JP7561669B2 - Magnetic geared motor and method of manufacturing the same - Google Patents

Description

This application relates to a magnetic-geared motor and a method for manufacturing a magnetic-geared motor.

In recent years, research and development has been conducted on magnetic gears, which are magnetic flux modulation type magnetic reducers that achieve high torque density. Magnetic geared motors, which are magnetic gear type rotating electric machines that integrate this magnetic gear with a wound stator, have also been researched and developed. In these magnetic geared motors, the high-speed rotor is rotated by the stator coil, and the low-speed rotor is rotated by modulating the magnetic flux of the magnets placed on the high-speed rotor with the modulating magnetic poles. This allows the low-speed rotor to obtain torque that is increased by the speed ratio (reduction ratio) of the high-speed rotor, thereby achieving high torque density. The following technologies have been disclosed as magnetic geared motors that can achieve such high torque density.

That is, a magnetic gear type rotating electric machine as a conventional magnetic geared motor is composed of a first permanent magnet field having multiple permanent magnet poles, a second permanent magnet field having multiple permanent magnet poles with a different number of poles, a modulation pole having multiple magnetic pole pieces, and a wound stator having multiple windings that interact with the first permanent magnet field. The first permanent magnet field is provided between the wound stator and the modulation pole. When the modulation pole is fixed in addition to the wound stator, the first permanent magnet field rotates in synchronization with the rotating magnetic field created by the wound stator, and the second permanent magnet field rotates at a speed determined by the gear ratio (for example, see Patent Document 1).

Patent No. 5723987

The above-mentioned conventional magnetic-geared motor mainly comprises four structures: a first permanent magnet which is a high-speed rotor, a second permanent magnet which is a low-speed rotor, a modulation pole, and a wound stator, and comprises two rotating structures for the first permanent magnet and the second permanent magnet. As described above, since there are two or more rotating structures, there is a problem that the structure for holding these rotating structures becomes complicated.
Furthermore, in the above-mentioned conventional magnetic-geared motor, when the wound stator and the modulating poles are fixed so as not to rotate, the relative position of the modulating poles with respect to the stator may be shifted, which increases torque pulsation and reduces performance.

This application discloses technology to solve the problems described above, and aims to provide a high-performance magnetic-geared motor with a simplified structure, and a method for manufacturing this magnetic-geared motor.

The magnetic geared motor disclosed in the present application is
A rotor having a magnetic pole pair in a circumferential direction;
a stator that is disposed coaxially with the rotor with a gap therebetween in the radial direction, the stator having a coil that functions as an electromagnet, the coil forming a magnetic pole pair in the circumferential direction to generate a rotating magnetic field;
a modulation pole group provided between the stator and the rotor, each having a plurality of pole pieces arranged with a gap set in the circumferential direction, for modulating a magnetic flux between the stator and the rotor to change a rotation speed of the rotating magnetic field and transmit the changed magnetic flux to the rotor;
the modulation magnetic pole group is fixed to the stator via a heat insulating portion, and a relative position of the modulation magnetic pole group with respect to the stator is fixed by the heat insulating portion ;
The rotor is provided as a rotating body with a rotating magnetic field and a rotational force being applied thereto by the stator.
It is something.
In addition, the manufacturing method of the magnetic geared motor disclosed in the present application includes:
a die having a protruding portion protruding from one axial end side is disposed on the other axial end side of the modulation pole group so that the protruding portion is inserted between the modulation pole group and the stator;
In a state where a circumferential end portion and a radially inner end portion of the teeth portion and a circumferential end portion and a radially outer end portion of the modulation magnetic pole group are supported by the protruding portion of the mold,
forming the molded resin portion by molding a resin between the modulation magnetic pole group and the stator, and fixing a relative position of the modulation magnetic pole group with respect to the stator by the molded resin portion;
It is something.

The magnetic-geared motor and the manufacturing method of the magnetic-geared motor disclosed in the present application provide a high-performance magnetic-geared motor with a simplified structure, and a manufacturing method of the magnetic-geared motor for manufacturing this magnetic-geared motor.

1 is a cross-sectional view in a direction parallel to the axial direction showing a schematic configuration of a magnetic-geared motor according to a first embodiment; 1 is a cross-sectional view in a direction perpendicular to the axial direction showing a schematic configuration of a magnetic-geared motor according to a first embodiment; 1 is a perspective view showing a schematic configuration of a magnetic geared motor according to a first embodiment; 1 is a perspective view showing a schematic configuration of a stator core according to a first embodiment; 1 is a top view showing a schematic configuration of a stator core according to a first embodiment. FIG. 1 is a perspective view showing a schematic configuration of a modulated magnetic pole group according to a first embodiment; FIG. 2 is a top view showing a schematic configuration of a modulated magnetic pole group according to the first embodiment. 1 is a perspective view showing a schematic configuration of a rotor according to a first embodiment; 1 is a top view showing a schematic configuration of a rotor of a magnetic-geared motor according to a first embodiment; 3A and 3B are diagrams for explaining magnetic poles of a rotor of the magnetic-geared motor according to the first embodiment. FIG. 11 is a perspective view showing a schematic configuration of a magnetic-geared motor according to a second embodiment. 11 is a cross-sectional view in a direction parallel to the axial direction showing a schematic configuration of a stator and a molded resin portion of a magnetic-geared motor according to a second embodiment. FIG. 11 is a perspective cross-sectional view showing a schematic configuration of a molded resin portion of a magnetic-geared motor according to a second embodiment. FIG. 11 is a cross-sectional view in a direction parallel to the axial direction of the magnetic-geared motor for explaining a manufacturing method for forming a molded resin portion according to the second embodiment. FIG. 11 is an enlarged cross-sectional view of a portion of a magnetic-geared motor in a direction perpendicular to the axial direction, illustrating the configuration of a molded resin portion according to a second embodiment of the present invention. FIG. 11 is a cross-sectional view in a direction parallel to the axial direction showing a schematic configuration of a magnetic-geared motor according to a third embodiment. FIG. 11 is a cross-sectional view in a direction perpendicular to the axial direction showing an example of the structure of a heat insulating part of a magnetic-geared motor according to embodiment 3. FIG. FIG. 11 is a cross-sectional view in a direction parallel to the axial direction showing a schematic configuration of a magnetic-geared motor according to a fourth embodiment. FIG. 13 is a cross-sectional view in a direction parallel to the axial direction showing a schematic configuration of a magnetic-geared motor according to a fifth embodiment. FIG. 13 is a cross-sectional view in a direction parallel to the axial direction showing a schematic configuration of a magnetic-geared motor according to a fifth embodiment.

