JP4050190B2 - Motor armature core - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an armature core of a motor formed by compression molding magnetic metal powder provided with an insulating film.
[0002]
[Prior art]
In an electric motor, an eddy current loss proportional to the square of the number of revolutions is generated in the armature core due to the rotation of the armature, and the iron loss increases as the rotation speed becomes higher. Therefore, it is known that the motor efficiency deteriorates. Yes. Conventionally, a laminated core composed of a plurality of core sheets has been used to reduce the iron loss. That is, as shown in FIG. 16, the laminated core 41 is manufactured by punching a cold-rolled steel plate 42 with a high-speed crank press to form a core sheet 43, and laminating a plurality of the core sheets 43. . In this laminated core 41, since it is insulated between the layers of each core sheet 43, iron loss can be reduced, but eddy current flows in each core sheet 43.
[0003]
As a technique for reducing iron loss, an armature core (powder core) is manufactured by compression molding of magnetic metal powder (such as pure iron powder with a high resistance film) with an insulating film. (For example, refer to Patent Document 1). In the case of this powder core, iron powder is insulated one by one with a high-resistance film, and eddy current flows only in the one iron powder, so iron loss can be further reduced.
[0004]
[Patent Document 1]
Japanese Patent Laid-Open No. 60-128840
[Problems to be solved by the invention]
However, the powder core as described above has a problem that iron loss increases due to the thickness of the core. FIG. 17 shows the relationship between the thickness of the powder core and the iron loss. In addition to the powder core, the figure shows the iron loss of a laminated core using a cold rolled steel plate (SPCC) and a laminated core using an electromagnetic steel plate (JIS standard: 50A470) as a comparative example. Yes. In the powder core, when the core thickness is about 45 mm or more, the iron loss of the SPCC laminated core becomes larger. Therefore, since the powder core with a large thickness has a problem of efficiency reduction due to iron loss, it has been difficult to apply it to a motor for high rotation. Incidentally, although the iron core has a small iron loss in the laminated core of the magnetic steel sheet, there is a problem that the magnetic steel sheet is expensive and the material cost increases.
[0006]
The present invention has been made to solve the above-described problems, and its object is to suppress an increase in iron loss accompanying the core thickness in an armature core formed by compression molding magnetic metal powder. It is in.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, the invention according to claim 1 is an armature core of a motor formed by compression molding a magnetic metal powder having an insulating film, comprising two or more core layers and each of the above core layers. and an insulating layer provided between the core layer, and a magnetic metal powder for forming the respective core layers, said insulating layer and a powder made of an insulating material for forming the insulating layer the Compressed so as to be sandwiched between core layers and integrally molded.
[0008]
The invention according to claim 2 is an armature core of a motor formed by compression molding magnetic metal powder having an insulating film, and is a compression bonded body in which two or more pre-compressed bodies are compression-bonded. , after forming the respective pre-compressed body from said magnetic metal powder by temporary compression molding, Ri Na further compression molding respective pre-compression member, voids Ru is formed between the respective pre-compression member .
[0009]
According to a third aspect of the present invention, in the armature core of the motor according to the first or second aspect, in addition to the magnetic metal powder provided with the insulating film, a compression binder is formed including a binder that functions as a binder. .
[0010]
According to a fourth aspect of the present invention, in the armature core of the motor according to the second aspect, the pre-compressors are made of the same material.
According to a fifth aspect of the present invention, in the armature core of the motor according to the second aspect, each pre-compressed body is made of a different material.
[0011]
According to a sixth aspect of the present invention, in the armature core of the motor according to the second aspect, the pre-compression body includes a plurality of compression bodies.
According to a seventh aspect of the present invention, in the armature core of the motor according to the second aspect of the present invention, the pressure at the time of compression molding in order to join the pre-compressed bodies is when the pre-compressed bodies are temporarily compression molded. Greater than the pressure.
[0012]
(Function)
According to the invention described in claim 1, by which the powder made of magnetic metal powder and an insulating material is compressed, and two or more core layers and the insulating layer of each core layers are integrally molded. As described above, since the generation of the eddy current is suppressed by providing the insulating layer between each core layer, an armature core with less iron loss can be realized.
[0013]
According to the second aspect of the present invention, since microscopic voids are formed between the compression-molded pre-compressed bodies, the voids cause the same effect as the core sheet gap in the conventional laminated core. Therefore, the generation of eddy current is suppressed. Thereby, an armature core with less iron loss can be realized. Further, in this case, a difference can be produced in the compression ratio of each pre-compressed body by temporary compression molding, and a uniform strength matched to the structure of the armature core can be ensured.
