U.S. patent application number 12/752755 was filed with the patent office on 2010-12-02 for rotor and motor.
This patent application is currently assigned to ASMO CO., LTD.. Invention is credited to Shigemasa KATO, Yoshiaki TAKEMOTO, Yoko TATEISHI, Yoji YAMADA, Seiya YOKOYAMA.
Application Number | 20100301695 12/752755 |
Document ID | / |
Family ID | 43219405 |
Filed Date | 2010-12-02 |
United States Patent
Application |
20100301695 |
Kind Code |
A1 |
YAMADA; Yoji ; et
al. |
December 2, 2010 |
Rotor and Motor
Abstract
A motor includes a rotor and a stator. The rotor includes a
plurality of magnets, which function as first magnetic poles, and
salient poles, which function as second magnetic poles. A ratio
X1:X2 of a quantity X1 of magnetic pole portions of the rotor,
which is the sum of the quantity of the magnets and the quantity of
the salient poles, and the quantity X2 of slots is 2n:3n (n being a
natural number). The sum of a magnetic pole occupying angle
.theta.1 of the magnet and a magnetic pole occupying angle .theta.2
of the salient pole is 360.degree.. The magnetic pole occupying
angle .theta.1 is set in a range of
180.degree.<.theta.1.ltoreq.230.degree..
Inventors: |
YAMADA; Yoji;
(Hamamatsu-shi, JP) ; YOKOYAMA; Seiya;
(Toyohashi-shi, JP) ; KATO; Shigemasa;
(Toyohashi-shi, JP) ; TAKEMOTO; Yoshiaki;
(Toyohashi-shi, JP) ; TATEISHI; Yoko; (Kosai-shi,
JP) |
Correspondence
Address: |
CARSTENS & CAHOON, LLP
13760 NOEL ROAD, SUITE 900
DALLAS
TX
75240
US
|
Assignee: |
ASMO CO., LTD.
Shizuoka-ken
JP
|
Family ID: |
43219405 |
Appl. No.: |
12/752755 |
Filed: |
April 1, 2010 |
Current U.S.
Class: |
310/156.01 |
Current CPC
Class: |
H02K 1/2746 20130101;
H02K 29/03 20130101; H02K 2213/03 20130101; H02K 21/16 20130101;
H02K 1/24 20130101 |
Class at
Publication: |
310/156.01 |
International
Class: |
H02K 21/16 20060101
H02K021/16 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 3, 2009 |
JP |
2009-091225 |
Apr 3, 2009 |
JP |
2009-091374 |
Apr 10, 2009 |
JP |
2009-096430 |
Apr 16, 2009 |
JP |
2009-100080 |
Mar 30, 2010 |
JP |
2010-079734 |
Claims
1. A motor comprising: a rotor including a rotor core, a plurality
of magnets arranged along a circumferential direction of the rotor
core to function as first magnetic poles, and salient poles formed
integrally with the rotor core and arranged between adjacent ones
of the magnets in the circumferential direction to function as
second magnetic poles; and a stator arranged facing toward the
rotor and including a plurality of slots; wherein the magnets and
salient poles each have a quantity in which the quantities sum
together to a quantity x1 of magnetic pole portions of the rotor,
and the slots are in a quantity x2, in which a ratio x1:x2 of the
quantity of the magnetic pole portions to the quantity of the slots
is 2n:3n (n being a natural number); when an electrical angle
corresponding to an angular range from an initiating point, which
is set between each magnet and the salient pole that is adjacent to
one side of the magnet in the circumferential direction, to a
terminating point, which is set between the magnet and the salient
pole that is adjacent to the other side of the magnet in the
circumferential direction, is defined as a magnetic pole occupying
angle .theta.1 of each of the magnets, and an electrical angle
corresponding to an angular range between the initiating point and
the terminating point on two sides of each salient pole in the
circumferential direction is defined as a magnetic pole occupying
angle .theta.2 of each of the salient poles, in which the magnetic
pole occupying angle .theta.1 and the magnetic pole occupying angle
.theta.2 sum to 360.degree.; and the magnetic pole occupying angle
.theta.1 is set in a range of
180.degree.<.theta.1.ltoreq.230.degree..
2. The motor according to claim 1, wherein the magnetic pole
occupying angle .theta.1 is set in a range of
200.degree..ltoreq..theta.1.ltoreq.220.degree..
3. The motor according to claim 2, wherein the magnetic pole
occupying angle .theta.1 is set in a range of
208.degree..ltoreq..theta.1.ltoreq.216.degree..
4. The motor according to claim 1, wherein a clearance is formed
between the magnet and the salient pole that are adjacent to each
other in the circumferential direction of the rotor; and the
initiating point and the terminating point of each of the magnetic
pole occupying angles .theta.1 and .theta.2 is a median point in
the circumferential direction of the clearance.
5. A motor comprising: a rotor including a rotor core, a plurality
of magnets arranged along a circumferential direction of the rotor
core to function as first magnetic poles, and salient poles formed
integrally with the rotor core and arranged between adjacent ones
of the magnets in the circumferential direction to function as
second magnetic poles; and a stator arranged facing toward the
rotor and including a plurality of slots; wherein the magnets and
salient poles each have a quantity in which the quantities sum
together to a quantity x1 of magnetic pole portions of the rotor,
and the slots are in a quantity x2, in which a ratio x1:x2 of the
quantity of the magnetic pole portions to the quantity of the slots
is 3n-1:3n (n being an odd number that is greater than or equal to
3) or 3n-2:3n (n being an even number that is greater than or equal
to 4); when an electrical angle corresponding to an angular range
from an initiating point, which is set between each magnet and the
salient pole that is adjacent to one side of the magnet in the
circumferential direction, to a terminating point, which is set
between the magnet and the salient pole that is adjacent to the
other side of the magnet in the circumferential direction, is
defined as a magnetic pole occupying angle .theta.1 of each of the
magnets, and an electrical angle corresponding to an angular range
between the initiating point and the terminating point on two sides
of each salient pole in the circumferential direction is defined as
a magnetic pole occupying angle .theta.2 of each of the salient
poles, a sum of the magnetic pole occupying angle .theta.1 and the
magnetic pole occupying angle .theta.2 is 360.degree.; and the
magnetic pole occupying angle .theta.1 is set in a range of
180.degree.<.theta.1.ltoreq.210.degree..
6. The motor according to claim 5, wherein the magnetic pole
occupying angle .theta.1 is set in a range of
184.degree..ltoreq..theta.1.ltoreq.202.degree..
7. The motor according to claim 6, wherein the magnetic pole
occupying angle .theta.1 is set in a range of
188.degree..ltoreq..theta.1.ltoreq.198.degree..
8. The motor according to claim 5, wherein a clearance is formed
between the magnet and the salient pole that are adjacent to each
other in the circumferential direction of the rotor; and the
initiating point and the terminating point of each of the magnetic
pole occupying angles .theta.1 and .theta.2 is a median point in
the circumferential direction of the clearance.
9. A motor comprising: a rotor including a rotor core, a plurality
of magnets arranged along a circumferential direction of the rotor
core to function as first magnetic poles, and salient poles formed
integrally with the rotor core and arranged between adjacent ones
of the magnets in the circumferential direction to function as
second magnetic poles; and a stator arranged facing toward the
rotor and including a plurality of slots; wherein the magnets and
salient poles each have a quantity in which the quantities sum
together to a quantity x1 of magnetic pole portions of the rotor,
and the slots are in a quantity x2, in which a ratio x1:x2 of the
quantity of the magnetic pole portions to the quantity of the slots
is 3n+1:3n (n being an odd number) or 3n+2:3n (n being an even
number); when an electrical angle corresponding to an angular range
from an initiating point, which is set between each magnet and the
salient pole that is adjacent to one side of the magnet in the
circumferential direction, to a terminating point, which is set
between the magnet and the salient pole that is adjacent to the
other side of the magnet in the circumferential direction, is
defined as a magnetic pole occupying angle .theta.1 of each of the
magnets, and an electrical angle corresponding to an angular range
between the initiating point and the terminating point on two sides
of each salient pole in the circumferential direction is defined as
a magnetic pole occupying angle .theta.2 of each of the salient
poles, a sum of the magnetic pole occupying angle .theta.1 and the
magnetic pole occupying angle .theta.2 is 360.degree.; and the
magnetic pole occupying angle .theta.1 is set in a range of
180.degree.<.theta.1.ltoreq.200.degree..
10. The motor according to claim 9, wherein the magnetic pole
occupying angle .theta.1 is set in a range of
182.degree..ltoreq..theta.1.ltoreq.197.degree..
11. The motor according to claim 10, wherein the magnetic pole
occupying angle .theta.1 is set in a range of
185.degree..ltoreq..theta.1.ltoreq.195.degree..
