JP6545393B2 - Conscious pole rotor, motor and air conditioner - Google Patents

Description

  BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to a consistent pole type rotor, a motor and an air conditioner.

  Conventionally, in order to improve the energy saving property of the air conditioner, a rare earth magnet having a high energy density such as a neodymium sintered magnet is generally used as a permanent magnet of a motor mounted on a compressor of the air conditioner. In addition, a motor using a neodymium sintered magnet has been developed for a fan of an air conditioner.

  Such permanent magnets are expensive because they contain valuable rare earth elements. Therefore, there is a strong demand for reducing the usage amount and processing cost of permanent magnets to reduce the cost.

  Permanent magnets are generally machined into block-shaped masses into specified shapes. Therefore, as the number of permanent magnets used in the motor increases, the processing cost increases.

  As a method of reducing the number of permanent magnets used in the motor, there is a method of configuring the rotor with so-called contingent poles. In a consistent pole type rotor, magnet magnetic poles by permanent magnets and salient poles formed on a core material regardless of permanent magnets are alternately arranged in the circumferential direction. Therefore, the number of magnet poles and the number of salient poles are both half the number of poles. Further, the magnet poles having half the number of poles have the same polarity, and the salient poles having half the number of poles have a polarity different from that of the magnet poles. As described above, in the case of a consistent pole type rotor, the number of permanent magnets is half that of a normal one. However, in the consistent pole type rotor, the inductance differs between the magnet magnetic pole and the salient pole, and there is a problem that vibration and noise become large due to the unbalance of the inductance.

  To solve this problem, the consistent pole type rotor disclosed in Patent Document 1 improves the asymmetry of the inductance by devising the shape of the flux barrier at both ends of the permanent magnet, and aims to reduce vibration and noise. ing. An electric motor using a consistent pole type rotor disclosed in Patent Document 1 includes a magnetic sensor for detecting a position in a rotational direction of the rotor, and the magnetic sensor leaks in an axial direction from magnet poles of the rotor. The rotation control of the rotor is performed by alternately detecting the magnetic field 1 and the second magnetic field leaking in the axial direction from the salient pole of the rotor.

JP 2012-244783

  However, in the consistent pole type rotor disclosed in Patent Document 1, since the magnetic flux leaking in the axial direction from the magnet pole is larger than the magnetic flux leaking in the axial direction from the salient pole, the first magnetic field detected by the magnetic sensor And the second magnetic field may become unbalanced, and the detection accuracy of the rotational position may decrease.

  The present invention has been made in view of the above, and it is an object of the present invention to obtain a consistent pole type rotor capable of improving the detection accuracy of the rotational position.

  In order to solve the problems described above and achieve the object, a consistent pole type rotor according to the present invention has a plurality of permanent magnets, and a first magnetic pole portion of a first polarity by the permanent magnets; A rotor core having a second magnetic pole portion of a second polarity different from the first polarity formed between adjacent permanent magnets, and an annular magnet provided at one axial end of the rotor core And the annular magnet is arranged in the rotational direction of the rotor core, and has a plurality of position detection magnets for detecting the positions of the first magnetic pole portion and the second magnetic pole portion of the rotor core And a plurality of connecting portions provided between adjacent position detection magnets and connecting the adjacent position detection magnets to each other, wherein the plurality of position detection magnets are arranged in the axial direction of the rotor core of the rotor core. The polarity of the magnetic pole of the end face on the opposite side is the same as the second polarity.

  The consistent pole type rotor according to the present invention has an effect that the detection accuracy of the rotational position can be improved.

Cross-sectional view of a motor provided with a consistent pole type rotor according to Embodiment 1 of the present invention Sectional view of the mold stator shown in FIG. Sectional drawing which shows the state in which the rotor was inserted in the mold stator shown in FIG. A block diagram of a stator core constructed of a plurality of divided core parts and developed in a band shape The figure which shows the state which bend | folded the expanded stator core shown in FIG. 4, and comprised cyclically | annularly Sectional view of the rotor shown in FIG. 1 A perspective view of a consistent pole type rotor according to a first embodiment of the present invention Front view of the rotor shown in FIG. 7 FIG. 7 is a perspective view of the annular magnet shown in FIG. The figure which shows the 1st modification of the consistent pole type rotor which concerns on Embodiment 1 of this invention. Front view of the rotor shown in FIG. 10 is a perspective view of the annular magnet shown in FIG. The figure which shows the 2nd modification of the consistent pole type rotor concerning Embodiment 1 of this invention. Front view of the rotor shown in FIG. First perspective view of the annular magnet shown in FIG. 13 Second perspective view of the annular magnet shown in FIG. The figure which shows an example of a structure of the air conditioner which concerns on Embodiment 2 of this invention.