[0014]
According to the third aspect of the present invention, since the binder binder functioning as a binder is added to the magnetic metal powder and compression molding is performed, the adhesion between the powders can be improved.
[0015]
According to invention of Claim 4, since each pre compression body consists of the same material, the adhering force of the joint surface in each pre compression body can be ensured uniformly.
According to the fifth aspect of the present invention, since each pre-compressed body is made of a different material, an armature core utilizing the characteristics of the material can be realized according to the purpose.
[0016]
According to the invention described in claim 6, since the pre-compressed body is composed of a plurality of compressed bodies, an armature core utilizing the characteristics and strength of the material can be realized according to the purpose.
According to the seventh aspect of the present invention, since the compression molding for bonding the pre-compressed bodies is performed at a pressure larger than that of the temporary compression molding, the particles left on the pre-compressed bodies during the temporary compression molding. The gaps between them are clogged, and the respective pre-compressed bodies can be reliably combined. In addition, the strength of the armature core can be sufficiently secured.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
(First embodiment)
A first embodiment of the present invention will be described below with reference to the drawings.
[0018]
FIG. 1 shows a perspective view of the armature core 1 of the present embodiment, and FIG. 2 shows a cross-sectional view of the armature core 1. The armature core 1 is used, for example, as a rotor core (iron core) in an in-vehicle motor.
[0019]
As shown in FIG. 1, the armature core 1 has a main body 2 having a center hole 2a for inserting a rotation shaft, and radially outward from the outer periphery of the main body 2 at equal angular intervals (45 °). A plurality of (eight) teeth 3 are provided. An armature coil is wound around the armature core 1 in a slot 4 formed between the teeth 3.
[0020]
As shown in FIGS. 1 and 2, the armature core 1 of the present embodiment has a first core layer 6, an insulating layer 7, and a second core layer 8 in the thickness direction (vertical direction in FIG. 2). The three layers are stacked. That is, the armature core 1 has a split laminated structure that is divided into two by the insulating layer 7, and this structure reduces the iron loss of the armature core 1 and improves the motor efficiency.
[0021]
Next, the manufacturing method of the armature core 1 in this embodiment is demonstrated according to FIGS.
A manufacturing apparatus 11 for manufacturing the armature core 1 is a molding machine that compresses and forms powder, and includes a die 12, a lower punch 13 and an upper punch 14 (see FIG. 7), and first and second feed boxes 15. , 16 etc. In the manufacturing apparatus 11, a cavity 17 having an open top is formed by the die 12 and the lower punch 13. A cylindrical core 18 is erected at the center of the cavity 17. The lower end (not shown) of the molding core 18 is fixed so as not to move with respect to the die 12. Although not shown in the figure, a convex portion that matches the slot shape is formed on the inner peripheral surface of the cavity 17. Moreover, on the die | dye 12, the 1st feed box 15 for conveying the iron powder (magnetic metal powder) X which gave the insulating film, and the 2nd feed box 16 for conveying the insulating powder Y are provided. These are provided so as to be movable in the left-right direction in the figure.
[0022]
When the armature core 1 is manufactured by the manufacturing apparatus 11, first, as shown in FIG. 3, the first feed box 15 is filled with iron powder X corresponding to half the core volume, and a predetermined amount ( The second feed box 16 is filled with a small amount of insulating powder Y as compared with the core volume.
[0023]
Thereafter, as shown in FIG. 4, the first feed box 15 is moved directly above the cavity 17, and the iron powder X of the first feed box 15 is filled into the cavity 17.
[0024]
Next, as shown in FIG. 5, the second feed box 16 is moved right above the cavity 17, and the insulating powder Y of the second feed box 16 is filled into the cavity 17. At this time, the first feed box 15 located on the die 12 is filled with iron powder X corresponding to half of the core volume.
[0025]
Then, as shown in FIG. 6, the first feed box 15 is moved again directly above the cavity 17 to fill the cavity 17 with the iron powder X of the first feed box 15.
[0026]
Thereafter, as shown in FIG. 7, the upper punch 14 is moved downward and fitted into the upper portion of the cavity 17. Further, the upper punch 14 pressurizes the powder (iron powder X, insulating powder Y) in the cavity 17 with a predetermined pressure, and the lower punch 13 moves the powder in the cavity 17 upward with a predetermined pressure. Pressurize. By this pressurization, the powder in the cavity 17 is compressed, and the armature core 1 is formed.