Hereinafter, the magnetic-geared motor and the manufacturing method of the magnetic-geared motor of the present application will be described with reference to the drawings.
In the following embodiment, the directions in the annular rotor are referred to as the circumferential direction S, the radial direction X, the radially inner direction X1, and the radially outer direction X2, the axial direction of the rotor shaft is referred to as the axial direction Y, the upper side on the drawing in FIG. 1 is referred to as the axially upper side Y1, and the lower side on the drawing in FIG. 1 is referred to as the axially lower side Y2, and other drawings are also shown based on these directions.

Embodiment 1.
FIG. 1 is a cross-sectional view in a direction parallel to the axial direction showing a schematic configuration of a magnetic-geared motor 100 according to a first embodiment.
FIG. 2 is a cross-sectional view in a direction perpendicular to the axial direction, showing a schematic configuration of magnetic-geared motor 100 according to the first embodiment.
FIG. 3 is a perspective view showing a schematic configuration of the magnetic-geared motor 100 according to the first embodiment.
As shown in FIG. 1 , a magnetic geared motor 100 which is a magnetic reduction mechanism of this embodiment includes a rotor 10 , a stator 20 which is a non-rotor, and a modulated magnetic pole group 30 .

In the magnetic-geared motor 100 of this embodiment, the rotor 10, the modulated magnetic pole group 30, and the stator 20 are arranged in this order from the radially inner side X1 to the radially outer side X2.
The configurations of the rotor 10, the modulated magnetic pole group 30, and the stator 20 will be described below.

First, the configuration of the stator 20 will be described.
As shown in FIGS. 1 to 3, the stator 20 includes a stator core 21 made of electromagnetic steel plate or the like, a coil 22, and an insulating material (not shown) that insulates the stator core 21 from the coil 22.
FIG. 4 is a perspective view showing a schematic configuration of the stator core 21 according to the first embodiment.
FIG. 5 is a top view showing a schematic configuration of stator core 21 according to the first embodiment.
4 and 5, the stator core 21 includes an annular back yoke portion 21Y and a plurality of T-shaped teeth 21T protruding radially inwardly X1 from the back yoke portion 21Y at set intervals in the circumferential direction S. The radially inwardly X1 of each tooth 21T is provided with a protrusion 21T1 protruding on both sides in the circumferential direction S.

The stator core 21 of this embodiment has nine teeth 21T. The coils 22 shown in Figures 1 to 3 are formed by winding wire around each tooth 21T in a concentrated manner while ensuring insulation with an insulating material (not shown). By passing a three-phase alternating current through the coils 22 of each tooth 21T, the coils 22 function as electromagnets, and the coils 22 form multiple magnetic pole pairs in the circumferential direction S, generating a rotating magnetic field. In this embodiment, it is configured to generate a six-pole (three pole pairs) magnetic field.

In this embodiment, the stator core 21 has all teeth 21T formed integrally with the back yoke portion 21Y, but this is not limited to the above. For example, the stator core 21 may be configured by assembling nine split stator cores, each split into nine teeth 21T, into a single piece that ultimately forms a ring shape.

Next, the configuration of the modulated magnetic pole group 30 will be described.
FIG. 6 is a perspective view showing a schematic configuration of the modulated magnetic pole group 30 according to the first embodiment.
FIG. 7 is a top view showing a schematic configuration of the modulated magnetic pole group 30 according to the first embodiment.
As shown in FIG. 6, the modulated magnetic pole group 30 is configured to have a required number of magnetic pole pieces 31 as magnetic pole pieces.
In this embodiment, the modulation pole group 30 is constituted by having 18 pole pieces 31 .

The pole pieces 31 are disposed at equal intervals with gaps set in the circumferential direction S. The pole pieces 31 are configured to extend with the same cross-sectional shape in the axial direction Y. Therefore, for example, when the pole pieces 31 are configured by stacking a plurality of thin plates in the axial direction Y, thin plates of the same shape can be used, which has the advantage of not increasing the number of types of parts.
As will be described below, the modulated magnetic pole group 30 is fixed integrally to the stator 20 by a molded resin portion 40 serving as a heat insulating portion.

As described above, the coils 22 are wound around the teeth 21T of the stator core 21 while insulation from the coils 22 is ensured by an insulating material. The coils 22 are then integrated with the stator core 21 by molding with a resin material to form the stator 20. In this embodiment, during this molding, the modulation magnetic pole group 30 arranged on the radially inner side X1 of the stator 20 is also molded with the stator core 21 together with the coils 22.
In this way, the number of work steps can be reduced and the processing time can be shortened compared to separately fixing the modulation magnetic pole group 30 and the stator 20. In addition, a separate member for fixing the stator 20 and the modulation magnetic pole group 30 is not required.