12. The motor according to claim 9, wherein a clearance is formed
between the magnet and the salient pole that are adjacent to each
other in the circumferential direction of the rotor; and the
initiating point and the terminating point of each of the magnetic
pole occupying angles .theta.1 and .theta.2 is a median point in
the circumferential direction of the clearance.
13. A motor comprising: a rotor including a rotor core, a plurality
of magnets arranged along a circumferential direction of the rotor
core to function as first magnetic poles, and salient poles formed
integrally with the rotor core and arranged between adjacent ones
of the magnets in the circumferential direction to function as
second magnetic poles; and a stator arranged facing toward the
rotor and including a plurality of slots; wherein the magnets and
salient poles each have a quantity in which the quantities sum
together to a quantity x1 of magnetic pole portions of the rotor,
and the slots are in a quantity x2, in which a ratio x1:x2 of the
quantity of the magnetic pole portions to the quantity of the slots
is 3n-1:3n (n being an odd number that is greater than or equal to
3) or 3n-2:3n (n being an even number that is greater than or equal
to 4); when an electrical angle corresponding to an angular range
from an initiating point, which is set between each magnet and the
salient pole that is adjacent to one side of the magnet in the
circumferential direction, to a terminating point, which is set
between the magnet and the salient pole that is adjacent to the
other side of the magnet in the circumferential direction, is
defined as a magnetic pole occupying angle .theta.1 of each of the
magnets, and an electrical angle corresponding to an angular range
between the initiating point and the terminating point on two sides
of each salient pole in the circumferential direction is defined as
a magnetic pole occupying angle .theta.2 of each of the salient
poles, a sum of the magnetic pole occupying angle .theta.1 and the
magnetic pole occupying angle .theta.2 is 360.degree.; and the
magnetic pole occupying angle .theta.1 is set in a range of
180.degree.<.theta.1.ltoreq.220.degree..
14. The motor according to claim 13, wherein a surface of the
magnet and a surface of the salient pole lie along the same
circumference, and a clearance between each of the surfaces and the
stator is set to have a dimension that is the same as a clearance
between the other one of the surfaces and the stator.
15. The motor according to claim 13, wherein a clearance is formed
between the magnet and the salient pole that are adjacent to each
other in the circumferential direction of the rotor; and the
initiating point and the terminating point of each of the magnetic
pole occupying angles .theta.1 and .theta.2 is a median point in
the circumferential direction of the clearance.
16. A motor comprising: a rotor including a rotor core, a plurality
of magnets arranged along a circumferential direction of the rotor
core to function as first magnetic poles, and salient poles formed
integrally with the rotor core and arranged between adjacent ones
of the magnets in the circumferential direction to function as
second magnetic poles, a first clearance being formed between the
magnet and the salient pole that are adjacent to each other in the
circumferential direction; and a stator arranged facing toward the
rotor spaced apart by a second clearance in a radial direction;
wherein the second clearance has a shortest radial distance A at
locations corresponding to the magnets and a shortest radial
distance B at locations corresponding to the salient poles, and a
ratio B/A is set in a range of 0.3.ltoreq.B/A<1.
17. The motor according to claim 16, wherein a radial distance of
the second clearance is constant in the circumferential direction
at locations corresponding to the magnets and the salient
poles.
18. The motor according to claim 16, wherein surfaces of the
salient pole facing toward the stator each include a central part
in the circumferential direction and two ends in the
circumferential direction, the second clearance has the shortest
radial distance B at the central part in the circumferential
direction and a radial distance C at the two ends in the
circumferential direction, and a ratio C/B is set in a range of
2.ltoreq.C/B.ltoreq.5.
19. The motor according to claim 18, wherein the surfaces of the
salient pole is curved at a constant curvature.
20. A rotor comprising: a rotor core; a plurality of magnets
arranged along a circumferential direction of the rotor core to
function as first magnetic poles; and a salient pole formed
integrally with the rotor core and arranged between adjacent ones
of the magnets in the circumferential direction to function as a
second magnetic pole, a first clearance being formed between the
magnets and the salient pole; wherein at least part of a surface of
the salient pole and at least part of surfaces of the magnets lie
along a reference circumference, and the surface of at least one of
the salient pole and the magnets is gradually spaced apart from the
reference circumference towards two circumferential ends of the
surface so as to have a convex shape.
21. The rotor according to claim 20, wherein the surface of the
salient pole is entirely curved at a constant curvature, and a
ratio r1/R of a curvature radius r1 of the surface and a radius R
of the reference circumference is set in a range of
0.2.ltoreq.r1/R.ltoreq.0.8.
22. The rotor according to claim 20, wherein the two
circumferential ends of the salient pole each have a round corner,
and a ratio r2/h of a curvature radius r2 of the corner and a
projecting length h of the salient pole is set in a range of
0.2.ltoreq.r2/h.ltoreq.0.9.
23. The rotor according to claim 22, wherein the surfaces of the
magnets are entirely curved at a constant curvature, and a ratio
r3/R of a curvature radius r3 of the surface of the magnet and the
radius R of the reference circumference is set in a range of
0.4.ltoreq.r3/R.ltoreq.0.8.
24. A motor comprising the rotor according to claim 20.
25. A rotor comprising: a rotor core; a plurality of magnets
arranged along a circumferential direction of the rotor core to
function as first magnetic poles; and salient poles formed
integrally with the rotor core and arranged between adjacent ones
of the magnets in the circumferential direction to function as
second magnetic poles, a first clearance being formed between the
magnet and the salient pole that are adjacent to each other in the
circumferential direction; wherein the salient poles relatively
project outward in a radial direction from the magnets, cover
members covering the magnets are hooked to the rotor core between
adjacent ones of the salient poles, and the cover members are
arranged so as not to project outward in the radial direction from
the salient poles.
26. The rotor according to claim 25, wherein the salient poles each
have a distal part having a hooking portion, and the cover members
are formed from a sheet of a nonmagnetic metal material and hooked
to the hooking portion.
27. The rotor according to claim 25, wherein the salient poles each
have a basal part having a hooking hole, and the cover members are
formed from a sheet of a nonmagnetic metal material and hooked to
the hooking hole.
28. The rotor according to claim 25, wherein the cover members are
formed from a resin material and molded integrally with the rotor
core to cover the magnets.
29. A motor comprising the rotor according to claim 25.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a rotor having a consequent
pole type structure and a motor including such a rotor.
[0002] Japanese Laid-Open Patent Publication No. 9-327139 discloses
a rotor having the so-called consequent pole type structure as one
example of a rotor used in a motor. The rotor described in the
publication includes a plurality of magnets, which are arranged in
a circumferential direction of a rotor core, and salient poles,
which are arranged between the magnets and formed integrally with
the rotor core. The plurality of magnets function as one magnetic
pole, and the plurality of salient poles function as the other
magnetic pole.
[0003] The rotor having the consequent pole type structure that is
disclosed in the publication includes the magnets, which generate a
magnetic flux, and the salient poles, which do not generate a
magnetic flux. Thus, there is a tendency for a magnetic unbalance
to occur in the consequent pole type structure rotor. This
increases torque ripple or the like and thereby lowers the rotation
performance.
SUMMARY OF THE INVENTION
[0004] It is an object of the present invention to provide a rotor
and a motor that optimizes the shape of each salient pole and
magnet and improves the rotation performance.
[0005] To achieve the above object, a first aspect of the present
invention provides a motor including a rotor and a stator. The
rotor includes a rotor core, a plurality of magnets, and salient
poles. The plurality of magnets are arranged along a
circumferential direction of the rotor core to function as first
magnetic poles. The salient poles are formed integrally with the
rotor core and arranged between adjacent ones of the magnets in the
circumferential direction to function as second magnetic poles. The
stator is arranged facing toward the rotor and includes a plurality
of slots. The magnets and salient poles each have a quantity in
which the quantities sum together to a quantity x1 of magnetic pole
portions of the rotor, and the slots are in a quantity x2. A ratio
x1:x2 of the quantity of the magnetic pole portions to the quantity
of the slots is 2n:3n (n being a natural number). An electrical
angle corresponding to an angular range from an initiating point,
which is set between each magnet and the salient pole that is
adjacent to one side of the magnet in the circumferential
direction, to a terminating point, which is set between the magnet
and the salient pole that is adjacent to the other side of the
magnet in the circumferential direction, is defined as a magnetic
pole occupying angle .theta.1 of each of the magnets. An electrical
angle corresponding to an angular range between the initiating
point and the terminating point on two sides of each salient pole
in the circumferential direction is defined as a magnetic pole
occupying angle .theta.2 of each of the salient poles. The sum of
the magnetic pole occupying angle .theta.1 and the magnetic pole
occupying angle .theta.2 is 360.degree.. The magnetic pole
occupying angle .theta.1 is set in a range of
180.degree.<.theta.1.ltoreq.230.degree..