[0027]
In addition, although said armature core 1 is a 2 division structure, by increasing the frequency | count of the filling process (refer FIG. 5) of the insulating powder Y and the filling process (refer FIG. 6) of the iron powder X, it is more than 3 divisions An armature core may be manufactured.
[0028]
FIG. 8 shows the relationship between the volume of the armature core and the iron loss. In the figure, the standard core is a core having half the volume of the armature core 1 (the same volume as each of the core layers 6 and 8), and is an integrally formed core obtained by compression-molding iron powder X.
[0029]
As shown in FIG. 8, in the case of an integrally formed core having a volume twice or six times that of the standard core, the iron loss increases in proportion to the increase in the core volume. On the other hand, as in this embodiment, the armature core (two-part laminated core) 1 having a structure in which the two core layers 6 and 8 are separated by the insulating layer 7 has a core volume twice that of the reference core. However, the iron loss is the same value as the standard core. Similarly, in the case of a three-part laminated core, the core volume is tripled, but the iron loss is maintained at substantially the same value.
[0030]
Specifically, it was confirmed that the armature core 1 having a two-part laminated structure can suppress iron loss of about 10% as compared with an integrally formed core having the same volume. In addition, the inventors of the present application configured a simple laminated core (simple laminated core) in which a plurality of standard cores are overlapped, and measured the iron loss (not shown) of the simple laminated core. And the evaluation result that the armature core 1 of the split laminated structure of this embodiment was substantially the same as the iron loss of the simple laminated core was able to be obtained.
[0031]
As described above in detail, the first embodiment has the following features.
(1) In the armature core 1, the powder material containing the iron powder X and the insulating powder Y is compressed in the cavity 17, so that the first and second core layers 6 and 8 and the insulating layer 7 are formed. It is integrally molded. In this case, since the insulating layer 7 is formed between the core layers 6 and 8, the generation of eddy current is suppressed, and the armature core 1 with less iron loss can be realized. In addition, the armature core 1 can be easily manufactured because only one material inlet is required for feeding the powder material into the cavity 17.
[0032]
(Second Embodiment)
A second embodiment embodying the present invention will be described below.
FIG. 9 shows a perspective view of the armature core 31 of the present embodiment, and FIG. 10 shows a cross-sectional view of the armature core 31. That is, unlike the first embodiment, the armature core 31 of the present embodiment omits the insulating layer 7. The armature core 31 has the same shape as that of the first embodiment, and includes a main body 2 having a center hole 2a and a plurality of teeth 3. The armature core 31 is a compression combination in which two pre-compression bodies for constituting the first and second core layers 6 and 8 are compression-coupled.
[0033]
Next, a method for manufacturing the armature core 31 will be described with reference to FIGS.
As shown in FIG. 11, the manufacturing apparatus 11 first fills the cavity 17 with iron powder X and compresses the iron powder X with the lower punch 13 and the upper punch 14 to form the first pre-compressed body P1. To do. Similarly, the iron powder X is filled into the cavity 17, and the iron powder X is compressed by the lower punch 13 and the upper punch 14 to form the second pre-compressed body P2.
[0034]
Further, as shown in FIG. 12, the pre-compressed bodies P <b> 1 and P <b> 2 are placed in the cavity 17 and compressed by the lower punch 13 and the upper punch 14. At this time, the punches 13 and 14 apply a pressure larger than the pressure when the pre-compression bodies P1 and P2 are temporarily compression molded. In this case, the gaps between the particles left in the pre-compression bodies P1 and P2 during the temporary compression molding are clogged, and the strength of the armature core 31 is secured, and the first and second pre-compression bodies P1 and P2 are secured. P2 is bound.
[0035]
As described above in detail, the second embodiment has the following features.
(1) Since microscopic voids are formed between the pre-compressed bodies P1 and P2 that have been compression-formed, eddy currents are generated by the voids in the same manner as the gaps of the core sheet 43 in the laminated core 41 of FIG. Is suppressed. Therefore, the armature core 31 with less iron loss can be realized.
[0036]
(2) Since compression molding for bonding the pre-compression bodies P1 and P2 is performed at a pressure larger than that of the temporary compression molding, the particles between the particles remaining in the pre-compression bodies P1 and P2 at the time of temporary compression molding The gap is clogged, and the respective pre-compressed bodies P1 and P2 can be reliably coupled. In this case, the strength of the armature core 31 can be sufficiently ensured.