In this way, the modulation magnetic pole group 30 is fixed to the radially inner side X1 of the stator 20 by the molded resin part 40 as a heat insulating part, and the relative position with respect to the stator 20 is fixed by this molded resin part 40. The radially inner side X1 of the teeth part 21T of the stator core 21 and the radially outer side X2 of the modulation magnetic pole group 30 are opposed to each other in the radial direction X.

Next, the configuration of the rotor 10 will be described.
FIG. 8 is a perspective view showing a schematic configuration of the rotor 10 of the magnetic-geared motor 100 according to the first embodiment.
FIG. 9 is a top view showing a schematic configuration of rotor 10 of magnetic-geared motor 100 according to the first embodiment.
FIG. 10 is a diagram for explaining the magnetic poles of the rotor 10 of the magnetic-geared motor 100 according to the first embodiment.
The rotor 10 is provided with a shaft 11 as a rotation axis at the center of the radially inner side X1. A rotor core 12 is fixed to the radially outer side X2 of the shaft 11. Furthermore, a plurality of permanent magnets 13 are fixed in the circumferential direction S to the radially outer side X2 of the rotor core 12.

As shown in FIG. 1, the shaft 11 is rotatably supported at both ends in the axial direction Y by a pair of bearings 50, which are constituted by a bearing 50A and a bearing 50B.
The bearing 50A provided on the axially upper side Y1 is disposed in a recess 40H provided in a part of the molded resin part 40. The bearing 50B provided on the axially lower side Y2 is disposed in a recess 51H formed in a bracket 51 made of an insulating resin material provided on the axially lower side Y2. The bracket 51 is fitted into the molded resin part 40 to ensure coaxiality with the bearing 50A.
The stator 20 is disposed coaxially with the rotor 10 with a gap set in the radial direction X therebetween.
In addition, in FIG. 2, for the sake of simplicity, the bearing 50A, the bearing 50B, the bracket 51, etc. are not shown.

Here, the permanent magnets 13 provided in the rotor 10 of this embodiment are composed of 15 pole pairs (30 poles) and are magnetized in the radial direction, as shown in Figure 10, to form multiple magnetic pole pairs in the circumferential direction S.
Possible materials for the permanent magnet 13 include rare earth and ferrite. They may also be sintered magnets or bonded magnets. In this embodiment, a ring-shaped rare earth bonded magnet is used. Using a rare earth magnet increases the energy density, which contributes to further miniaturization of the product. Also, using a bonded magnet makes it possible to employ an integrated molding method in which the magnet is molded directly onto the rotor core 12, which makes it possible to produce a less expensive product compared to when the magnet is bonded with an adhesive or the like.

Possible resin materials used for the molded resin portion 40 and the bracket 51 include PPS (Poly Phenylene Sulfide Resin), PBT (Polybutyleneterephthalate), epoxy resin, unsaturated polyester resin, etc. This resin material is used to fix the modulated magnetic pole group 30, so it is preferable to use a non-conductive material. This can suppress eddy currents and contribute to improving the efficiency of the device. The bracket 51 may also be an iron material, such as SPCC (Steel Plate Cold Commercial), S45C, etc.

The rotor core 12, modulated magnetic pole group 30, and stator core 21 are made of soft magnetic materials such as electromagnetic steel sheets, pressed powder iron cores, amorphous metals, and permendur. However, ferromagnetic materials such as S45C and SS400 may also be used if there are no problems with the specifications. It is desirable to use multiple thin sheets of amorphous iron cores, electromagnetic steel sheets, S45C, SPCC, and other iron sheets in a stack to prevent eddy currents caused by magnetic flux changes.

In the magnetic-geared motor 100 configured in this manner, as described above, three-phase AC current is passed through the coils 22 of each tooth portion 21T of the stator 20. In this way, the coils 22 function as electromagnets, forming multiple magnetic pole pairs in the circumferential direction, and are configured to generate a rotating magnetic field with six poles (three pole pairs). This provides a rotational force to the rotor 10.

The magnetic flux between the stator 20 and the rotor 10 is modulated by the pole pieces 31 of the modulated magnetic pole group 30, and torque with a changed rotational speed is transmitted to the rotor 10. The rotor 10 rotates at a rotational speed at a set reduction ratio G relative to the rotational speed of the rotating magnetic flux of the stator 20.
In this embodiment, when the number of magnetic pole pairs generated by the coils of the stator 20 is Nh, the number of magnetic pole pairs formed by the permanent magnets 13 of the rotor 10 is Nl, and the number of magnetic pole pieces 31 of the modulated magnetic pole group 30 is Ns, the following relationship is obtained.
Nl = Ns ± Nh

In this case, the reduction ratio G is G=Nh/Nl. As a result, the force generated in the stator 20 is multiplied by G and added to the torque of the rotor 10.
The number of magnetic pole pairs Nh of the stator 20, the number of magnetic pole pairs Nl of the rotor 10, and the gaps between the magnetic pole pieces 31 in the circumferential direction S are each determined so as to generate a desired reduction ratio G. In the first embodiment, Nl=15, Ns=18, and Nh=3. That is, the reduction ratio G=5.

In this first embodiment, the stator is given the function of the high-speed rotor in a typical magnetic-geared motor. In other words, by making the coil on the stator function as an electromagnet, it generates a magnetic flux equivalent to that of a typical high-speed rotor, generating a rotating magnetic field without rotating the stator. The magnetic flux is then modulated by the modulated magnetic pole group, causing the rotor to rotate at a speed determined by the reduction ratio G. In this way, it is possible to configure the rotor as the only rotating body.