  Hereinafter, a consistent pole type rotor, a motor and an air conditioner according to an embodiment of the present invention will be described in detail based on the drawings. The present invention is not limited by the embodiment.

Embodiment 1
FIG. 1 is a cross-sectional view of a motor provided with a consistent pole type rotor according to a first embodiment of the present invention. The motor 100 shown in FIG. 1 includes a mold stator 10, a rotor 20, and a metal bracket 30 attached to one axial end of the mold stator 10. The “axial direction” is equal to the stacking direction of the plurality of rotor cores constituting the rotor 20. The motor 100 is a brushless DC motor that has a permanent magnet on a rotor 20 and is driven by an inverter. The rotor 20 is of the internal magnet type and of the consistent pole type.

  The mold stator 10 includes a stator 40 and a mold resin 50 covering the stator 40. The axial direction of the mold stator 10 coincides with the axial direction of the shaft 23 penetrating the rotor 20. In FIG. 1, the stator core 41, the coil 42 wound around the stator core 41, the insulating portion 43 provided on the stator core 41, and the insulating portion 43 which are components of the stator 40 are provided. And the neutral point terminal 44b is shown. Further, in FIG. 1, a substrate 45 attached to the insulating portion 43, which is a component of the stator 40, a lead wire lead-out component 46 assembled to the substrate 45, and a lead wire 47 lead out from the lead wire lead-out component 46 , An IC (Integrated Circuit) 49 a mounted on the substrate 45, and a Hall IC 49 b which is a magnetic sensor mounted on the surface of the substrate 45 on the side of the rotor 20 are shown.

  The rotor 20 includes a shaft assembly 27, a resin portion 24 that integrates the rotor 20 main body and the shaft assembly 27, and a load-side roller mounted on the shaft 23 and supported by the bearing support 11 of the molded stator 10. A bearing 21 a and a non-load side rolling bearing 21 b attached to the shaft 23 and supported by the bracket 30 are provided. The load side 110 represents the end face side where the shaft 23 protrudes out of both end faces of the motor 100, and the anti-load side 120 represents the end face side where the bracket 30 is provided.

  Further, the rotor 20 is installed at one end 5a of the rotor core 5 in the axial direction, and a plurality of position detection magnets 70 for detecting the position of the rotor core 5 in the rotation direction, A plurality of connecting parts 71 which connect 70 are provided. The Hall IC 49 b alternately detects the magnetic field generated in the axial direction from the position detection magnet 70 and the magnetic field generated in the axial direction from the first magnetic pole portion described later, and has a pulse shape corresponding to the detected magnetic field Output a signal. The IC 49a performs rotation control of the rotor 20 by calculating the position in the rotation direction of the rotor 20 based on the signal output from the Hall IC 49b. The detailed configuration of the position detection magnet 70 and the connecting portion 71 will be described later. In the present embodiment, the Hall IC 49b is used as a position detection means for detecting the position of the rotor core 5 in the rotational direction, but the position detection means is not limited to the Hall IC 49b. An element that alternately detects the magnetic field generated in the axial direction and the magnetic field generated in the axial direction from the first magnetic pole portion may be used.

  The shaft assembly 27 includes an insulating sleeve 26 consisting of a pair of insulating sleeves 26-1 and 26-2, and the insulating sleeve 26 is disposed between the non-load side rolling bearing 21b and the shaft 23.

  FIG. 2 is a cross-sectional view of the mold stator shown in FIG. In FIG. 2, the same components as in FIG. 1 are assigned the same reference numerals. In the mold stator 10, an opening 10b is formed at one axial end of the mold stator 10, and the rotor 20 is inserted into the opening 10b. A hole 11a larger than the diameter of the shaft assembly 27 of the rotor 20 shown in FIG. 1 is formed at the axial end of the molded stator 10 to which the load-side rolling bearing 21a of the rotor 20 inserted into the opening 10b is fitted. It is open.

  FIG. 3 is a cross-sectional view showing a state in which the rotor is inserted into the mold stator shown in FIG. In FIG. 3, the same components as in FIG. 1 are denoted by the same reference numerals. The rotor 20 inserted from the opening 10b of the molded stator 10 shown in FIG. 2 is arranged such that the load side of the shaft assembly 27 is pulled out of the molded stator 10 through the hole 11a shown in FIG. Ru. At this time, the load-side rolling bearing 21 a attached to the shaft 23 is pushed into contact with the bearing support 11 shown in FIG. 1 and supported by the bearing support 11. The bearing support 11 is an axial end of the mold stator 10 and is provided on the opposite side of the opening 10 b.

  On the non-load side of the shaft assembly 27, an anti-load side rolling bearing 21b is attached. The mounting of the anti-load side rolling bearing 21b is generally by press-fitting. Although details will be described later, an insulating sleeve 26 integrally formed with the shaft 23 is provided between the non-load side rolling bearing 21 b and the non-load side of the shaft 23.