[0006] A second aspect of the present invention provides a motor
including a rotor and a stator. The rotor includes a rotor core, a
plurality of magnets, and salient poles. The plurality of magnets
are arranged along a circumferential direction of the rotor core to
function as first magnetic poles. The salient poles are formed
integrally with the rotor core and arranged between adjacent ones
of the magnets in the circumferential direction to function as
second magnetic poles. The stator is arranged facing toward the
rotor and includes a plurality of slots. The magnets and salient
poles each have a quantity in which the quantities sum together to
a quantity x1 of magnetic pole portions of the rotor, and the slots
are in a quantity x2. A ratio x1:x2 of the quantity of the magnetic
pole portions to the quantity of the slots is 3n-1:3n (n being an
odd number that is greater than or equal to 3) or 3n-2:3n (n being
an even number that is greater than or equal to 4). An electrical
angle corresponding to an angular range from an initiating point,
which is set between each magnet and the salient pole that is
adjacent to one side of the magnet in the circumferential
direction, to a terminating point, which is set between the magnet
and the salient pole that is adjacent to the other side of the
magnet in the circumferential direction, is defined as a magnetic
pole occupying angle .theta.1 of each of the magnets. An electrical
angle corresponding to an angular range between the initiating
point and the terminating point on two sides of each salient pole
in the circumferential direction is defined as a magnetic pole
occupying angle .theta.2 of each of the salient poles. The sum of
the magnetic pole occupying angle .theta.1 and the magnetic pole
occupying angle .theta.2 is 360.degree.. The magnetic pole
occupying angle .theta.1 is set in a range of
180.degree.<.theta.1.ltoreq.210.degree..
[0007] A third aspect of the present invention provides a motor
including a rotor and a stator. The rotor includes a rotor core, a
plurality of magnets, and salient poles. The plurality of magnets
are arranged along a circumferential direction of the rotor core to
function as first magnetic poles. The salient poles are formed
integrally with the rotor core and arranged between adjacent ones
of the magnets in the circumferential direction to function as
second magnetic poles. A stator is arranged facing toward the rotor
and includes a plurality of slots. The magnets and salient poles
each have a quantity in which the quantities sum together to a
quantity x1 of magnetic pole portions of the rotor, and the slots
are in a quantity x2. A ratio x1:x2 of the quantity of the magnetic
pole portions to the quantity of the slots is 3n+1:3n (n being an
odd number) or 3n+2:3n (n being an even number). An electrical
angle corresponding to an angular range from an initiating point,
which is set between each magnet and the salient pole that is
adjacent to one side of the magnet in the circumferential
direction, to a terminating point, which is set between the magnet
and the salient pole that is adjacent to the other side of the
magnet in the circumferential direction, is defined as a magnetic
pole occupying angle .theta.1 of each of the magnets. An electrical
angle corresponding to an angular range between the initiating
point and the terminating point on two sides of each salient pole
in the circumferential direction is defined as a magnetic pole
occupying angle .theta.2 of each of the salient poles. The sum of
the magnetic pole occupying angle .theta.1 and the magnetic pole
occupying angle .theta.2 is 360.degree.. The magnetic pole
occupying angle .theta.1 is set in a range of
180.degree.<.theta.1.ltoreq.200.degree..
[0008] A fourth aspect of the present invention provides a motor
including a rotor and a state. The rotor includes a rotor core, a
plurality of magnets, and salient poles. The plurality of magnets
are arranged along a circumferential direction of the rotor core to
function as first magnetic poles. The salient poles are formed
integrally with the rotor core and arranged between adjacent ones
of the magnets in the circumferential direction to function as
second magnetic poles. The stator is arranged facing toward the
rotor and includes a plurality of slots. The magnets and salient
poles each have a quantity in which the quantities sum together to
a quantity x1 of magnetic pole portions of the rotor, and the slots
are in a quantity x2. A ratio x1:x2 of the quantity of the magnetic
pole portions to the quantity of the slots is 3n-1:3n (n being an
odd number that is greater than or equal to 3) or 3n-2:3n (n being
an even number that is greater than or equal to 4). An electrical
angle corresponding to an angular range from an initiating point,
which is set between each magnet and the salient pole that is
adjacent to one side of the magnet in the circumferential
direction, to a terminating point, which is set between the magnet
and the salient pole that is adjacent to the other side of the
magnet in the circumferential direction, is defined as a magnetic
pole occupying angle .theta.1 of each of the magnets. An electrical
angle corresponding to an angular range between the initiating
point and the terminating point on two sides of each salient pole
in the circumferential direction is defined as a magnetic pole
occupying angle .theta.2 of each of the salient poles. The sum of
the magnetic pole occupying angle .theta.1 and the magnetic pole
occupying angle .theta.2 is 360.degree.. The magnetic pole
occupying angle .theta.1 is set in a range of
180.degree.<.theta.1.ltoreq.220.degree..
[0009] A fifth aspect of the present invention provides a motor
including a rotor and a stator. The rotor includes a rotor core, a
plurality of magnets, and salient poles. The plurality of magnets
are arranged along a circumferential direction of the rotor core to
function as first magnetic poles. The salient poles are formed
integrally with the rotor core and arranged between adjacent ones
of the magnets in the circumferential direction to function as
second magnetic poles. A first clearance is formed between the
magnet and the salient pole that are adjacent to each other in the
circumferential direction. The stator is arranged facing toward the
rotor spaced apart by a second clearance in a radial direction. The
second clearance has a shortest radial distance A at locations
corresponding to the magnets and a shortest radial distance B at
locations corresponding to the salient poles. A ratio B/A is set in
a range of 0.3.ltoreq.B/A<1.
[0010] A sixth aspect of the present invention provides a rotor
including a rotor core, a plurality of magnets, and a salient pole.
The plurality of magnets are arranged along a circumferential
direction of the rotor core to function as first magnetic poles.
The salient pole is formed integrally with the rotor core and
arranged between adjacent ones of the magnets in the
circumferential direction to function as a second magnetic pole. A
first clearance is formed between the magnets and the salient pole.
At least part of a surface of the salient pole and at least part of
surfaces of the magnets lie along a reference circumference. The
surface of at least one of the salient pole and the magnets is
gradually spaced apart from the reference circumference towards two
circumferential ends of the surface so as to have a convex
shape.
[0011] A seventh aspect of the present invention provides a rotor
including a rotor core, a plurality of magnets, and salient poles.
The plurality of magnets are arranged along a circumferential
direction of the rotor core to function as first magnetic poles.
The salient poles are formed integrally with the rotor core and
arranged between adjacent ones of the magnets in the
circumferential direction to function as second magnetic poles. A
first clearance is formed between the magnet and the salient pole
that are adjacent to each other in the circumferential direction.
The salient poles relatively project outward in a radial direction
from the magnets. Cover members covering the magnets are hooked to
the rotor core between adjacent ones of the salient poles. The
cover members are arranged so as not to project outward in the
radial direction from the salient poles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention, together with objects and advantages thereof,
may best be understood by reference to the following description of
the presently preferred embodiments together with the accompanying
drawings in which:
[0013] FIG. 1 is a plan view showing a motor according to a first
embodiment of the present invention;
[0014] FIG. 2 is a partially enlarged view showing the motor of the
first embodiment;
[0015] FIG. 3 is a graph showing the relationship of a magnetic
pole occupying angle and torque ripple and the relationship of the
magnetic pole occupying angle and torque in the first
embodiment;
[0016] FIG. 4 is a plan view showing a motor according to a second
embodiment of the present invention;
[0017] FIG. 5 is a partially enlarged view showing the motor of the
second embodiment;
[0018] FIG. 6A is a graph showing magnetic flux density variation
in the motor of the second embodiment;
[0019] FIG. 6B is an enlarged graph showing magnetic flux density
variation near an electrical angle of 180.degree. in the second
embodiment;
[0020] FIG. 7 is a graph showing the relationship of a magnetic
pole occupying angle and torque ripple ratio and the relationship
of the magnetic pole occupying angle and torque ratio in the second
embodiment;
[0021] FIG. 8 is a diagram showing the relationship of the magnetic
pole occupying angle and magnetic pole switching position in the
second embodiment;
[0022] FIG. 9 is a plan view showing a motor according to a third
embodiment of the present invention;
[0023] FIG. 10 is a partially enlarged view showing the motor of
the third embodiment;
[0024] FIG. 11 is a graph showing the relationship of a magnetic
pole occupying angle and torque ripple ratio and the relationship
of the magnetic pole occupying angle and torque ratio in the third
embodiment;
[0025] FIG. 12 is a plan view showing a motor according to a fourth
embodiment of the present invention;
[0026] FIG. 13 is a partially enlarged view showing the motor of
the fourth embodiment;
[0027] FIG. 14 is a graph showing the relationship of a clearance
distance ratio B/A and radial force change in the fourth
embodiment;
[0028] FIG. 15 is a graph showing the relationship of the clearance
distance ratio B/A and torque ratio in the fourth embodiment;
[0029] FIG. 16 is a graph showing the relationship of the clearance
distance ratio B/A and torque ripple ratio in the fourth
embodiment;
[0030] FIG. 17 is a partially enlarged view of a motor according to
a fifth embodiment of the present invention;
[0031] FIG. 18 is a graph showing the relationship of a clearance
distance ratio C/B and a radial force pulsation ratio in the fifth
embodiment;
[0032] FIG. 19 is a plan view showing a rotor according to a sixth
embodiment of the present invention;
[0033] FIG. 20 is a partially enlarged view showing the rotor of
the sixth embodiment;
[0034] FIG. 21 is a graph showing the relationship of an r1/R ratio
and magnetic flux density variation in the sixth embodiment;
[0035] FIG. 22 is a graph showing the relationship of the r1/R
ratio and torque ratio in the sixth embodiment;
[0036] FIG. 23 is a graph showing the relationship of the r1/R
ratio and torque ripple ratio in the sixth embodiment;
[0037] FIG. 24 is a partially enlarged view of a rotor according to
a seventh embodiment of the present invention;
[0038] FIG. 25 is a graph showing the relationship of an r2/R ratio
and torque ratio in the seventh embodiment;
[0039] FIG. 26 is a graph showing the relationship of the r2/R
ratio and torque ripple ratio in the seventh embodiment;
[0040] FIG. 27 is a plan view showing a rotor according to an
eighth embodiment of the present invention;
[0041] FIG. 28 is a partially enlarged view showing the rotor of
the eighth embodiment;
[0042] FIG. 29 is a graph showing the relationship of an r3/R ratio
and magnetic flux density variation in the eighth embodiment;
[0043] FIG. 30 is a graph showing the relationship of the r3/R
ratio and torque ratio in the eighth embodiment;
[0044] FIG. 31 is a graph showing the relationship of the r3/R
ratio and torque ripple ratio in the eighth embodiment;
[0045] FIG. 32 is a plan view showing a motor according to a ninth
embodiment of the present invention;
[0046] FIG. 33 is a partially enlarged view showing the motor of
the ninth embodiment;
[0047] FIG. 34 is a partially enlarged view showing another example
of a motor; and
[0048] FIG. 35 is a partially enlarged view showing a further
example of a motor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
[0049] A first embodiment of the present invention will now be
discussed with reference to FIGS. 1 to 3.