The magnetic-geared motor of this embodiment configured as described above has the following features:
A rotor having a magnetic pole pair in a circumferential direction;
a stator that is disposed coaxially with the rotor with a gap therebetween in the radial direction, the stator having a coil that functions as an electromagnet, the coil forming a magnetic pole pair in the circumferential direction to generate a rotating magnetic field;
a modulation pole group provided between the stator and the rotor, each having a plurality of pole pieces arranged with a gap set in the circumferential direction, for modulating a magnetic flux between the stator and the rotor to change a rotation speed of the rotating magnetic field and transmit the changed magnetic flux to the rotor;
The modulated magnetic pole group is fixed to the stator via a heat insulating portion, and a relative position of the modulated magnetic pole group with respect to the stator is fixed by the heat insulating portion.
It is something.

In this way, the stator is arranged coaxially with the rotor with a gap in the radial direction, and has a coil that functions as an electromagnet to form a magnetic pole pair in the circumferential direction to generate a rotating magnetic field. In this way, it is possible to generate a rotating magnetic field and rotate the rotor without rotating the stator. Here, by providing a modulating magnetic pole group that modulates the magnetic flux between the stator and the rotor to change the rotation speed of this rotating magnetic field and transmit it to the rotor, it is possible to rotate the rotor at a desired reduction ratio. In this way, it is possible to eliminate the need for a high-speed rotor that is an input (rotational force) from another device such as a motor to rotate the rotor, and to simplify the structure related to the bearings for holding the rotating structure, the fixing parts of the magnetic pole pieces, etc. This allows for cost reduction.
As described above, while a typical system is configured using both a motor and a magnetic reduction mechanism, this embodiment can be configured using only the magnetic reduction mechanism, which makes it possible to reduce the size of the entire system including the magnetic reduction mechanism.

Furthermore, the modulation pole group is integrated with the stator with its relative position fixed by the heat insulating section, which prevents the modulation pole group from being displaced relative to the stator, thereby suppressing torque fluctuations due to manufacturing variations.
Furthermore, since the modulated magnetic poles do not rotate, the teeth of the stator facing the modulated magnetic poles can always be the same individual teeth. In the case where the modulated magnetic pole group is structured to rotate, one modulated magnetic pole piece can be configured to face all of the teeth of the stator. Normally, it is difficult for each tooth of the stator to have the same dimensions due to manufacturing variations, etc., and dimensional errors occur, leading to deviations in relative position. Furthermore, the relative position between the modulated magnetic pole group and the stator changes due to runout and eccentricity caused by rotation. In this embodiment, the relative position of the modulated magnetic pole group to the stator is fixed by the heat insulating portion, so torque pulsation caused by such deviations in relative position can be suppressed, and a high-performance magnetic-geared motor can be provided.

Here, in this embodiment, the modulated magnetic pole group is integrated with the stator, but heat is generated in the coil of the stator by current flow. Normally, the magnetic steel sheet used for the pole pieces of the modulated magnetic pole group has temperature characteristics, and as the temperature increases, the saturation magnetic flux density decreases, and the magnetic flux cannot be used effectively. Therefore, if the axial dimension of the pole pieces is lengthened to obtain the desired torque in order to suppress temperature changes, the amount of material used increases, and the volume of the magnetic geared motor also increases. Furthermore, if heat is transferred to the permanent magnet of the rotor arranged radially inside the modulated magnetic pole group, there is a possibility that the permanent magnet will be demagnetized. If an attempt is made to suppress heat generation by suppressing the current flowing through the stator coil to prevent demagnetization, it becomes necessary to lengthen the axial dimension in order to obtain the desired torque. In this case, the amount of material used increases and the volume of the magnetic geared motor increases.

In this embodiment, the modulated magnetic pole group is fixed to the stator via a heat insulating section. By interposing a heat insulating section between the modulated magnetic pole group and the stator in this way, it is possible to reduce the heat generated in the stator coil from being transferred to the modulated magnetic pole group. This makes it possible to obtain the desired torque, reduce the amount of material used, and reduce the volume of the magnetic-geared motor.

In the magnetic-geared motor of the present embodiment configured as described above,
The heat insulating portion is
A molded resin portion is provided between the modulation magnetic pole group and the stator by molding resin.
It is something.

In this way, by using a molding resin with low thermal conductivity as the heat insulating portion, it is possible to improve the heat insulating performance.
Furthermore, by using the molded resin portion, the stator core 21 and the coil 22 can be integrated, and the modulated magnetic pole group 30 and the stator 20 can be integrated at the same time. This reduces the number of work steps and the processing time. In addition, since there is no need to prepare fixing members and heat insulating members separately, costs can be reduced.
In addition, if the molded resin portion is made of insulating resin, it is possible to prevent electrical corrosion caused by electrical conduction between the inner and outer rings of the shaft bearing, and it is possible to further improve the quality of the magnetic-geared motor. The same applies to the bracket.

In addition, the magnetic geared motor of this embodiment configured as described above has the following features:
The rotor, the modulated magnetic pole group, and the stator are arranged in this order from the inside to the outside in the radial direction.
It is something.

This type of configuration results in an inner rotor type rotating electric machine, which makes it possible to reduce the amount of expensive permanent magnets used in the rotor compared to a configuration in which the rotor is positioned radially outward, thereby providing an inexpensive magnetic geared motor.

In addition, the magnetic geared motor of this embodiment configured as described above has the following features:
The rotor is provided as a rotating body with a rotating magnetic field and a rotational force being applied thereto by the stator.
It is something.

The rotor can be rotated by the stator at a set reduction ratio, so the rotor can be the only rotating structure. This makes it possible to reduce the number of bearings, which are wear parts, for example, and provide an inexpensive magnetic geared motor.

