Magnetic inductor electric motor and manufacturing method therefor

Patent metadata

Field	Value
Publication number	US-2016248308-A1
Application number	US-201415029748-A
Country	US
Kind code	A1
Filing date	Jul 16, 2014
Priority date	Dec 25, 2013
Publication date	Aug 25, 2016
Grant date	—

Abstract

A first stator core and a second stator ore are configured by arranging core block pairs into an annular shape, the core block pairs being configured by stacking together core blocks so as to be spaced apart axially, each of the core blocks including a core back portion and one tooth, and a permanent magnet is configured so as to be divided into a plurality of magnet blocks that each include: a base portion; one shaft portion that protrudes radially inward from an inner circumferential surface of the base portion; and flange portions that protrude on two circumferential sides from a radially inner end portion of the shaft portion, the magnet blocks being held between the core block pairs such that the base portion and the shaft portion are positioned inside the core block pairs and such that the flange portions protrude circumferentially from the core block pairs.

First claim

1 . A magnetic inductor electric motor comprising:
a housing that is produced using a nonmagnetic material; a stator comprising:
a stator core that is configured such that a first stator core and a second stator core that are produced so as to have identical shapes in which a plurality of teeth are each formed so as to have a tapered shape in which a circumferential width becomes gradually narrower radially inward and are disposed at a uniform angular pitch circumferentially so as to project radially inward from an inner circumferential surface of a cylindrical core back are disposed coaxially so as to be separated axially and such that circumferential positions of said teeth are aligned, such that slots are configured into open slots; and
a plurality coils that are produced by winding a jointless, continuous conductor wire using a concentrated winding method on a pair of said teeth that face each other in an axial direction of said stator core,
said stator being disposed inside said housing;
a rotor comprising a first rotor core and a second rotor core that are produced so as to have identical shapes in which salient poles are disposed so as to project at a uniform angular pitch circumferentially on an outer circumferential surface of a cylindrical base portion, said rotor being fixed coaxially to a rotating shaft such that said first rotor core is positioned on an inner circumferential side of said first stator core and said second rotor core is positioned on an inner circumferential side of said second stator core, and such that said first rotor core and said second rotor core are offset circumferentially by a pitch of half a salient pole from each other, said rotor being disposed rotatably inside said housing; and a permanent magnet that is disposed between said first stator core and said second stator core, and that generates field magnetic flux such that said salient poles of said first rotor core and said salient poles of said second rotor core have different polarity, wherein: said first stator core and said second stator core are configured by arranging core block pairs into an annular shape such that circumferential side surfaces of circular arc-shaped core back portions contact each other, said core block pairs being configured by stacking together core blocks so as to be spaced apart axially, each of said core blocks comprising said core back portion and one of said teeth, which protrudes radially inward from an inner circumferential surface of said core back portion; and said permanent magnet is configured so as to be divided into a plurality of magnet blocks that each comprise:
a circular arc-shaped base portion;
one shaft portion that protrudes radially inward from an inner circumferential surface of said base portion; and
flange portions that protrude on two circumferential sides from a radially inner end portion of said shaft portion,
said magnet blocks being held between said core block pairs such that said base portion and said shaft portion are positioned inside said core block pairs and such that said flange portions protrude circumferentially from said core block pairs.

2 . The magnetic inductor electric motor according to claim 1 , wherein said flange portions are formed so as to be thicker than a thickness of said shaft portion.

3 . The magnetic inductor electric motor according to claim 2 , wherein:
an expanded portion is formed on an end portion near a tip end of said shaft portion so as to have a thickness that is similar or identical to that of said flange portions so as to link between said flange portions; a recess portion is formed on a radially inner end portion of a surface of said teeth of said core blocks that faces said magnet block; and said magnet blocks are held between said core block pairs by fitting said expanded portion into said recess portion.

4 . The magnetic inductor electric motor according to claim 1 , wherein at least one of a radially inner corner portion and a radially outer corner portion of said flange portions is beveled to form an inclined surface.

5 . The magnetic inductor electric motor according to claim 1 , wherein two circumferential side surfaces of said portions are beveled to form inclined surfaces.

6 . The magnetic inductor electric motor according to claim 1 , wherein a gap is formed between circumferentially adjacent flange portions.

7 . The magnetic inductor electric motor according to claim 1 , wherein a protective member is coated onto two axial end surfaces of said magnet blocks.

8 . The magnetic inductor electric motor according to claim 1 , wherein said magnet blocks are produced such that a circumferential width Wmag and an axial length Hmag of a radially inner end surface thereof satisfy:
Wmag+{Hmag×(Hcoil/Wcoil)}<(Wcoil 2 +Hcoil 2 ) 1/2 ,

where Wcoil is a circumferential width and Hcoil is an axial length of a radially inner opening of said coils.

9 . The magnetic inductor electric motor according to claim 1 , wherein insulators are mounted so as to be fitted over said pairs of said teeth that face each other in said axial direction of said stator core, and said coils are wound onto said insulator.

10 . A method for manufacturing the magnetic inductor electric motor according to claim 1 , said method for manufacturing said magnetic inductor electric motor comprising steps of:
producing a coil assembly by winding said jointless, continuous conductor wire into a concentrated winding; inserting said magnet block inside said coil assembly so as to be rotated so as to avoid interference between said flange portions and said coil assembly; inserting one of said core blocks inside said coil assembly on a first side of said magnet block; and inserting another of said core blocks inside said coil assembly on a second side of said magnet block.

Assignees

• Mitsubishi Electric Corp

Inventors

• Ogawa Toru
• Arita Hideaki
• Daikoku Akihiro
• Komatsu Taiga
• Miyama Yoshihiro

Classifications

• H02K15/04

  of windings prior to their mounting into the machines (insulating windings H02K15/10, H02K15/12) · CPC title

• H02K15/03

  having permanent magnets · CPC title

• H02K1/24

  Rotor cores with salient poles {; Variable reluctance rotors} · CPC title

• H02K15/022

  with salient poles · CPC title

• H02K3/18

  Windings for salient poles · CPC title