[0050] FIGS. 1 and 2 show an inner rotor type brushless motor M.
The motor M of the first embodiment uses a rotor 10A including a
substantially annular rotor core 12, which is formed from a
magnetic metal material and fixed to an outer circumferential
surface of a rotation shaft 11, four N-pole magnets 13, which are
arranged along the circumferential direction of the rotor core 12,
and salient poles 12a, which are formed integrally with the rotor
core 12 and arranged between adjacent ones of the magnets 13 in the
circumferential direction. The salient poles 12a function as
S-poles. In other words, the rotor 10A is a so-called consequent
pole type having eight magnetic pole portions. A stator 20 includes
a stator core 21, which has twelve teeth 21a, and coils 22, which
are wound around the teeth 21a. Slots for accommodating the coils
22 are formed between the teeth 21a that are adjacent to each other
in the circumferential direction. The stator 20 includes twelve
magnetic pole portions. That is, in the brushless motor M of the
first embodiment, the magnetic pole portion quantity X1 of the
rotor 10A and the slot quantity X2 (number of teeth) of the stator
20 are set at a ratio X1:X2 of 8:12, that is, 2n:3n ("n" is
four).
[0051] The coils 22 includes coils of three phases, namely, the U,
V, and W phases, which are arranged counterclockwise in the order
of a W phase (forward winding), W bar phase (reverse winding), V
bar phase, V phase, U phase, U bar phase, W bar phase, W phase, V
phase, V bar phase, U bar phase, and U phase in the clockwise
direction. In other words, the coils 22 are arranged so that a
forward winding and reverse winding are arranged next to each other
for each coil of the same phase. The magnets 13 and the salient
poles 12a are alternately arranged in equal angular intervals on
the peripheral portion of the rotor 10A.
[0052] The magnet 13 has a circumferential length that is slightly
longer than that of the salient pole 12a. Further, the magnet 13 is
substantially box-shaped and has a flat inner surface 13a and a
curved outer surface 13b. The inner surface 13a of the magnet 13 is
fixed to a flat fixation surface 12b arranged between adjacent ones
of the salient poles 12a on the rotor core 12. A clearance (gap in
the circumferential direction) S1 is formed between a magnet 13 and
salient pole 12a that are adjacent to each other in the
circumferential direction.
[0053] The salient pole 12a has a circumferential length that is
slightly shorter than that of the magnet 13. Further, the salient
pole 12a projects outward from the peripheral portion of the rotor
core 12 and has an arcuate shape. The salient pole 12a has a curved
outer surface 12c that lies along the same circumference as the
outer surface 13b of the magnet 13. Thus, a clearance S2 between
the outer surface 12c of the salient pole 12a and the stator 20
(distal surface of the teeth 21a) is the same as the clearance S2
between the outer surface 13b of the magnet 13 and the stator 20
(distal surface of the teeth 21a).
[0054] In FIG. 2, each magnet 13 has a circumferential length shown
as a magnetic pole occupying angle .theta.1, and each salient pole
12a has a circumferential length shown as a magnetic pole occupying
angle .theta.2. Each of the magnetic pole occupying angles .theta.1
and .theta.2 is an angular range, the initiating point and
terminating point of which are the median point of the clearance S1
between the magnet 13 and the salient pole 12a. In other words, the
magnetic pole occupying angle .theta.1 of each magnet 13 is defined
as the angular range from the median point (initiating point) of
the clearance S1 on one circumferential side of the magnet 13 to
the median point (terminating point) of the clearance S1 on the
other circumferential side of the magnet 13. The magnetic pole
occupying angle .theta.2 of each salient pole 12a is defined as the
angular range from the median point (initiating point) of the
clearance S1 on one circumferential side of the salient pole 12a to
the median point (terminating point) of the clearance S1 on the
other circumferential side of the salient pole 12a. FIG. 3 shows
the torque ripple and the torque of the motor when changing the
magnetic pole occupying angles .theta.1 and .theta.2. In FIG. 3,
the torque ripple is shown by the solid line, and the torque is
shown by a single-dash line. In FIG. 3, the magnetic pole occupying
angles .theta.1 and .theta.2 are shown as electrical angles. In the
description hereafter, the magnetic pole occupying angles .theta.1
and .theta.2 will be described as electrical angles unless
otherwise mentioned. The sum of the magnetic pole occupying angle
.theta.1 of a single magnet 13 and the magnetic pole occupying
angle .theta.2 of a single salient pole 12a is electrical angle
360.degree. (.theta.1+.theta.2=360.degree.). Thus, only the
magnetic pole occupying angle .theta.1 of the magnet 13 will be
described below.
[0055] In FIG. 3, the magnitude of the torque is defined as 100%
when the magnetic pole occupying angle .theta.1 of the magnet 13 is
180.degree., that is, when the magnetic pole occupying angle
.theta.1 of the magnet 13 and the magnetic pole occupying angle
.theta.2 of the salient pole 12a are equal to each other. The
magnitude of the torque when the magnetic pole occupying angle
.theta.1 differs from 180.degree. is indicated as a ratio in
relation with the magnitude of the torque when the magnetic pole
occupying angle .theta.1 is 180.degree.. The torque becomes less
than 100% when the magnetic pole occupying angle .theta.1 is less
than 180.degree.. The torque exceeds 100% when the magnetic pole
occupying angle .theta.1 is in the range of 180.degree. and
230.degree..
[0056] In FIG. 3, the magnitude of the torque ripple is defined as
100% when the magnetic pole occupying angle .theta.1 of the magnet
13 is 180.degree., and the magnitude of the torque ripple when the
magnetic pole occupying angle .theta.1 differs from 180.degree. is
indicated as a ratio in relation with the magnitude of the torque
ripple when the magnetic pole occupying angle .theta.1 is
180.degree.. The torque ripple becomes greater than 100% when the
magnetic pole occupying angle .theta.1 is less than 180.degree..
When the magnetic pole occupying angle .theta.1 is increased to
greater than 180.degree., the torque ripple is reduced to 90% at
the magnetic pole occupying angle .theta.1 of 200.degree.. When the
magnetic pole occupying angle .theta.1 is further increased, the
torque ripple is reduced to 85% at the magnetic pole occupying
angle .theta.1 of 208.degree.. When the magnetic pole occupying
angle .theta.1 is approximately 213.degree., the torque ripple is
reduced to a minimum value of about 82%. After the magnetic pole
occupying angle .theta.1 becomes greater than approximately
213.degree., the torque ripple increases as the magnetic pole
occupying angle .theta.1 increases. The torque ripple becomes 85%
at the magnetic pole occupying angle .theta.1 of 216.degree., 90%
at the magnetic pole occupying angle .theta.1 of 220.degree., and
greater than or equal to 100% when the magnetic pole occupying
angle .theta.1 exceeds 230.degree.. That is, compared to a
structure in which the magnetic pole occupying angles .theta.1 and
.theta.2 are equal to each other, the torque ripple is reduced when
the magnetic pole occupying angle .theta.1 of the magnet 13 is in
the range of 180.degree.<.theta.1.ltoreq.230.degree.. The torque
ripple is reduced to 90% in the range of
200.degree..ltoreq..theta.1.ltoreq.220.degree.. Further, the torque
ripple is reduced to 85% in the range of
208.degree..ltoreq..theta.1.ltoreq.216.degree..
