacturing method according to a sixth embodiment of the present invention.
11A and 11B are plan views showing a manufacturing method according to a seventh embodiment of the present invention.
[Explanation of symbols]
1 is a stator, 10 is a rotor, 12 is a rotor core, 13 is a magnet insertion hole, 14 is a permanent magnet for field, 15 is resin, 17 is a steel plate, 18 is an interposition part, 19 is a connection part, 20 is Main body, 21 is an opening, 23 is a rotor core, 24 is a steel plate, 26 is a first steel plate, 27 is a second steel plate, 29 is a first steel plate, 30 is a second steel plate, 31 is a rotor. An iron core, 32 is a first steel sheet lamination group, 33 and 34 are caulked parts, 36 is a first steel sheet, 37 is a second steel sheet, 38 is a magnet falling prevention part, 40 is a rotor iron core, 41 is a steel sheet, 42 Indicates an opening, 45 indicates a rotor core, and 46 indicates a steel plate.

Claims

A rotor core having a ring shape formed by laminating a plurality of steel plates and having 2n (n is an integer of 1 or more) magnet insertion holes in the circumferential direction, and 2n field magnets inserted into the magnet insertion holes Permanent magnet type motor having a rotor having a permanent magnet for
The rotor core communicates with the magnet insertion hole only at one end of the circumferential ends of each of the interposed portions interposed between the magnet insertion hole and the stator, and is connected to the stator side. A permanent magnet type motor, wherein a plurality of steel plates each having an opening formed therein are laminated.

The rotor core is configured by laminating steel plates formed at only one of the ends on the clockwise direction or the counterclockwise direction when viewed from one end face side in the axial direction. 2. The permanent magnet type motor according to claim 1, wherein:

The rotor core is formed by laminating steel plates with openings formed in each interposition part, which are alternately formed in the circumferential direction at the clockwise end and the counterclockwise end when viewed from one axial end face. The permanent magnet type motor according to claim 1, wherein the motor is configured as follows.

The rotor core has an opening in each interposed portion formed only at the clockwise end when viewed from one axial end surface, and only at the counterclockwise end. 2. The permanent magnet type motor according to claim 1, wherein said second steel plate and said second steel plate are alternately laminated.

A rotor core having a ring shape formed by laminating a plurality of steel plates and having 2n (n is an integer of 1 or more) magnet insertion holes in the circumferential direction, and 2n field magnets inserted into the magnet insertion holes Permanent magnet type motor having a rotor having a permanent magnet for
The rotor core is formed at both ends in the circumferential direction of each of the interposed portions interposed between the magnet insertion holes and the stator to form openings that are open to the stator side in communication with the magnet insertion holes. In addition, the first steel sheet having the interposed portion independent from the main portion and the second steel plate having at least one end connected to the main portion at least one of both ends in the circumferential direction of the interposed portion are laminated, and each of these steel plates is laminated. Wherein the interposed portions are connected to each other and the main portions are connected to each other.

A rotor core having a ring shape formed by laminating a plurality of steel plates and having 2n (n is an integer of 1 or more) magnet insertion holes in the circumferential direction, and 2n field magnets inserted into the magnet insertion holes Permanent magnet type motor having a rotor having a permanent magnet for
The rotor core has an opening that opens to the stator side in communication with the magnet insertion hole at least at one end of the circumferential ends of each interposed portion interposed between each of the magnet insertion holes and the stator. A plurality of first steel sheets each having a portion formed thereon are laminated, and the first steel sheets are laminated on one or both sides in the axial direction of the laminated first steel sheets, and the dropout of the field permanent magnet inserted into the magnet insertion hole is performed. A permanent magnet type motor comprising a second steel plate having a magnet falling-off preventing portion for preventing the occurrence of a permanent magnet.

The permanent magnet type motor according to any one of claims 1 to 6, wherein the rotor core is formed by connecting a plurality of circumferentially divided cores in a ring shape.

A rotor core having a ring shape formed by laminating a plurality of steel plates and having 2n (n is an integer of 1 or more) magnet insertion holes in the circumferential direction, and 2n field magnets inserted into the magnet insertion holes A method for manufacturing a permanent magnet type motor having a rotor with a permanent magnet for
When manufacturing the rotor, the resin is molded in a state where the field permanent magnets are inserted into the respective magnet insertion holes, and thereafter, between the respective magnet insertion holes and the stator of the rotor core. A permanent magnet type motor, characterized in that openings at the circumferential ends of each of the interposed portions, which open to the stator side in communication with the magnet insertion holes, are formed by post-processing. Production method.

A rotor core having a ring shape formed by laminating a plurality of steel plates and having 2n (n is an integer of 1 or more) magnet insertion holes in the circumferential direction, and 2n field magnets inserted into the magnet insertion holes A method for manufacturing a permanent magnet type motor having a rotor with a permanent magnet for
When manufacturing the rotor, the rotor core forms an opening that opens toward the stator only at one circumferential end of each of the interposed portions interposed between the magnet insertion hole and the stator. In addition, the magnet insertion hole is formed so as to become wider toward the opening, and after inserting the field permanent magnet into each of the magnet insertion holes, the opening of the magnet insertion hole is narrowed. A method of manufacturing a permanent magnet type motor, wherein each of the interposed portions is molded with a resin while being deformed toward the field permanent magnet.

The method for manufacturing a permanent magnet motor according to claim 8 or 9, wherein the rotor core is formed by connecting a plurality of circumferentially divided cores in an annular shape.