  The bracket 30 shown in FIG. 1 closes the opening 10b of the molded stator 10 shown in FIG. 2 and supports the anti-load side rolling bearing 21b shown in FIG. . The bracket 30 includes a bearing support portion 30a and a press-fit portion 30b integrally formed with the bearing support portion 30a. The bearing support portion 30a supports the anti-load side rolling bearing 21b. The press-fit portion 30b has a ring shape.

  The bracket 30 is attached to the mold stator 10 by press-fitting the press-fit portion 30 b to the opening 10 b side of the inner peripheral portion 10 a of the mold stator 10. The outer diameter of the press-fit portion 30 b is larger than the inner diameter of the inner circumferential portion 10 a of the mold stator 10 by the press-fit margin. As a material of the bracket 30, a galvanized steel plate, an aluminum alloy, an austenitic stainless alloy, a copper alloy, cast iron, steel or iron alloy can be exemplified.

  The configuration of the mold stator 10 will be described below. The mold stator 10 shown in FIG. 2 includes a stator 40 and a mold resin 50 for molding. As the mold resin 50, unsaturated polyester resin is used. In particular, a mass clay-like thermosetting resin (Bulk Molding Compound: BMC) in which various additives are added to unsaturated polyester resin is desirable as a motor. Thermoplastic resins such as polybutylene terephthalate (PBT) and poly phenylene sulfide (PPS) are better because they can recycle runners during molding.

  However, unsaturated polyester resin and BMC have linear expansion coefficients close to that of iron-based materials such as stator core 41, load side rolling bearing 21a, and anti-load side rolling bearing 21b, and their thermal contraction rate is 1 of thermoplastic resin. By being 10/10 or less, it is excellent in obtaining a dimensional accuracy.

  In addition, when the outer shell of the motor 100 is formed of unsaturated polyester resin and BMC as compared with the case where the outer shell of the motor 100 is formed of metal such as iron and aluminum, the heat dissipation is excellent. When the outer shell of the motor 100 is formed of metal, the metal forming the outer shell of the motor 100 is separated from the coil 42 and the substrate 45 due to the insulation problem. On the other hand, since unsaturated polyester resin and BMC are insulators, there is no insulation problem even if the coil 42 and the substrate 45 are covered, and the thermal conductivity is also high, so the heat dissipation is excellent, and the high output of the motor 100 Contribute to

  The load side rolling bearing 21 a is supported by the bearing support 11 formed of the mold resin 50, and the anti-load side rolling bearing 21 b and the bracket 30 are supported by the inner circumferential portion 10 a formed of the mold resin 50. Therefore, when the dimensional accuracy of the mold resin 50 is poor, the axial center of the rotor 20 and the axial center of the stator 40 are displaced, which causes vibration and noise. However, the use of unsaturated polyester resin and BMC having a small heat shrinkage ratio makes it easy to ensure dimensional accuracy after molding.

  In addition, when a resin having a large linear expansion coefficient is used, rattling of the bearing may be a problem when the motor 100 becomes high temperature. The unsaturated polyester resin and BMC have a linear expansion coefficient close to that of an iron-based material such as the stator core 41, the load side rolling bearing 21a and the anti-load side rolling bearing 21b, and therefore rotate regardless of the temperature of the motor 100. Deviation between the axis of the child 20 and the axis of the stator 40 can be suppressed.

  In addition, since the unsaturated polyester resin and BMC restrain the stator 40 when it is cured, it is possible to suppress the deformation of the stator 40 accompanying the excitation force of the motor 100, and to suppress the vibration and the noise.

  FIG. 4 is a structural view of a stator core which is constituted by a plurality of divided core portions and developed in a band shape. In the stator core 41 shown in FIG. 4, the plurality of divided core portions 400 are arranged such that each of the plurality of divided core portions 400 is in contact with another adjacent one of the plurality of divided core portions 400. . Each of the plurality of split core portions 400 has a back yoke 401 and teeth 402 protruding from the back yoke 401. Thin portions 403 connecting the back yokes 401 are provided between the adjacent back yokes 401.

  FIG. 5 is a view showing a state in which the unfolded stator core shown in FIG. 4 is bent to form an annular shape. After the coil 42 of FIG. 1 is applied to each of the plurality of teeth 402 shown in FIG. 4, the annular stator core 41 shown in FIG. It is formed.

  As shown in FIG. 4 and FIG. 5, the stator core 41 configured of the plurality of divided core portions 400 can wind the coil 42 in a state of being expanded in a band shape, so high densification of the coil 42 is possible and the efficiency is high. It is effective for However, since the split core portion 400 is connected by the thin portion 403, the rigidity of the stator core 41 when formed in an annular shape is low, and a motor having a large excitation force such as the consistent pole type motor 100 is not suitable. It is effective to mold the stator core 41 with saturated polyester resin, that is, to cover the stator core 41 with unsaturated polyester resin.