[0057] Accordingly, in the range of
180.degree.<.theta.1.ltoreq.230.degree., the magnetic pole
occupying angle .theta.1 is set in the range of
208.degree..ltoreq..theta.1.ltoreq.216.degree. for the rotor 10A of
the first embodiment. Thus, compared to a structure in which the
magnetic pole occupying angles .theta.1 and .theta.2 are equal to
each other, the torque ripple is reduced while suppressing torque
decrease. Consequently, the rotation performance of the rotor 10A
is improved.
[0058] The first embodiment has the advantages described below.
[0059] (1) In the first embodiment, the magnetic pole occupying
angle .theta.1 of the magnet 13 is set in the range of
180.degree.<.theta.1.ltoreq.230.degree. in the motor M of which
the ratio X1:X2 of the magnetic pole portion quantity X1 of the
rotor 10A and the slot quantity X2 of the stator 20 is 2n:3n (n is
a natural number). Thus, compared to a typical motor in which the
magnetic pole occupying angle .theta.1 of the magnet 13 and the
magnetic pole occupying angle .theta.2 of the salient pole 12a are
the same, the motor M of the first embodiment reduces torque ripple
while suppressing torque decrease (see FIG. 3). This improves the
rotation performance of the rotor 10A.
[0060] (2) In the first embodiment, the magnetic pole occupying
angle .theta.1 of the magnet 13 is set in a range of
200.degree..ltoreq..theta.1.ltoreq.220.degree.. Thus, compared to a
structure in which the magnetic pole occupying angle .theta.1 of
the magnet 13 and the magnetic pole occupying angle .theta.2 of the
salient pole 12a are the same, the motor M of the first embodiment
reduces torque ripple to about 90% (see FIG. 3). This further
improves the rotation performance of the rotor 10A.
[0061] (3) In the first embodiment, the magnetic pole occupying
angle .theta.1 of the magnet 13 is set the range of
208.degree..theta.1.ltoreq.216.degree.. Thus, compared to a
structure in which the magnetic pole occupying angle .theta.1 of
the magnet 13 and the magnetic pole occupying angle .theta.2 of the
salient pole 12a are the same, the motor M of the first embodiment
reduces torque ripple to about 85% (see FIG. 3). This further
improves the rotation performance of the rotor 10A.
[0062] (4) In the first embodiment, the clearance S1 is formed
between the magnet 13 and the salient pole 12a that are adjacent to
each other in the circumferential direction of the rotor 10A. The
magnetic pole occupying angles .theta.1 and .theta.2 are each set
using the median point in the circumferential direction of the
clearance S1 as an initiating point and a terminating point. Thus,
the clearance S1 suppresses sudden changes in the magnetic flux
density at the boundary of an adjacent magnet 13 and salient pole
12a. Further, torque ripple is reduced while suppressing torque
decrease in the motor M that includes the rotor 10A.
[0063] The first embodiment may be modified as described below.
[0064] In the first embodiment, the magnetic pole occupying angle
.theta.1 of the magnet 13 is set in the range of
208.degree..ltoreq..theta.1.ltoreq.216.degree.. However, the
magnetic pole occupying angle .theta.1 may be set in a wider range
of 200.degree..ltoreq..theta.1.ltoreq.220.degree. or in an even
wider range of 180.degree.<.theta.1.ltoreq.230.degree..
[0065] In the first embodiment, the ratio X1:X2 of the magnetic
pole portion quantity X1 of the rotor 10A and the slot quantity X2
of the stator 20 is set to 8:12, that is, 2n:3n ("n" is 4). The
value of "n" may be changed to other natural numbers.
[0066] The numerical ranges in the first embodiment may be changed
as required in accordance with the situation or the like.
Second Embodiment
[0067] A second embodiment of the present invention will now be
discussed with reference to FIGS. 4 to 8.
[0068] In the second embodiment, the quantity of magnetic pole
portions in the rotor differs from the first embodiment.
Accordingly, the same reference numerals are given to those
components that are the same as the corresponding components of the
first embodiment. Such components will not be described in
detail.
[0069] As shown in FIGS. 4 and 5, the motor M of the second
embodiment uses a rotor 10B includes five N-pole magnets 13, which
are arranged along the circumferential direction of the rotor core
12, and five salient poles 12a, arranged between adjacent ones of
the magnets 13 in the circumferential direction. The salient poles
12a function as the S-poles. In other words, the rotor 10B is a
so-called consequent pole type having ten magnetic pole portions.
The stator 20 includes twelve teeth 21a in the same manner as in
the first embodiment. That is, the ratio X1:X2 of the magnetic pole
portion quantity X1 of the rotor 10B and the slot quantity X2
(number of teeth) of the stator 20 is set to 10:12, that is,
3n-2:3n ("n" is 4) in the brushless motor M of the second
embodiment.
[0070] The magnet 13 has a circumferential length that is slightly
longer than that of the salient pole 12a. The magnet 13 has a
curved shape and a thickness (dimension in the radial direction) of
which is constant in the circumferential direction. Accordingly,
the inner surface 13a and the outer surface 13b of the magnet 13
are parallel. The fixation surface 12b of the rotor core 12, to
which the inner surface 13a of the magnet 13 is fixed, has a curved
shape conforming to the inner surface 13a. The clearance (gap in
the circumferential direction) S1 is formed between a magnet 13 and
salient pole 12a that are adjacent to each other in the
circumferential direction. The clearance S1 is set to have a
dimension that is about one to two times greater than the clearance
S2 between the rotor 10B and the stator 20 (clearance S2 between
the outer surface of the salient pole 12a or magnet 13 and the
distal surface of the teeth 21a).
[0071] FIGS. 6A and 6B show the surface magnetic flux density
variation of the rotor 10B when the magnetic pole occupying angles
.theta.1 and .theta.2 of the magnet 13 and the salient pole 12a are
changed. FIG. 7 shows torque ripple and the torque. In FIG. 7, the
torque ripple is shown by a solid line, and the torque is shown by
a single-dash line.
[0072] FIGS. 6A and 6B show the magnetic flux density variation of
the rotor 10B when the magnetic pole occupying angle .theta.1 of
the magnet 13 is changed to 171.degree., 180.degree., 198.degree.,
and 208.degree. (189.degree., 180.degree., 162.degree., 152.degree.
in order for the magnetic pole occupying angle .theta.2). For all
of these magnetic pole occupying angles .theta.1, the magnetic flux
density varies in a similar manner. Specifically, the curve
indicating the magnetic flux density variation has a substantially
trapezoidal shape in the magnetic pole zone of the magnet 13 and a
convex shape in the magnetic pole zone of the salient pole 12a in
which the area near the middle of the magnetic pole drops more than
the area near the ends of the magnetic pole.
[0073] When the magnetic pole occupying angle .theta.1 of the
magnet 13 is set to 180.degree., that is, when the magnetic pole
occupying angle .theta.1 of the magnet 13 and the magnetic pole
occupying angle .theta.2 of the salient pole 12a are equal to each
other, the magnetic flux density does not become zero at the
electrical angles 0.degree., 180.degree., 360.degree. (=0.degree.)
in the rotor 10B, which has a magnetically unbalanced structure.
Specifically, when the magnetic pole occupying angle .theta.1 of
the magnet 13 is 180.degree., the magnetic flux density rises so as
to pass by zero at an electrical angle that is slightly larger than
0.degree. and falls so as to pass by zero at an electrical angle
that is slightly smaller than 180.degree.. That is, the range of
the magnetic pole of the magnet 13 appears as a range that is
smaller than the range of the magnetic pole of the salient pole 12a
in the circumferential direction.
[0074] When the magnetic pole occupying angle .theta.1 of the
magnet 13 is 171.degree., which is smaller than 180.degree., the
point at which the magnetic flux density becomes zero is more
spaced apart from the electrical angles 0.degree. and 180.degree.
than when the magnetic pole occupying angle .theta.1 is
180.degree.. Accordingly, the range of the magnetic pole of the
magnet 13 appears as a range that is further smaller than the range
of the magnetic pole of the salient pole 12a in the circumferential
direction. The drop in the magnetic flux density near the middle of
the magnetic pole zone of the salient pole 12a also becomes
larger.