In addition, the magnetic geared motor of this embodiment configured as described above has the following features:
The number of pole pairs of the stator, the number of pole pairs of the rotor, and the number of the pole pieces of the modulated magnetic pole group are configured to satisfy the following relationship:
Ns = N1 ± Nh
where Ns is the number of pole pairs of the stator, Nh is the number of pole pairs of the rotor, and N1 is the number of the pole pieces of the modulated magnetic pole group.
It is something.

In this way, the stator can control the rotation of the rotor at a set reduction ratio without the need for a high-speed rotor that receives rotational force from an external motor, etc.

Embodiment 2.
Hereinafter, the second embodiment of the present invention will be described with reference to the drawings, focusing on the differences from the first embodiment. The same parts as those in the first embodiment will be denoted by the same reference numerals, and the description thereof will be omitted.
FIG. 11 is a perspective view showing a schematic configuration of a magnetic-geared motor 200 according to the second embodiment.
FIG. 12 is a cross-sectional view in a direction parallel to the axial direction, showing a schematic configuration of a stator 20 and a molded resin portion 440 of a magnetic-geared motor 200 according to the second embodiment.
FIG. 13 is a perspective cross-sectional view showing a schematic configuration of a molded resin portion 440 of a magnetic-geared motor 200 according to the second embodiment.

The magnetic-geared motor 200 of this embodiment differs from the first embodiment in the shape of the end portion of the molded resin portion 440 on the axial lower side Y2 side. In the first embodiment, the molded resin portion 40 is located at the same position in the axial direction Y as the end face of the axial lower side Y2 of the modulation magnetic pole group 30. In this embodiment, as shown in FIG. 12, the end face of the axial lower side Y2 of the molded resin portion 440 is formed on the axial upper side Y1 by the length Yset shown in FIG. 12 from the end faces of the axial lower side Y2 of the stator 20 and the pole piece 31. As a result, the molded resin portion 40 is formed with a notch 440K as a recess recessed by the length Yset on the axial upper side Y1.
Thus, the space between the modulation magnetic pole group 30 and the stator 220 on the axial lower side Y2 is not sealed with molded resin, and a portion of the modulation magnetic pole group 30 is exposed from the end face of the molded resin part 440 on the axial lower side Y2.

A method for manufacturing the magnetic-geared motor 200 of this embodiment having such a configuration will be described below.
FIG. 14 is a cross-sectional view in a direction parallel to the axial direction of magnetic-geared motor 200 for explaining a manufacturing method for forming molded resin portion 440 according to the second embodiment.
FIG. 15 is an enlarged cross-sectional view of a portion of magnetic-geared motor 200 taken in a direction perpendicular to the axial direction, showing the configuration of molded resin portion 440 according to the second embodiment.

First, the pole pieces 31 of the modulation magnetic pole group 30 are evenly arranged in the circumferential direction, and the stator core 21 is arranged at a set interval on the radially outer side X2 of the pole pieces 31. At this time, the stator core 21 is in a state where the coils 22 have been wound around the teeth portions 21T.
Here, a mold 60 consisting of an upper mold 60U and a lower mold 60D is prepared.
The lower die 60D has a protruding portion 60P that protrudes by a length Yset on the axially upper side Y1. The lower die 60D is disposed on the axially lower side Y2 of the modulation magnetic pole group 30 and the stator 20 so that the protruding portion 60P is inserted between the modulation magnetic pole group 30 and the stator 20.

As shown in FIG. 15, the surface of the radially inner X1 end of the teeth 21T is the abutment surface A1, and the surface of the end of the protrusion 21T1 of the teeth 21T on the circumferential S side is the abutment surface A2. The surface of the radially outer X2 end of the pole piece 31 is the abutment surface A3, and the end surface of the pole piece 31 on the circumferential S side is the abutment surface A4.

The protruding portion 60P of the lower die 60D has a structure including abutment surfaces that come into contact with the abutment surfaces A1 and A2 of the teeth portion 21T and the abutment surfaces A3 and A4 of the pole piece 31, respectively.
When the protruding portion 60P of the lower die 60D is inserted into the gap between the pole piece 31 and the teeth portion 21T, the pole piece 31 is positioned relative to the teeth portion 21T in the radial direction X and circumferential direction S by the gap fit. Then, with the abutment surfaces A1, A2 of the teeth portion 21T and the abutment surfaces A3, A4 of the pole piece 31 being supported by the protruding portion 60P of the lower die 60D, resin is molded between the modulation magnetic pole group 30 and the stator 220 to form the molded resin portion 440.

The molded resin part 440 thus formed has dimensions determined by the protruding part 60P of the lower mold 60D, and includes first support parts B1, B2 that support the abutment surfaces A1, A2 of the teeth part 21T, and second support parts B3, B4 that support the abutment surfaces A3, A4 of the pole piece 31, as shown in FIG. 15. In this way, the relative position of the modulated magnetic pole group 30 in the radial direction X and circumferential direction S with respect to the stator core 21 is secured.

The manufacturing method of the magnetic-geared motor of the present embodiment configured as described above is as follows:
a die having a protruding portion protruding from one axial end side is disposed on the other axial end side of the modulation pole group so that the protruding portion is inserted between the modulation pole group and the stator;
In a state where a circumferential end portion and a radially inner end portion of the teeth portion and a circumferential end portion and a radially outer end portion of the modulation magnetic pole group are supported by the protruding portion of the mold,
forming the molded resin portion by molding a resin between the modulation magnetic pole group and the stator, and fixing a relative position of the modulation magnetic pole group with respect to the stator by the molded resin portion;
It is something.