  The stator core 41 formed of a plurality of divided core portions 400 has an uneven surface at the end of the back yoke 401 in addition to the structure in which the adjacent back yokes 401 are connected by the thin portion 403 as shown in FIG. It may have a structure in which the dowels are connected to each other by forming a shape-like dowel, or a structure in which a plurality of back yokes 401 separated from each other are fixed by welding or fitting. By covering the stator core 41 configured in this manner with unsaturated polyester resin, vibration and noise can be reduced.

  Thus, it is desirable to completely cover the stator core 41 with unsaturated polyester resin, but as shown in FIG. 2, from the outer peripheral portion 41-1 of the stator core 41 to the outer peripheral portion 10-1 of the unsaturated polyester resin Assuming that the thickness is T1 and the thickness from the inner circumferential portion 41-2 of the stator core 41 to the inner circumferential portion 10-2 of the unsaturated polyester resin is T2, the mold stator 10 satisfies the relationship of T1> T2. It is desirable to be configured to

  If the thickness T2 is too large, the diameter of the rotor 20 must be reduced, the magnetic gap between the stator core 41 and the rotor 20 becomes large, and the motor characteristics deteriorate. Therefore, in the molded stator 10 according to the first embodiment, the rigidity T1 of the radially outer side is increased by making the thickness T1 larger than the thickness T2. The “radial direction” indicates the radial direction of the rotor 20.

  If the shaft center of the rotor 20 and the shaft center of the stator 40 are offset and an imbalance occurs in the gap between the stator core 41 and the rotor 20, the excitation force due to the eccentricity is superimposed, The eccentricity should be assembled as small as possible. It is also effective to make the thickness T2 zero because the above-mentioned gap is more likely to be unbalanced when the thickness T2 is increased, in which case between adjacent teeth 402 of the stator core 41. Fill the space with unsaturated polyester resin up to the tip of the teeth. As the excitation force, there is also a force that shakes the tip of the teeth left and right, and completely filling the space between the teeth 402 leads to suppressing the influence of this force.

  Further, in the case of the stator core 41 shown in FIG. 4 and FIG. 5, by providing the unsaturated polyester resin on the division surface 404 between the adjacent divided core portions 400, the influence of the excitation force acting on the teeth 402 can be suppressed.

  Therefore, in the stator core 41, holes 405 are formed in the division surface 404 of the annular stator core 41 shown in FIG. The holes 405 are formed by providing a groove or a notch between the adjacent back yokes 401. When the unsaturated stator is molded on the annular stator core 41, the holes 405 are filled with the unsaturated polyester resin. The hole 405 does not have to be filled with unsaturated polyester in the entire area from one end face to the other end face of the stator core 41 in the axial direction, and is slightly filled from one end face of the stator core 41 in the axial direction. Even in this case, the effect of damping the vibration can be expected. The larger the holes 405 in order to increase the filling amount, the lower the magnetic properties. Therefore, the filling amount is appropriately determined. The same effect can be obtained even if the hole 405 of the dividing surface 404 has a groove shape opened to the outer peripheral surface of the stator core 41 or a groove shape opened to the slot 406 side.

  Next, the configuration of the rotor 20 shown in FIG. 1 will be described.

  6 is a cross-sectional view of the rotor shown in FIG. The rotor 20 has an annular rotor core 5 and five magnet insertion holes 2 arranged in the circumferential direction. The “circumferential direction” indicates the circumferential direction of the rotor 20. The number of magnet insertion holes 2 is half the number of poles of the rotor 20. The five magnet insertion holes 2 are arranged at equal intervals in the circumferential direction. The five magnet insertion holes 2 are disposed equidistant from the rotation shaft 6. The rotation axis 6 coincides with the axis of the rotor core 5. The five magnet insertion holes 2 penetrate in the axial direction of the rotor core 5. The magnet insertion hole 2 is formed near the outer peripheral surface of the rotor core 5 and extends in the circumferential direction. Adjacent magnet insertion holes 2 are spaced apart. The rotor core 5 has a shaft insertion hole 7 at its center.

  The rotor core 5 is formed of a core material which is a soft magnetic material, and specifically, is formed by laminating a plurality of electromagnetic steel plates. The thickness of one electromagnetic steel sheet is generally 0.1 mm to 0.7 mm.

  Five permanent magnets 1 are inserted into the five magnet insertion holes 2 respectively. The permanent magnet 1 is a flat plate having a rectangular cross section. The plate thickness of the permanent magnet 1 can be 2 mm, for example. The permanent magnet 1 is a rare earth magnet and is a neodymium sintered magnet having Nd (neodymium)-Fe (iron)-B (boron) as a main component.