[0075] When the magnetic pole occupying angle .theta.1 of the
magnet 13 is 198.degree., which is larger than 180.degree., the
magnetic flux density becomes zero at the electrical angles
0.degree. and 180.degree.. That is, the range of the magnetic pole
of the magnet 13 appears as a range equal to the range of the
magnetic pole of the salient pole 12a in the circumferential
direction. The drop in the magnetic flux density near the middle of
the magnetic pole zone of the salient pole 12a becomes small.
[0076] When the magnetic pole occupying angle .theta.1 of the
magnet 13 is 208.degree. and further larger, the magnetic flux
density rises so as to pass by zero at an electrical angle that is
slightly smaller than 0.degree. and falls so as to pass by zero at
an electrical angle that is slightly larger than 180.degree.. That
is, the range of the magnetic pole of the magnet 13 appears as a
range that is larger than the range of the magnetic pole of the
salient pole 12a in the circumferential direction. The drop near
the middle of the magnetic pole zone of the salient pole 12a of the
magnetic flux density becomes smaller.
[0077] FIG. 7 shows the torque ripple and the torque when changing
the magnetic pole occupying angle .theta.1 of the magnet 13. If the
magnitude of torque is 100% when the magnetic pole occupying angle
.theta.1 of the magnet 13 is 180.degree., the torque is less than
100% when the magnetic pole occupying angle .theta.1 is smaller
than 180.degree.. The torque exceeds 100% in the range in which the
magnetic pole occupying angle .theta.1 is between 180.degree. and
220.degree..
[0078] In FIG. 7, if the magnitude of the torque ripple is 100%
when the magnetic pole occupying angle .theta.1 of the magnet 13 is
180.degree., the torque ripple is greater than 100% when the
magnetic pole occupying angle .theta.1 is smaller than 180.degree..
When the magnetic pole occupying angle .theta.1 is increased to be
larger than 180.degree., the torque ripple is reduced to 85% at the
magnetic pole occupying angle .theta.1 of 184.degree.. When the
magnetic pole occupying angle .theta.1 is further increased, the
torque ripple is reduced to 75% at the magnetic pole occupying
angle .theta.1 of 188.degree.. The torque ripple is reduced to a
minimum value of about 73% when the magnetic pole occupying angle
.theta.1 is approximately 190.degree. to 195.degree.. After the
magnetic pole occupying angle .theta.1 becomes greater than
approximately 195.degree., the torque ripple increases as the
magnetic pole occupying angle .theta.1 increases and becomes 75% at
the magnetic pole occupying angle .theta.1 of 198.degree., 85% at
the magnetic pole occupying angle .theta.1 of 202.degree., and
greater than or equal to 100% just about when the magnetic pole
occupying angle .theta.1 exceeds 210.degree.. That is, compared to
a structure in which the magnetic pole occupying angle .theta.1 and
the magnetic pole occupying angle .theta.2 are equal to each other,
the range of 180.degree.<.theta.1.ltoreq.210.degree. is a
satisfactory range that reduces the torque ripple. The range of
184.degree..ltoreq..theta.1.ltoreq.202.degree. is a satisfactory
range where the torque ripple can be reduced to 85%. The range of
188.degree..ltoreq..theta.1.ltoreq.198.degree. is a further
satisfactory range that reduces the torque ripple to 75%.
[0079] Accordingly, in the range of
180.degree.<.theta.1<210.degree., the magnetic pole occupying
angle .theta.1 is set in the range of
188.degree..ltoreq..theta.1.ltoreq.198.degree. in the rotor 10B of
the second embodiment. Thus, compared to a structure in which the
magnetic pole occupying angles .theta.1 and .theta.2 are equal to
each other, the torque ripple is reduced while suppressing torque
decrease. As a result, the rotation performance of the rotor 10B is
improved.
[0080] The second embodiment has the advantages described
below.
[0081] (5) In the second embodiment, the magnetic pole occupying
angle .theta.1 of the magnet 13 is set in the range of
180.degree.<.theta.1.ltoreq.210.degree. in the motor M of which
the ratio X1:X2 of the magnetic pole portion quantity X1 of the
rotor 10B and the slot quantity X2 of the stator X2 is 3n-2:3n (n
is an even number that is greater than or equal to 4). Thus,
compared to a structure in which the magnetic pole occupying angle
.theta.1 of the magnet 13 and the magnetic pole occupying angle
.theta.2 of the salient pole 12a are the same, the motor M of the
second embodiment reduces the torque ripple while suppressing
torque decrease (see FIG. 7) and improves the rotation performance
of the rotor 10B.
[0082] (6) In the second embodiment, the magnetic pole occupying
angle .theta.1 of the magnet 13 is set in the range of
184.degree..ltoreq..theta.1.ltoreq.202.degree.. Thus, compared to a
structure in which the magnetic pole occupying angle .theta.1 of
the magnet 13 and the magnetic pole occupying angle .theta.2 of the
salient pole 12a are the same, the motor M of the second embodiment
reduces the torque ripple to about 85% (see FIG. 7). This further
improves the rotation performance of the rotor 10B.
[0083] (7) In the second embodiment, the magnetic pole occupying
angle .theta.1 of the magnet 13 is set in the range of
188.degree..theta.1.ltoreq.198.degree.. Thus, compared to a
structure in which the magnetic pole occupying angle .theta.1 of
the magnet 13 and the magnetic pole occupying angle .theta.2 of the
salient pole 12a are the same, the motor M of the second embodiment
reduces the torque ripple to about 75% (see FIG. 7). This further
improves the rotation performance of the rotor 10B.
[0084] (8) In the second embodiment, the clearance S1 is formed
between a magnet 13 and salient pole 12a that are adjacent to each
other in the circumferential direction of the rotor 10B.
Accordingly, advantage (4) of the first embodiment is also
obtained.
[0085] (9) In the second embodiment, the relationship of the
magnetic pole occupying angles (electrical angles) .theta.1 and
.theta.2 and the deviation of the magnetic pole switching position
is shown in FIG. 8. FIG. 8 shows the relationship of the magnetic
pole occupying angle .theta.1 of the magnet 13 and the deviation,
of the magnetic pole switching position. As described above, the
deviation of the magnetic pole switching position becomes 0.degree.
at .theta.1=198.degree. at which the size of the magnetic pole
range of the magnet 13 and the size of the magnetic pole range of
the salient pole 12a that actually appear on the surface of the
rotor 10B become equal to each other. When the magnetic pole
occupying angle .theta. of the magnet 13 becomes smaller than
198.degree., the deviation of the magnetic pole switching position
gradually increases in the negative side. This indicates that the
magnetic pole range of the magnet 13 that actually appears on the
surface of the rotor 10B is small in the circumferential direction.
When the magnetic pole occupying angle .theta. of the magnet 13
increases from 198.degree., the deviation in the magnetic pole
switching position gradually increases in the positive side. This
indicates that the magnetic pole range of the magnet 13 that
actually appears on the surface of the rotor 10B is large in the
circumferential direction.
[0086] Further, when the magnetic pole occupying angles .theta.1
and .theta.2 of the magnet 13 and the salient pole 12a are the
same, the deviation of the magnetic pole switching position of the
magnet 13 that actually appears on the surface of the rotor 10B is
-7.degree.. Thus, the deviation of the magnetic pole switching
position is less than .+-.7.degree. when the magnetic pole
occupying angle .theta.1 of the magnet 13 is in the range of
180.degree.<.theta.1<220.degree.. This range is a
satisfactory range since the magnitude of the magnetic pole range
of the magnet 13 and the magnitude of the magnetic pole range of
the salient pole 12a that actually appear on the surface of the
rotor 10B become equal or substantially equal in the
circumferential direction.
[0087] Compared to a structure in which the magnetic pole occupying
angle .theta.1 of the magnet 13 and the magnetic pole occupying
angle .theta.2 of the salient pole 12a are the same, the
above-described setting for the magnetic pole occupying angle
.theta.1 magnetically balances the motor M and improves the
rotation performance of the rotor 10B.
[0088] The second embodiment may be modified as described
below.
[0089] In the second embodiment, the magnetic pole occupying angle
.theta.1 of the magnet 13 is set in the range of
188.degree..ltoreq..theta.1.ltoreq.198.degree. but may be set in a
wider range of 184.degree..ltoreq..theta.1.ltoreq.202.degree. or an
even wider range of 180.degree.<.theta.1.ltoreq.210.degree..
[0090] In the second embodiment, the ratio X1:X2 of the magnetic
pole portion quantity X1 of the rotor 10B and the slot quantity X2
of the stator 20 is set to 10:12, that is, 3n-2:3n ("n" is 4).
However, the value of "n" may be changed when required to another
even number that is greater than or equal to 4. The ratio X1:X2 for
the magnetic pole portion quantity X1 of the rotor 10B and the slot
quantity X2 of the stator 20 may be set to 3n-1:3n ("n" is an odd
number greater than or equal to 3), for example, a ratio X1:X2 of
8:9 or 11:12.