In this way, the modulation pole group can be positioned relative to the stator teeth using a mold, which makes it possible to suppress variation in relative position, thereby reducing torque pulsation and contributing to stabilizing performance. In addition, the modulation pole group can be easily positioned relative to the stator teeth.
In this embodiment, an example has been shown in which the protrusion 60P is inserted only on the axially lower side Y2 between the modulated magnetic pole group 30 and the stator 220, but the protrusion may be inserted on the axially upper side Y1, or the protrusion 60P may be inserted on both the axially upper side Y1 and the axially lower side Y2.

Embodiment 3.
Hereinafter, the third embodiment of the present invention will be described with reference to the drawings, focusing on the differences from the first embodiment. The same parts as those in the first embodiment will be denoted by the same reference numerals and the description thereof will be omitted.
FIG. 16 is a cross-sectional view in a direction parallel to the axial direction, showing a schematic configuration of a magnetic-geared motor 300 according to the third embodiment.
The method of fixing the modulated magnetic pole group 30 is different from that of the first embodiment. In the first and second embodiments, the molded resin portion 40, 440 is used as a heat insulating portion for insulating the modulated magnetic pole group from the stator. In the present embodiment, a gap portion 340 is interposed between the modulated magnetic pole group and the stator as this heat insulating portion.

To form this gap 340, the modulation magnetic pole group 30 uses a connecting member 340A as a heat insulating portion, which is yet another member.
The axial upper side Y1 of the multiple modulation pole groups 30 arranged evenly in the circumferential direction S is fixed to the connecting member 340A with an adhesive or the like. The connecting member 340A is made of a non-magnetic material, such as stainless steel or resin. The connecting member 340A is fixed to the molded part of the stator 20 with a screw. Furthermore, the length of the axial direction Y of the modulation pole group 30 is made longer than the length of the axial direction Y of the stator core 21, and the bracket 51 is fixed to the axial lower side Y2 of the modulation pole group 30 with a screw. In this way, both ends of the modulation pole group 30 in the axial direction Y can be fixed. This allows the modulation pole group 30 to be fixed more firmly.

In the magnetic-geared motor of this embodiment configured as described above,
The heat insulating portion is
A gap is provided between the modulated magnetic pole group and the stator.
It is something.

By providing a gap with low thermal conductivity and high thermal insulation between the modulated magnetic pole group and the stator in this way, it is possible to reduce the transfer of heat generated in the stator coil to the modulated magnetic pole group, making it possible to obtain the desired torque, reduce the amount of material used, and reduce the volume of the magnetic geared motor. Furthermore, by using a connecting member that fixes the modulated magnetic pole group to the molded part of the stator as one of the elements that make up this thermal insulation section, the relative position of the modulated magnetic pole group to the stator can be secured.

Hereinafter, a configuration example will be described in which both a molded resin portion and an air gap are used as a heat insulating portion for insulating the modulated magnetic pole group and the stator.
FIG. 17 is a cross-sectional view in a direction perpendicular to the axial direction showing an example of the structure of a heat insulating portion of a magnetic-geared motor according to the third embodiment.
As shown in the figure, a gap 340H may be provided in the molded resin portion 40 between the pole piece 31 and the stator core 21 so as to extend in the axial direction Y.
If at least one end of the gap 340H in the axial direction Y is configured to be open on the axial end side of the molded resin part 40, heat within the molded resin part 40 can be dissipated to the outside.

In the magnetic-geared motor of this embodiment configured as described above,
In a configuration in which the heat insulating portion includes the mold resin portion and the gap portion,
The gap is formed to extend in the axial direction within the molded resin portion, and at least one end of the gap is open at an axial end side of the molded resin portion.
It is something.

By providing a void that penetrates the axial direction in this way within the molded resin section, a cooling air passage is created, improving the heat dissipation in the molded resin section. Furthermore, the amount of molded resin used is reduced, leading to cost savings.

Embodiment 4.
Hereinafter, the fourth embodiment of the present invention will be described with reference to the drawings, focusing on the differences from the first embodiment. The same parts as those in the first embodiment will be denoted by the same reference numerals, and the description thereof will be omitted.
FIG. 18 is a cross-sectional view in a direction parallel to the axial direction, showing a schematic configuration of a magnetic-geared motor 400 according to the fourth embodiment.
In the magnetic-geared motor 400 according to the fourth embodiment, a fan 415 is provided on the rotor 10. Also, a hole 440H is provided in the molded resin part 40, which communicates between the external space of the magnetic-geared motor 400 and the space around the rotor 10. Also, a hole 451H is provided in the bracket 51, which communicates between the external space of the magnetic-geared motor 400 and the space around the rotor 10.

Furthermore, a third support portion 540K that supports the axial lower side Y2 of the pole piece 31 is formed in the molded resin portion 40. Both ends of the third support portion 540K in the circumferential direction S are connected to the molded resin portion 40 that fills the space between the pole pieces 31.

First, the fan 415 is provided on the axially upper side Y1 of the housing that accommodates the bearing 50A by the molded resin part 40. In this manner, the fluid can be circulated by the fan 415 together with the rotation of the rotor 10, which is advantageous for cooling the magnetic-geared motor 400.
Furthermore, a hole 440H is provided in the molded resin part 40 near where the fan 415 is provided, which connects the external space of the magnetic-geared motor 400 with the space around the rotor 10. This allows the fluid whose temperature has increased around the rotor 10 to be expelled to the outside, making cooling more effective.

Furthermore, the hole 451H provided in the bracket 51 allows the fan 415 to rotate, allowing fluid to flow continuously from the axial lower side Y2 to the axial upper side Y1 of the magnetic-geared motor 400, thereby further improving the cooling efficiency of the magnetic-geared motor 400.