  The magnet insertion hole 2 is composed of a rectangular first area 3A into which the permanent magnet 1 is inserted and two second areas 3B into which the permanent magnet 1 is not inserted. The second area 3B is a first area In the longitudinal direction of the region 3A, one region is formed. The second area 3B has the function of a flux barrier that suppresses the leakage flux a with respect to the permanent magnet 1 inserted in the first area 3A, and the magnetic flux density distribution on the outer peripheral surface of the rotor core 5 is It has a function close to a sine wave and short-circuiting the magnetic flux of the permanent magnet 1 inserted in the adjacent magnet insertion hole 2 via the rotor core 5.

  The rotor 20 has ten magnetic poles arranged on the outer peripheral surface of the rotor core 5 so as to alternate in polarity in the circumferential direction. Specifically, the rotor 20 is formed on five first magnetic poles each formed by five permanent magnets 1 and having the same polarity, and a rotor core 5 between the permanent magnets 1 adjacent to each other. It has five second magnetic poles having different polarities than the first magnetic pole. In the illustrated example, the first magnetic pole is N pole, and the second magnetic pole is S pole, but may be reversed. The ten magnetic poles of the rotor 20 are arranged at equal angular intervals in the circumferential direction, with the pole pitch being 360 degrees / 10 = 36 degrees.

  Thus, in the rotor 20 of the consistent pole type, five permanent magnets 1 having half the number of poles each provide five first magnetic poles. Furthermore, each of the five second magnetic poles having half the number of poles is formed in the core material of the rotor core 5 between the permanent magnets 1 adjacent to each other. The second magnetic pole is a so-called salient pole, and is formed by magnetizing the rotor 20.

  Therefore, in the rotor 20, the first magnetic pole portion 60 including the permanent magnet 1 and having the first polarity by the permanent magnet 1, and the core magnetic pole portion not including the permanent magnet 1 and the virtual second pole The second magnetic pole portions 61 are alternately arranged in the circumferential direction of the rotor 20. In the case of the consistent pole type rotor 20, the number of poles is an even number of 4 or more.

  The outer shape of the rotor core 5 is a so-called flower circle. The flower round shape is a shape in which the outer diameter of the rotor core 5 is maximum at the pole centers 62 and 63 and is minimum at the interpoles 64, and a shape from the pole centers 62 and 63 to the interpoles 64 is arc-shaped It is. The pole center 62 is the pole center of the first magnetic pole, and the pole center 63 is the pole center of the second magnetic pole. In the illustrated example, the flower round shape is a shape in which ten isomorphic and same size petals are arranged at uniform angles. Thus, the outer diameter of rotor core 5 at pole center 62 is equal to the outer diameter of rotor core 5 at pole center 63. The circumferential width of the magnet insertion hole 2 is wider than the pole pitch.

  FIG. 7 is a perspective view of a consistent pole type rotor according to Embodiment 1 of the present invention. FIG. 8 is a front view of the rotor shown in FIG. FIG. 9 is a perspective view of the annular magnet shown in FIG. The rotor 20 is provided at one end 5 a of the rotor core 5 in the axial direction, and includes a plurality of position detection magnets 70 for detecting the position of the rotor core 5 in the rotation direction. Between the position detection magnets 70 adjacent to each other, a plurality of connecting portions 71 each connecting the position detection magnets 70 are provided. An annular magnet 72 is formed by alternately connecting the position detection magnet 70 and the connecting portion 71.

  In each of the plurality of position detection magnets 70, the polarity of the magnetic pole of one end face 70 b 1 of each in the axial direction is the same as the second polarity of the second magnetic pole portion 61, and the rotation of the second magnetic pole portion 61 It is installed at the same phase as the phase in the direction. Specifically, the position detection magnet 70 is provided with two end surfaces 70b1 and 70b2 in the axial direction. The end surface 70 b 1 is an end surface of the position detection magnet 70 opposite to the rotor core 5. The polarity of the end face 70b1 is a south pole. The end surface 70 b 2 is an end surface on the rotor core 5 side of the position detection magnet 70. The polarity of the end face 70b2 is N pole. The magnetic flux direction of the position detection magnet 70 is axial as shown in FIG. The second magnetic pole portion 61 has a radially outer polarity of S pole and a radially inner polarity of N pole. The south pole of the second magnetic pole portion 61 corresponds to the second polarity described above. As shown in FIG. 7, the arrow from the N pole to the S pole of the second magnetic pole portion 61 indicates the magnetic flux direction of the second magnetic pole portion 61. Of the magnetic flux of the second magnetic pole portion 61, the magnetic flux leaking in the axial direction is assisted by the magnetic flux leaking in the axial direction from the position detection magnet 70, and is detected by the above-described Hall IC 49b. The first magnetic pole portion 60 has a radially outer polarity of N pole and a radially inner polarity of S pole. The N pole of the first magnetic pole portion 60 corresponds to the first polarity described above. As shown in FIG. 7, the arrow from the N pole to the S pole of the first magnetic pole portion 60 indicates the magnetic flux direction of the first magnetic pole portion 60. As a material of each of the plurality of position detection magnets 70, a bond magnet can be exemplified. By using a bonded magnet, the degree of freedom in processing of the position detection magnet 70 is higher than in the case of using a sintered magnet, so that the number of processing steps at the time of manufacturing the position detection magnet 70 is reduced. The manufacturing cost of 70 can be reduced.