[0091] The numerical ranges in the second embodiment may be changed
as required in accordance with the situation or the like.
Third Embodiment
[0092] A third embodiment of the present invention will now be
discussed with reference to FIGS. 9 to 11.
[0093] In the third embodiment, the quantity of magnetic pole
portions of the rotor differs from the first embodiment.
Accordingly, the same reference numerals are given to those
components that are the same as the corresponding components of the
first embodiment. Such components will not be described in
detail.
[0094] As shown in FIGS. 9 and 10, the motor M of the third
embodiment uses a rotor 10C including seven N-pole magnets 13,
which are arranged along the circumferential direction of the rotor
core 12, and seven salient poles 12a, which are arranged between
adjacent ones of the magnets 13 in the circumferential direction.
The salient poles 12a function as the S-poles. In other words, the
rotor 10C is a so-called consequent pole type having fourteen
magnetic pole portions. The stator 20 includes twelve teeth 21a in
the same manner as the first embodiment. That is, in the brushless
motor M of the third embodiment, the ratio X1:X2 of the magnetic
pole portion quantity X1 of the rotor 10C and the slot quantity X2
(number of teeth) of the stator 20 is set to 14:12, that is,
3n+2:3n ("n" is 4).
[0095] FIG. 11 shows the torque ripple and the torque when changing
the circumferential lengths of the magnet 13 and the salient pole
12a, that is, when changing the magnetic pole occupying angles
(electrical angles) .theta.1 and .theta.2, the initiating points
and terminating points of which are the median points of the
clearances S1 between the magnets 13 and the salient poles 12a. In
FIG. 11, the torque ripple is shown by a solid line, and the torque
is shown by a single-dashed line.
[0096] In FIG. 11, the magnitude of torque is defined as 100% when
the magnetic pole occupying angle .theta.1 of the magnet 13 is
180.degree., that is, when the magnetic pole occupying angle
.theta.1 of the magnet 13 and the magnetic pole occupying angle
.theta.2 of the salient pole 12a are equal to each other. The
torque becomes less than 100% when the magnetic pole occupying
angle .theta.1 is smaller than 180.degree.. The torque exceeds 100%
when the magnetic pole occupying angle .theta.1 is in the range of
180.degree. to 210.degree..
[0097] In FIG. 11, the magnitude of the torque ripple is defined as
100% when the magnetic pole occupying angle .theta.1 of the magnet
13 is 180.degree.. The torque ripple becomes greater than 100% when
the magnetic pole occupying angle .theta.1 is smaller than
180.degree.. When the magnetic pole occupying angle .theta.1 is
increased to be larger than 180.degree., the torque ripple is
reduced to 98% at the magnetic pole occupying angle .theta.1 of
182.degree.. The torque ripple is reduced to about 96% (near
minimum value) when the magnetic pole occupying angle .theta.1 is
about 185.degree. to 195.degree.. After the magnetic pole occupying
angle .theta.1 exceeds 195.degree., the torque ripple increases as
the magnetic pole occupying angle .theta.1 increases and becomes
98% when the magnetic pole occupying angle .theta.1 is
approximately 197.degree.. The torque ripple becomes greater than
or equal to 100% just about when the magnetic pole occupying angle
.theta.1 exceeds 200.degree.. That is, compared to a structure in
which the magnetic pole occupying angles .theta.1 and .theta.2 are
equal to each other, the torque ripple is reduced when the magnetic
pole occupying angle .theta.1 of the magnet 13 is in the range of
180.degree.<.theta.1.ltoreq.200.degree., the torque ripple is
reduced to 98% in the range of
182.degree..ltoreq..theta.1.ltoreq.197.degree., and the torque
ripple is reduced to about 96% in the range of
185.degree..ltoreq..theta.1.ltoreq.195.degree..
[0098] Accordingly, in the range of
180.degree.<.theta.1.ltoreq.200.degree., the magnetic pole
occupying angle .theta.1 is set in the range of
185.degree..ltoreq..theta.1.ltoreq.195.degree. in the rotor 10C of
the third embodiment. Thus, compared to a structure in which the
magnetic pole occupying angles .theta.1 and .theta.2 are the same,
the torque ripple is reduced while suppressing torque decrease. As
a result, the rotation performance of the rotor 10C is
improved.
[0099] The third embodiment has the advantages described below.
[0100] (10) In the third embodiment, the magnetic pole occupying
angle .theta.1 of the magnet 13 is set in the range of
180.degree.<.theta.1.ltoreq.200.degree. in the motor M of which
the ratio X1:X2 of the magnetic pole portion quantity X1 of the
rotor 10C and the slot quantity X2 of the stator X2 is 3n+2:3n (n
is an even number). Thus, compared to a structure in which the
magnetic pole occupying angle .theta.1 of the magnet 13 and the
magnetic pole occupying angle .theta.2 of the salient pole 12a are
the same, the motor M of the third embodiment reduces torque ripple
while suppressing torque decrease (see FIG. 11). This improves the
rotation performance of the rotor 10C.
[0101] (11) In the third embodiment, the magnetic pole occupying
angle .theta.1 of the magnet 13 is set in the range of
182.degree..theta.1.ltoreq.197.degree.. Thus, compared to a
structure in which the magnetic pole occupying angle .theta.1 of
the magnet 13 and the magnetic pole occupying angle .theta.2 of the
salient pole 12a are the same, the motor M of the third embodiment
reduces torque ripple to about 98% (see FIG. 11). This further
improves the rotation performance of the rotor 10C.
[0102] (12) In the third embodiment, the magnetic pole occupying
angle .theta.1 of the magnet 13 is set in the range of
185.degree..theta.1.ltoreq.195.degree.. Thus, compared to a
structure in which the magnetic pole occupying angle .theta.1 of
the magnet 13 and the magnetic pole occupying angle .theta.2 of the
salient pole 12a are the same, the motor M of the third embodiment
reduces the torque ripple to about 96% (see FIG. 11). This further
improves the rotation performance of the rotor 10C.
[0103] (13) In the third embodiment, the clearance S1 is formed
between a magnet 13 and salient pole 12a that are adjacent to each
other in the circumferential direction of the rotor 10C.
Accordingly, advantage (4) of the first embodiment is also
obtained.
[0104] The third embodiment may be modified as described below.
[0105] In the third embodiment, the magnetic pole occupying angle
.theta.1 of the magnet 13 is set in the range of
185.degree..ltoreq..theta.1.ltoreq.195.degree. but may be set in a
wider range of 182.degree..ltoreq..theta.1.ltoreq.197.degree. or an
even wider range of 180.degree.<.theta.1.ltoreq.200.degree..
[0106] In the third embodiment, the ratio X1:X2 of the magnetic
pole portion quantity X1 of the rotor 10C and the slot quantity X2
of the stator 20 is set to 14:12, that is, 3n+2:3n ("n" is 4).
However, the value of "n" may be changed when required to another
even number. The ratio X1:X2 of the magnetic pole portion quantity
X1 of the rotor 10C and the slot quantity X2 of the stator 20 may
be set to 3n+1:3n ("n" is an odd number), for example, the ratio
X1:X2 may be set to 4:3 or 7:6.
[0107] The numerical ranges in the third embodiment may be changed
as required in accordance with the situation or the like.
[0108] The first to third embodiments of the present invention may
include the structures of fourth to ninth embodiments, which will
now be discussed.
Fourth Embodiment
[0109] A fourth embodiment will now be discussed with reference to
FIGS. 12 to 16. The same reference numerals are given to those
components that are the same as the corresponding components of the
first embodiment. Such components will not be described in
detail.
[0110] As shown in FIGS. 12 and 13, the motor M of the fourth
embodiment uses a rotor 10D including seven N-pole magnets 13,
which are arranged along the circumferential direction of the rotor
core 12, and seven salient poles 12a, which are arranged between
adjacent ones of the magnets 13 in the circumferential direction.
The salient poles 12a function as the S-poles. In other words, the
rotor 10D is a so-called consequent pole type having fourteen
magnetic pole portions. The stator 20 includes twelve teeth 21a in
the same manner as the first embodiment.
[0111] The circumferential length of the salient pole 12a is
slightly shorter than the circumferential length of the magnet 13
by an amount corresponding to the clearance S1.
[0112] In the fourth embodiment, the outer surface 12c of the
salient pole 12a is arranged outward in the radial direction
relative to the outer surface 13b of the magnet 13. In other words,
a radial distance B between the salient pole 12a and the stator 20B
is less than a radial distance A between the magnet 13 and the
stator 20 in the clearance S2 between the stator 20 (distal surface
of the teeth 21a) and the rotor 10D. Each of the radial distances B
and A is constant in the circumferential direction. That is, the
radial distance A is the shortest radial distance at any location
in the circumferential direction corresponding to the magnet 13,
and the radial distance B is the shortest radial distance at any
location in the circumferential direction corresponding to the
magnet 13.