[0037]
(3) The first core layer 6 and the second core layer in the armature core 31 have the same shape (the shape overlapped in the thickness direction is the same). Therefore, each pre-compression body P1, P2 can be compression-molded by the same cavity 17 in the manufacturing apparatus 11, which is practically preferable.
[0038]
Finally, the first embodiment is compared with the second embodiment. In the armature core 31 of the second embodiment, since it is necessary to manufacture the two pre-compressed bodies P1 and P2 in advance by compression molding of magnetic metal powder, the molding time and mold cost increase. On the other hand, since the armature core 1 of 1st Embodiment can be manufactured by one compression molding, molding time, metal mold | die cost, etc. are suppressed. That is, the armature core 1 of the first embodiment can reduce the manufacturing cost because the molding time and mold cost are suppressed as compared with the case where the armature core 31 of the second embodiment is manufactured. Can do. In addition, as a specific cost estimate, a cost reduction of about 30% is possible.
[0039]
In addition to the above, it can be embodied in the following form.
-In each said embodiment, you may compression-mold including the binding binder which functions as a binding material to the iron powder X which gave the insulating film. In this case, the adhesion force of the iron powder X can be improved. Further, since the insulating film of the iron powder X is protected by the binder, eddy current loss can be suppressed.
[0040]
-In 1st Embodiment, although the insulating powder Y was used as an insulating material which forms the insulating layer 7, you may use the insulating sheet which consists of resin. In the second embodiment, the armature core may be manufactured by compression molding in a state where an insulating sheet is disposed between the first pre-compression body P1 and the second pre-compression body P2.
[0041]
In the second embodiment, the first pre-compression body P1 and the second pre-compression body P2 have the same shape and are formed with the same cavity 17, but the present invention is not limited to this. When the shapes of the first pre-compression body P1 and the second pre-compression body P2 are different, they may be compression-molded in separate cavities (molds). Moreover, the pressure at the time of carrying out temporary compression molding of each precompression body P1, P2 may be varied, and the difference may be produced in the compression ratio of each precompression body P1, P2. In this case, uniform strength matched to the structure of the armature core can be ensured.
[0042]
Moreover, although each core layer 6 and 8 (pre-compression body P1, P2) of the armature core 31 is shape | molded using the same material (iron powder X), even if it shape | molds using a different material, respectively. Good. Here, when each pre-compression body P1, P2 is shape | molded with the same material, the adhering force of the joint surface in each pre-compression body P1, P2 can be ensured uniformly. Moreover, when each precompression body P1, P2 is shape | molded with a different material, the armature core 31 using the characteristic of material can be implement | achieved according to the objective.
[0043]
In the second embodiment, the armature core 31 is embodied in two layers (first and second core layers 6 and 8) compression-molded by two pre-compressed bodies P1 and P2. It may be embodied in a multi-layer armature core in which two or more pre-compressed bodies are compression bonded. As a specific example, FIG. 13 shows a five-layer armature core 33 having first to fifth core layers 33a to 33e. The armature core 33 is manufactured by further compression-molding five pre-compressed bodies. Also in the armature core 33, the same material may be used for each of the core layers 33a to 33e, or different materials may be used.
[0044]
The armature core 35 shown in FIG. 15 may be compression molded using two pre-compressed bodies P10 shown in FIG. Specifically, the pre-compression body P10 in FIG. 14 is a compression combination in which three compression bodies are compression-coupled, and the armature core 35 in FIG. 15 is a compression combination in which two pre-compression bodies P10 are further compression-coupled. It is. First to third core layers 36 to 38 are formed on the pre-compressed body P10. The material of the first core layer 36 formed in the lower portion of the second core layer 37 is iron powder that is coarser than the second core layer 37 and is formed in the upper portion of the second core layer 37. The material of the third core layer 38 that is formed is finer iron powder than the second core layer 37.
[0045]
And the armature core 35 of FIG. 15 is manufactured by combining the first core layers 36 of the respective pre-compression bodies P10 by compression molding. That is, in the armature core 35, the first core layer 36 of coarse particles is formed in the center portion, and the third core layer 38 of fine particles is formed at the upper and lower end portions. In this case, the bonding strength of each pre-compressed body P10 can be improved. Further, in this armature core 35, the third core layer 38 of fine particles forms the upper and lower end faces, so that the appearance can be improved. Thus, in the armature core 35, the pre-compression body P10 is composed of a plurality of compression bodies. With this configuration, the armature core 35 using the characteristics and strength of the material can be realized according to the purpose.