  Each of the plurality of connecting portions 71 may be made of the same material as the mold resin 50 or may be made of a magnet of the same polarity as the first polarity of the first magnetic pole portion 60. By configuring the plurality of connecting portions 71 with the same material as the mold resin 50, the manufacturing cost of the rotor 20 can be reduced as compared to the case of configuring with the magnet.

  The thickness of the connecting portion 71 in the axial direction is T3, the thickness of the position detecting magnet 70 in the axial direction is T4, the thickness of the connecting portion 71 in the radial direction is T5, and the thickness of the position detecting magnet 70 in the radial direction is T6. The rotor 20 is configured such that the relationship of T4> T3 and T6> T5 is satisfied.

  In the consistent pole type rotor 20, the magnetic flux leaking axially from the first magnetic pole portion 60 is larger than the magnetic flux leaking axially from the second magnetic pole portion 61. Therefore, the first magnetic field detected in Hall IC 49b by the magnetic flux leaking in the axial direction from the first magnetic pole portion 60 and the second magnetic field detected in Hall IC 49b by the magnetic flux leaking in the axial direction from the second magnetic pole portion 61 And the unbalance with this may increase, and the detection accuracy of the rotational position may decrease.

  As described above, the rotor 20 according to the first embodiment includes the plurality of permanent magnets 1, and between the first magnetic pole portion 60 of the first polarity by the permanent magnets 1 and the adjacent permanent magnets 1. A rotor core 5 having a plurality of second magnetic pole portions 61 of a second polarity different from the formed first polarity, and provided at one end of the rotor core 5 in the axial direction of the rotor core 5 And the annular magnet 72 is arranged in the rotational direction of the rotor core 5 to detect the positions of the first magnetic pole portion 60 and the second magnetic pole portion 61 of the rotor core 5 The plurality of position detection magnets 70 for making the position detection magnet 70 and the plurality of connecting portions 71 provided between the adjacent position detection magnets 70 connect the adjacent position detection magnets 70 with each other. Further, in the plurality of position detection magnets 70 and the plurality of connection portions 71, the polarity of the magnetic pole of the end face 70b1 on the opposite side of the rotor core 5 in the axial direction of the rotor core 5 is the same as the second polarity. With this configuration, the magnetic flux leaking in the axial direction from the second magnetic pole portion 61 is assisted by the magnetic flux generated from the position detection magnet 70, so the second magnetic field detected by the Hall IC 49b is the position detection magnet 70. It becomes a large value compared with the case without it. This alleviates the imbalance between the first and second magnetic fields. In the first embodiment, the polarity of the end face 70b1 of the position detection magnet 70 may be the same polarity as the second polarity, and is not limited to the S pole. That is, when the second polarity of the second magnetic pole portion 61 is the N pole, the polarity of the end face 70b1 of the position detection magnet 70 is the N pole.

  Since the phases of the first magnetic pole portion 60 and the position detection magnet 70 detected in the Hall IC 49b in the rotational direction coincide with each other, the motor 100 shown in FIG. 1 has a magnetic flux leaking axially from the first magnetic pole portion 60. The position of the rotor 20 can be detected with high accuracy by utilizing the magnetic flux that leaks in the axial direction from the position detection magnet 70.

  The rotor 20 according to the first embodiment uses the number of position detection magnets 70 corresponding to half of the total number of magnetic poles, so compared to the case where the number of position detection magnets 70 corresponding to the total number of magnetic poles is used. Thus, it is possible to suppress an increase in the manufacturing cost of the rotor 20 while improving the position detection accuracy.

  Moreover, since the motor 100 according to the first embodiment uses the annular magnet 72, the assembly time of the rotor 20 is greater than when the plurality of position detection magnets 70 are separately manufactured and assembled to the rotor core 5 It can be shortened. Further, by using the annular magnet 72, it is possible to reduce the risk that the position detection magnet 70 is detached during assembly of the rotor 20 and the yield is reduced, and the position detection magnet 70 is detached during operation of the motor 100. The risk of being scattered within 100 can be reduced. Therefore, the motor 100 according to the first embodiment can improve the position detection accuracy while suppressing an increase in the manufacturing cost of the motor 100 and suppressing a decrease in quality.