In the magnetic-geared motor of this embodiment configured as described above,
a fan provided on a rotation shaft of the rotor;
and a hole formed on at least one side in the axial direction, the hole communicating a space around the rotor with an external space of the magnetic-geared motor.
It is something.

This can further improve the cooling efficiency of the magnetic-geared motor. Thus, even when the modulation poles are fixed to the coils that generate heat, the heat generated in the stator coils can be efficiently cooled and the desired torque can be obtained.
In addition, by efficiently cooling a magnetic-geared motor, it is possible to increase the output for the same volume, or reduce the volume for the same output. It is also possible to reduce material costs by lowering the heat resistance grade of the permanent magnet and reducing the cross-sectional area of the coil.

In the magnetic-geared motor of the present embodiment configured as described above,
The molded resin portion includes a third support portion that supports an axial end portion of the pole piece.
It is something.

In the molded resin part 440 shown in the second embodiment, a notch 440K was formed to position the modulation pole group 30 in the radial direction X and circumferential direction S relative to the stator 20. Therefore, the molded resin was not present on the axially lower side Y2 than the end face of the axially lower side Y2 of the modulation pole group 30, but in this embodiment, as shown in FIG. 18, a third support part 540K is formed to support the end of the axially lower side Y2 of the modulation pole group 30. With this configuration, for example, it is possible to prevent the modulation pole group 30 from being displaced in the axial direction Y due to rotational vibrations, etc. In addition, a wider range of the modulation pole group 30 can be fixed by the molded resin, which makes it possible to increase the fixing strength of the modulation pole group 30 and improve the cooling efficiency.

Embodiment 5.
Hereinafter, the fifth embodiment of the present invention will be described with reference to the drawings, focusing on the differences from the first embodiment. The same parts as those in the first embodiment will be denoted by the same reference numerals, and the description thereof will be omitted.
FIG. 19 is a cross-sectional view in a direction parallel to the axial direction, showing a schematic configuration of a magnetic-geared motor 500 according to the fifth embodiment.

The magnetic-geared motor 100 of the first embodiment has an inner rotor type configuration in which the rotor 10, the modulated magnetic pole group 30, and the stator 20 are arranged in this order from the radial inside X1 to the radial outside X2.
The magnetic-geared motors 500 and 500A of the present embodiment have an outer rotor type configuration in which the stator 20, the modulated magnetic pole group 30, and the rotor 10 are arranged in this order from the radially inner side X1 to the radially outer side X2. The rotation speed of the magnetic field generated by the stator 20 is higher than the rotation speed of the rotor 10.

A through hole is provided in the radial center of the stator 20, penetrating in the axial direction, and the shaft 11 is inserted into it. The stator core 21 is fixed to the radial outside X2 of this shaft 11. As in the first embodiment, in the stator 20, an electromagnet is formed by winding a coil 22 around the stator core 21. Also, on the radial outside X2 of the stator core 21, a modulated magnetic pole group 30 has multiple magnetic pole pieces 31 arranged with gaps set in the circumferential direction S, and is fixed integrally with the stator 20 by a molded resin part 40.

A permanent magnet 13 is arranged opposite the modulated magnetic pole group 30 with a gap in the radial direction X. This permanent magnet 13 is fixed to the rotor core 12 and is magnetized in the radial direction. Brackets 51 are arranged on both ends of the rotor core 12 in the axial direction Y, and a pair of bearings 51A, 51B are located at the axial center of the brackets 51. In other words, in this embodiment, the rotor 10 rotates at the outermost radial position X2.

In this embodiment, the shaft 11 does not rotate. The shaft 11 is a hollow cylindrical part, and a cable for passing electricity to the coil 22 of the stator 20 can be passed through its inner diameter. In this way, there is no concern that the electricity-carrying cable will get entangled even when the rotor 10 rotates.

FIG. 20 is a cross-sectional view in a direction parallel to the axial direction, showing a schematic configuration of a magnetic-geared motor 500A according to the fifth embodiment.
The magnetic-geared motor 500A shown in Figure 20 is a fan driver (ventilator) and has a structure in which a blade portion 515 extending radially outward X2 is attached to the end face of the rotor 10 of the magnetic-geared motor 500 shown in Figure 11 on the radially outward X2.
In other words, air can be blown out by rotating the rotor 10 to drive the fan.

In the inner rotor type shown in embodiment 1, the blades must be attached to a position where the shaft 11 is extended in the axial direction Y, which results in a long axial length as a fan drive. However, in this embodiment, it is only necessary to attach the blade portion 515 directly to the outer diameter portion of the rotor 10, which is advantageous for products where it is desired to shorten the axial length Y.

Furthermore, fan boss portions 516 that house the stator 20 are provided at both ends of the rotor 10 in the axial direction Y. The fan boss portions 516 are rotatably supported by the shaft 11 via bearings 51A and 51B, and the fan boss portions 516 rotate in conjunction with the rotation of the rotor 10.

In the magnetic-geared motor of this embodiment configured as described above,
The stator, the modulated magnetic pole group, and the rotor are arranged in this order from the inside to the outside in the radial direction.
It is something.

This configuration results in an outer rotor type rotating electric machine, which reduces the amount of material used for the stator compared to when the stator is positioned radially outward.

In the magnetic-geared motor of the present embodiment configured as described above,
A blade portion extending radially outward is provided on a radially outer end surface of the rotor.
It is something.

In this way, it is possible to reduce the number of parts compared to when a separate member is fixed to the radial outside of the rotor and then fixed to the blade portion. This makes it possible to provide a high-performance fan drive with a simplified structure.

In the magnetic-geared motor of the present embodiment configured as described above,
A rotating shaft of the rotor is inserted into a through hole that is provided in a radial center of the stator and passes through the stator in an axial direction,
a fan boss portion for accommodating the stator is provided at both axial ends of the rotor, the fan boss portion is rotatably supported by the rotating shaft via a bearing, and the fan boss portion rotates in accordance with the rotation of the rotor;
It is something.