[0046]
-Although the coupling | bond part of each precompression body P1, P2, P10 is a plane, you may provide a level | step-difference part in the coupling | bonding part, and may increase a coupling | bond area. If it does in this way, the adhering force between the pre-compression bodies can be improved.
[0047]
The armature core is not limited to the shape of the armature core 1 shown in FIG. 1 (the shape of the main body 2 and the teeth 3), and can be changed as appropriate.
A technical idea that can be grasped from the above embodiment will be described.
[0048]
(B) said insulating material is an insulating powder, or Ru insulating sheet der. In the case where the insulating material is an insulating powder, the insulating powder can be put into the mold through a material inlet common to the magnetic metal powder. In addition, when the insulating material is an insulating sheet, the insulating layer can be formed uniformly.
[0049]
(B) The armature core of the motor according to claim 1 or 2, wherein the material for forming the core layer located in the center is a material of particles that are coarser than the core layer provided outside the core layer. . According to this structure, the core layer located in the center can be reliably joined.
[0050]
【The invention's effect】
As described above in detail, according to the present invention, in the armature core formed by compression-molding magnetic metal powder, it is possible to suppress an increase in iron loss accompanying the core thickness.
[Brief description of the drawings]
FIG. 1 is a perspective view showing an armature core according to a first embodiment.
FIG. 2 is a cross-sectional view of an armature core.
FIG. 3 is an explanatory diagram for explaining a method of manufacturing an armature core.
FIG. 4 is an explanatory diagram for explaining a method of manufacturing an armature core.
FIG. 5 is an explanatory diagram for explaining a method of manufacturing an armature core.
FIG. 6 is an explanatory diagram for explaining a method of manufacturing an armature core.
FIG. 7 is an explanatory diagram for explaining a method of manufacturing an armature core.
FIG. 8 is an explanatory diagram showing the relationship between core volume and iron loss.
FIG. 9 is a perspective view showing an armature core according to a second embodiment.
FIG. 10 is a cross-sectional view showing an armature core according to a second embodiment.
FIG. 11 is an explanatory diagram for explaining a method of manufacturing an armature core.
FIG. 12 is an explanatory diagram for explaining a method of manufacturing an armature core.
FIG. 13 is a cross-sectional view showing another example of an armature core.
FIG. 14 is a cross-sectional view showing another example of the pre-compression body.
FIG. 15 is a cross-sectional view showing another example of an armature core.
FIG. 16 is an explanatory diagram for explaining a conventional laminated core.
FIG. 17 is an explanatory view showing the relationship between the thickness of the powder core and the iron loss.
[Explanation of symbols]
P1, P2, P10 ... Pre-compressed body, X ... Iron powder as magnetic metal powder, Y ... Insulating powder as insulating material, 1, 31, 33, 35 ... Armature core, 6, 8, 33a to 33e , 36, 37, 38 ... core layer, 7 ... insulating layer.

Claims (7)

An armature core of a motor formed by compression molding magnetic metal powder with an insulating film,
And an insulating layer provided between the two or more core layers each core layer, and a magnetic metal powder for forming the respective core layers, made of an insulating material for forming the insulating layer A motor armature core, wherein powder is compressed and integrally molded so that the insulating layer is sandwiched between the core layers . An armature core of a motor formed by compression molding magnetic metal powder with an insulating film,
A compression-bonded body in which two or more pre-compression bodies are compression-bonded. After each pre-compression body is formed from the magnetic metal powder by temporary compression molding, each pre-compression body is further compression-molded. Do Ri, motor armature core, characterized in Rukoto the gap formed between the respective pre-compression member. The armature core for a motor according to claim 1 or 2, wherein the armature core is compression-molded including a binding binder that functions as a binding material in addition to the magnetic metal powder provided with the insulating film. The armature core of the motor according to claim 2, wherein each of the pre-compression bodies is made of the same material. The armature core of the motor according to claim 2, wherein each of the pre-compression bodies is made of a different material. The armature core of the motor according to claim 2, wherein the pre-compression body includes a plurality of compression bodies. 3. The armature core for a motor according to claim 2, wherein a pressure at which the pre-compression bodies are compression-molded to join the pre-compression bodies is greater than a pressure at which the pre-compression bodies are temporarily compression-molded.

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