The following method can be exemplified as a method of installing the annular magnet 72 on the rotor core 5.
(1) By providing a rib-like member (not shown) between the shaft 23 and the position detection magnet 70 and providing a rib-like member (not shown) between the shaft 23 and the connecting portion 71, the rotor core 5 An annular magnet 72 is installed.
(2) At one end 5a of the rotor core 5 in the axial direction, a plurality of pedestals (not shown) spaced apart in the circumferential direction are provided, and an annular magnet 72 is installed in the pedestal group.

  Below, the modification of the rotor 20 which concerns on Embodiment 1 is demonstrated.

  FIG. 10 is a diagram showing a first modified example of a consistent pole type rotor according to Embodiment 1 of the present invention. 11 is a front view of the rotor shown in FIG. FIG. 12 is a perspective view of the annular magnet shown in FIG.

  The difference between the rotor 20A shown in FIGS. 10, 11 and 12 and the rotor 20 shown in FIG. 7 is that the thickness of the connecting portion 71 in the radial direction is different. The rotor 20A is configured such that the relationship of T4> T3 and T5 = T6 is satisfied. Since the connecting portion 71 does not need a function to assist the magnetic flux leaking in the axial direction from the first magnetic pole portion 60, the thicknesses T3 and T5 of the connecting portion 71 are thinner than the thicknesses T4 and T6 of the position detection magnet 70. can do. Therefore, compared with the case where the thicknesses T3 and T5 of the connecting portion 71 are the same as the thicknesses T4 and T6 of the position detection magnet 70, the manufacturing cost of the annular magnet 72 can be reduced without lowering the position detection accuracy. The thicknesses T3 and T5 of the connecting portion 71 can be set in consideration of a strength that can prevent breakage of the rotors 20 and 20A at the time of manufacture and can prevent damage at the time of operation of the motor 100 shown in FIG.

  FIG. 13 is a diagram showing a second modified example of the consistent pole type rotor according to the first embodiment of the present invention. FIG. 14 is a front view of the rotor shown in FIG. FIG. 15 is a first perspective view of the annular magnet shown in FIG. FIG. 16 is a second perspective view of the annular magnet shown in FIG.

  The difference between the rotor 20B shown in FIGS. 13, 14 and 15 and the rotor 20 shown in FIG. 7 is that the annular magnet 72 of the rotor 20B has a plurality of projections 73 extending axially from the annular magnet 72. Is provided.

  As shown in FIGS. 15 and 16, each of the plurality of protrusions 73 is disposed closer to both end faces 70 a in the circumferential direction of the position detection magnet 70, and the other end face of the position detection magnet 70 in the axial direction It has a shape extending in the axial direction from the 70 b 2 side. More specifically, pedestals 74 are provided on both end faces 70 a in the circumferential direction of the position detection magnet 70. The pedestal 74 is disposed on the other end surface 70 b 2 of the position detection magnet 70 in the axial direction. The protrusion 73 is disposed on the pedestal 74 and is formed to extend in the axial direction on the opposite side of the pedestal 74 to the position detection magnet 70. The protrusion 73 and the pedestal 74 are manufactured by integral molding with the annular magnet 72.

  As shown in FIGS. 13 and 14, each of the plurality of protrusions 73 is inserted into the second area 3 </ b> B that constitutes the magnet insertion hole 2. At this time, the pedestal 74 is in contact with one end 5 a of the rotor core 5 to position each of the plurality of projections 73 in the axial direction.

  In motor 100 according to the present embodiment, the detection accuracy of the rotational position can be improved by matching the phases in the rotational direction of first magnetic pole portion 60 detected by Hall IC 49b and magnet 70 for position detection. . In the rotor 20B shown in FIGS. 13 to 16, the plurality of projections 73 inserted in the second region 3B function as positioning projections of the annular magnet 72 in the rotational direction. Therefore, in the rotor 20B, when assembling the annular magnet 72, it is possible to suppress a shift between the phase in the rotational direction of the position detection magnet 70 and the phase in the rotational direction of the second magnetic pole portion 61. Therefore, the motor 100 using the rotor 20B can improve the detection accuracy of the rotational position as compared with the motor 100 using the rotor 20 or the rotor 20A.

  Further, since the rotor 20B can be manufactured by integrally molding the projection 73 and the pedestal 74 with the annular magnet 72, the position detection magnet 70 and an axial positioning member (not shown) are separately manufactured to form the rotor core 5 Since the assembly time of the rotor 20 can be shortened and the number of parts to be manufactured can be reduced as compared with the case of assembly, the yield can be improved and the increase in the manufacturing cost of the rotor 20B can be suppressed.