In this way, the blades are provided radially outward of the rotor, and the stator and rotor of the magnetic-geared motor are housed within the fan boss. By housing each component that makes up the magnetic-geared motor within the fan boss in this way, the components that make up the magnetic-geared motor are not in the air path when the blades rotate. This makes it possible to increase the efficiency of electrical equipment without increasing wind loss.

Although the present application describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to application to a particular embodiment, but may be applied to the embodiments alone or in various combinations.
Therefore, countless modifications not exemplified are assumed within the scope of the technology disclosed in the present application, including, for example, modifying, adding, or omitting at least one component, and further, extracting at least one component and combining it with a component of another embodiment.

10 rotor, 20 stator, 21 stator core, 21Y back yoke portion,
21T teeth portion, 22 coil, 30 modulated magnetic pole group, 31 magnetic pole piece,
40, 440 molded resin portion (insulating portion), 340, 340H gap portion (insulating portion),
B1, B2 first support part, B3, B4 second support part, 540K third support part,
440K: notch (recess); 415: fan; 440H, 451H: hole;
515 Blade portion, 516 Fan boss portion,
100, 300, 400, 500, 500A magnetic geared motors.

Claims (13)

A rotor having a magnetic pole pair in a circumferential direction;
a stator that is disposed coaxially with the rotor with a gap therebetween in the radial direction, the stator having a coil that functions as an electromagnet, the coil forming a magnetic pole pair in the circumferential direction to generate a rotating magnetic field;
a modulation pole group provided between the stator and the rotor, each having a plurality of pole pieces arranged with a gap set in the circumferential direction, for modulating a magnetic flux between the stator and the rotor to change a rotation speed of the rotating magnetic field and transmit the changed magnetic flux to the rotor;
the modulation magnetic pole group is fixed to the stator via a heat insulating portion, and a relative position of the modulation magnetic pole group with respect to the stator is fixed by the heat insulating portion ;
The rotor is provided as a rotating body with a rotating magnetic field and a rotational force being applied thereto by the stator.
Magnetic geared motor. The heat insulating portion is
The magnetic pole piece is configured to have at least one of a molded resin portion formed by molding a resin between the magnetic pole piece and the stator, and a gap portion formed between the magnetic pole piece and the stator.
The magnetic geared motor according to claim 1 . the stator has a stator core including an annular back yoke portion and a plurality of teeth protruding radially inwardly from the back yoke portion at predetermined intervals in the circumferential direction,
The coil is wound around the teeth,
In a configuration in which the heat insulating portion has the molded resin portion,
The molded resin portion includes a first support portion that supports a circumferential end portion and a radially inner end portion of the teeth portion, and a second support portion that supports a circumferential end portion and a radially outer end portion of the modulation magnetic pole group.
The magnetic geared motor according to claim 2 . The molded resin portion includes a third support portion that supports an axial end portion of the pole piece.
The magnetic geared motor according to claim 3 . Among the end faces at both ends in the axial direction of the molded resin portion, at least one end face is formed on the other axial end side with respect to the end faces at the one axial end of the stator and the pole pieces.
5. The magnetic geared motor according to claim 3 or 4. In a configuration in which the heat insulating portion includes the mold resin portion and the gap portion,
The gap is formed to extend in the axial direction within the molded resin portion, and at least one end of the gap is open at an axial end side of the molded resin portion.
The magnetic geared motor according to any one of claims 3 to 5. The rotor, the modulated magnetic pole group, and the stator are arranged in this order from the inside to the outside in the radial direction.
The magnetic geared motor according to any one of claims 1 to 6. a fan provided on a rotation shaft of the rotor;
and a hole formed on at least one side in the axial direction, the hole communicating a space around the rotor with an external space of the magnetic-geared motor.
The magnetic geared motor according to any one of claims 1 to 7. The stator, the modulated magnetic pole group, and the rotor are arranged in this order from the inside to the outside in the radial direction.
The magnetic geared motor according to any one of claims 1 to 7. A blade portion extending radially outward is provided on a radially outer end surface of the rotor.
The magnetic geared motor according to claim 9. A rotating shaft of the rotor is inserted into a through hole that is provided in a radial center of the stator and passes through the stator in an axial direction,
a fan boss portion for accommodating the stator is provided at both axial ends of the rotor, the fan boss portion is rotatably supported by the rotating shaft via a bearing, and the fan boss portion rotates in accordance with the rotation of the rotor;
The magnetic geared motor according to claim 10. The number of pole pairs of the stator, the number of pole pairs of the rotor, and the number of the pole pieces of the modulated magnetic pole group are configured to satisfy the following relationship:
Ns = N1 ± Nh
where Ns is the number of pole pairs of the stator, Nh is the number of pole pairs of the rotor, and N1 is the number of the pole pieces of the modulated magnetic pole group.
The magnetic geared motor according to any one of claims 1 to 11 . A method for manufacturing a magnetic-geared motor according to claim 5, comprising the steps of:
a die having a protruding portion protruding from one axial end side is disposed on the other axial end side of the modulation pole group so that the protruding portion is inserted between the modulation pole group and the stator;
In a state where a circumferential end portion and a radially inner end portion of the teeth portion and a circumferential end portion and a radially outer end portion of the modulation magnetic pole group are supported by the protruding portion of the mold,
forming the molded resin portion by molding a resin between the modulation magnetic pole group and the stator, and fixing a relative position of the modulation magnetic pole group with respect to the stator by the molded resin portion;
A manufacturing method for a magnetic geared motor.