Second Embodiment
FIG. 17 is a diagram showing an example of the configuration of an air conditioner according to Embodiment 2 of the present invention. The air conditioner 300 includes an indoor unit 310 and an outdoor unit 320 connected to the indoor unit 310. An indoor unit blower (not shown) is mounted on the indoor unit 310, and an outdoor unit blower 330 is mounted on the outdoor unit 320. In addition, the compressor 340 is mounted on the outdoor unit 320. The motor 100 according to the first embodiment is used for the indoor unit blower, the outdoor unit blower 330, and the compressor 340.

  As described above, by using the motor 100 according to Embodiment 1 as a drive source of the indoor unit blower, the outdoor unit blower 330, and the compressor 340, the accuracy of the rotational position detection is improved to improve the motor efficiency. In addition, the air conditioner 300 can be obtained which can suppress the manufacturing cost.

  Motor 100 according to Embodiment 1 can also be mounted on an electric device other than air conditioner 300, and in this case also, the same effect as that of the present embodiment can be obtained.

  The configuration shown in the above embodiment shows an example of the contents of the present invention, and can be combined with another known technique, and one of the configurations is possible within the scope of the present invention. Parts can be omitted or changed.

  DESCRIPTION OF SYMBOLS 1 permanent magnet, 2 magnet insertion hole, 3A 1st area | region, 3B 2nd area | region, 5 rotor core, 5a one end part, 6 rotating shaft, 7 shaft insertion hole, 10 mold stator, 10-1, 41- DESCRIPTION OF SYMBOLS 1 outer peripheral part, 10-2, 10a, 41-2 inner peripheral part, 10b opening part 11, 30a bearing support part, 11a, 405 hole, 20, 20A, 20B rotor, 21a load side rolling bearing, 21b anti load Side rolling bearing, 23 shaft, 24 resin part, 26, 26-1 insulating sleeve, 27 shaft assembly, 30 bracket, 30b press-fit part, 40 stator, 41 stator core, 42 coil, 43 insulating part, 44b neutral point Terminal, 45 substrate, 46 lead wire extraction part, 47 lead wire, 49b Hall IC, 50 mold resin, 60 first magnetic pole portion, 61 second magnetic pole portion 62, 63 pole center, 61a, 61b, 70a, 70b1, 70b2 end face, 64 poles, 70 position detection magnets, 71 connecting portions, 72 annular magnets, 73 protrusions, 74 pedestals, 100 motor, 110 load side, 120 non-load side, 300 air conditioners, 310 indoor units, 320 outdoor units, 330 outdoor unit blowers, 340 compressors, 400 split core portions, 401 back yokes, 402 teeth, 403 thin wall portions, 404 split surfaces, 406 slots .

Claims (9)

A second magnetic pole of a second polarity different from the first polarity formed between the adjacent permanent magnets and having a plurality of permanent magnets, the first magnetic pole portion of the first polarity by the permanent magnets A rotor core having a portion;
An annular magnet provided at one axial end of the rotor core;
Equipped with
The annular magnet is
A plurality of position detection magnets, arranged in the rotational direction of the rotor core, for detecting the positions of the first magnetic pole portion and the second magnetic pole portion of the rotor core;
A plurality of connecting parts provided between the adjacent position detection magnets and connecting the adjacent position detection magnets together;
Equipped with
The plurality of position detection magnets are
A consistent pole type rotor in which the polarity of the magnetic pole of the end face on the opposite side to the rotor core in the axial direction of the rotor core is the same as the second polarity.   The consequent pole type according to claim 1, wherein the plurality of position detection magnets are arranged at a position where the phase in the rotational direction of the rotor core coincides with the phase in the rotational direction of the second magnetic pole portion. Rotor.   The rotor according to claim 1 or 2, wherein the plurality of position detection magnets are connected to each other by a connecting portion having a thickness smaller than the thickness of the position detection magnets. The rotor core includes a plurality of magnet insertion holes into which the permanent magnet is inserted,
The plurality of position detection magnets include protrusions for positioning the position detection magnets.
The consequent pole type according to any one of claims 1 to 3, wherein the projection is inserted in a region between the permanent magnet inserted into the magnet insertion hole and the magnet insertion hole. Rotor.   5. The consistent pole rotor according to claim 4, wherein a pedestal in contact with one end of the rotor core is provided between the position detection magnet and the projection.   The thickness of the said position detection magnet is larger than the thickness of the said connection part, The rotor of the consistent pole type as described in any one of Claims 3-5.   The rotor according to any one of claims 1 to 6, wherein the position detection magnet is a bonded magnet.   A motor comprising the stator of the contingent pole type according to any one of claims 1 to 7 and a stator.   An air conditioner comprising the motor according to claim 8.

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