[0113] FIG. 4 shows the variation in the radial force received by
the teeth 21a when changing the ratio B/A of the clearance
distances B and A, FIG. 15 shows the torque, and FIG. 16 shows the
torque ripple.
[0114] FIG. 14 shows the variation in the radial force received by
a single tooth 21a when changing the ratio to B/A=1, B/A=0.65, and
B/A=0.3. For B/A=1, the difference between the maximum value and
the minimum value of the radial force is large and the variation is
random. For B/A=0.65, the difference between the maximum value and
the minimum value is small and the variation slightly stabilizes.
For B/A=0.3, the difference between the maximum value and the
minimum value becomes smaller, and the variation stabilizes to the
same extent.
[0115] FIG. 15 shows the torque of the motor M when changing the
ratio B/A. The magnitude of the torque is defined as 100% when
B/A=1 is satisfied, that is, when the radial distances B and A of
the salient pole 12a and the magnet 13 are the same. In FIG. 15,
the torque increases in a substantially constant manner as B/A
becomes smaller (as the salient pole 12a projects relative to the
magnet 13). The torque increases to about 110% when B/A=0.3 is
satisfied.
[0116] FIG. 16 shows the torque ripple when changing the B/A. The
magnitude of the torque ripple is defined as 100% when B/A=1 is
satisfied. The torque ripple increases as the B/A decreases. In
this case, the variation rate of the torque ripple is slightly
greater when changing the B/A from 0.6 to 0.3 than when changing
the ratio B/A from 1 to 0.6, and the variation rate of the torque
ripple suddenly increases from B/A=0.3.
[0117] Accordingly, the ratio B/A of the radial distances B and A
is set within a range of 0.3.ltoreq.B/A<1 in the rotor 10D of
the fourth embodiment. That is, in the fourth embodiment, the
radial distances B and A are each optimized to appropriately
increase the gap permanence at the side of the salient pole 12a and
increase the intensity of the magnetic field acting on the stator
20. This increases the motor torque while suppressing an increase
in torque ripple (torque pulsation). Thus, the rotation performance
of the rotor 10D is improved.
[0118] The fourth embodiment has the advantages described
below.
[0119] (14) In the fourth embodiment, the ratio B/A of the radial
distance A and the radial distance B is set in the range of
0.3.ltoreq.B/A<1. This increases the motor torque while
suppressing an increase in torque ripple (see FIGS. 15 and 16) and
improves the rotation performance of the rotor 10D. That is, the
rotation performance of the motor M is improved.
[0120] (15) In the fourth embodiment, the outer surface 13b of the
magnet 13 is arranged inward relative to the outer surface 12c of
the salient pole 12a. This allows for the attachment of a
scattering prevention cover of the magnet 13 using the space
produced by the inward arrangement. Thus, the salient pole 12a,
which does not need to be covered, is arranged closer to the stator
20 by a distance corresponding to the thickness of the cover. This
increases the motor torque.
Fifth Embodiment
[0121] A fifth embodiment will now be discussed with reference to
FIGS. 17 and 18.
[0122] As shown in FIG. 17, in the rotor 10D of the fifth
embodiment, the outer surface 12c of the salient pole 12a has a
larger curvature than the outer surface 12c of the fourth
embodiment. The curvature is constant throughout the entire outer
surface 12c. Accordingly, the central part in the circumferential
direction of the outer surface 12c projects outward in the radial
direction relative to the two ends in the circumferential
direction. More specifically, when a circumference having
substantially the same curvature as a circumference connecting the
distal surfaces of the teeth 21a of the stator 20 and passing by
the central part in the circumferential direction of each salient
pole 12a, or the outermost circumferential part of the salient
poles 12a, defines a reference circumference C1, the salient pole
12a becomes more spaced apart from the circumference C1 as the
circumferential ends of the salient pole 12a become closer.
[0123] With respect to the outer surface 12c, the radial distance
(shortest radial distance) between the circumferential central part
and the stator 20 (distal surface of the teeth 21a) is represented
by B, and the radial distance between the circumferential ends and
the stator 20 is represented by C. In this case, the radial force
pulsation received by the teeth 21a when changing the ratio C/B is
shown in FIG. 18.
[0124] FIG. 18 shows the magnitude of the radial force pulsation
when changing the ratio C/B. When C/B=1 is satisfied and the radial
distances B and C are the same, that is, when the circumferential
central part and the circumferential ends are both located on the
circumference C1, the magnitude of the radial force pulsation is
100%. As the ratio C/B increases, that is, as the curvature of the
outer surface 12c of the salient pole 12a increases, the radial
force pulsation varies in a manner that it decreases once but then
increases again as the circumferential ends become relatively far
from the stator 20. The radial force pulsation drastically
decreases when the C/B is 1 to 2 but is still 80% and large when
the C/B is 2. The radial force pulsation varies relatively stably
from 80% to 75% when the C/B is 2 to 5. The radial force pulsation
gradually decreases from 80% to 75% when the C/B is 2 to 3, and the
radial force pulsation gradually increases from 75% to 80% when the
C/B is 3 to 5. After C/B increases from 5, the radial force
pulsation gradually increases from 80% at the same rate as when the
C/B is 3 to 5.
[0125] Accordingly, the ratio C/B of the radial distances B and C
is set in a range of 2.ltoreq.C/B.ltoreq.5 in the rotor 10D of the
fifth embodiment. In the fifth embodiment, the radial force
pulsation is thus suppressed to less than or equal to about 80%.
This decreases the radial force received by the stator 20, and
reduces vibration of the motor M.
[0126] The fifth embodiment has the advantages described below.
[0127] (16) In the fifth embodiment, the ratio C/B is set within
the range of 2.ltoreq.C/B.ltoreq.5. This decreases the pulsation of
the radial force received by the stator 20 is thus reduced (see
FIG. 18) and reduces vibration of the motor M.
[0128] The fourth and fifth embodiments may be modified as
described below.
[0129] The numerical ranges in the fourth and fifth embodiments may
be changed as required in accordance with the situation or the
like.
[0130] In the fifth embodiment, the curved shape of the outer
surface 12c has a constant curvature. However, the curvature of the
outer surface 12c may be partially changed. Further, the shape of
the outer surface 12c may be changed to be linear. Further, just
the corners of the salient poles 12a may be rounded or
chamfered.
[0131] The structures of the fourth and fifth embodiments are
applied to the rotor 10D that includes fourteen magnetic pole
portions, which are formed by the seven salient poles 12a and the
seven magnets 13. However, the quantity of the magnetic pole
portions may be changed as required, and the quantity of the
magnetic pole portions on the stator side may be changed
accordingly.
Sixth Embodiment
[0132] A sixth embodiment will now be discussed with reference to
FIGS. 19 to 23. The same reference numerals are given to those
components that are the same as the corresponding components of the
first embodiment. Such components will not be described in
detail.
[0133] FIGS. 19 and 20 show a rotor 10E of the sixth embodiment.
The rotor 10E includes seven N-pole magnets 13, which are arranged
along the circumferential direction of the rotor core 12, and
salient poles 12a, which are arranged between adjacent ones of the
magnets 13 in the circumferential direction. The salient poles 12a
function as the S-poles. In other words, the rotor 10B is a
so-called consequent pole type having fourteen magnetic pole
portions.
[0134] The magnet 13 has a circumferential length that is slightly
longer than that of the salient pole 12a. The magnet 13 has a
curved shape and a thickness (dimension in the radial direction)
that is constant in the circumferential direction. Accordingly, the
inner surface 13a and the outer surface 13b of the magnet 13 are
parallel. The fixation surface 12b of the rotor core 12, to which
the inner surface 13a of the magnet 13 is fixed, has a curved shape
that conforms to the inner surface 13a. A clearance (gap in the
circumferential direction) S is formed between a magnet 13 and
salient pole 12a that are adjacent to each other in the
circumferential direction. In the same manner as the second
embodiment, the clearance S formed between the inner surface 13a of
the magnet 13 and the salient pole 12a is set to be about one to
two times greater than the clearance between the rotor 10E and the
stator.
[0135] The salient pole 12a includes a central part in the
circumferential direction and two ends in the circumferential
direction. With respect to a circumference C1 connecting the inner
surfaces 13a of the magnets 13, the circumferential central part
has a large projecting length, and the two circumferential ends
have a projecting length that is smaller than the circumferential
central part. Further, the salient pole 12a is shaped in symmetry
in the circumferential direction. In other words, the projecting
length decreases from the central circumferential part to the two
circumferential ends. The circumferential central part in the outer
surface 12c of the salient pole 12a, that is, at least part of the
outer surface 12c lies along a circumference C2 connecting the
outer surfaces 13b of the magnets 13. Further, the circumferential
ends of the outer surface 12c are located radially inward from the
circumference C2. That is, the outer surface 12c of the salient
pole 12a has a curvature that is greater than the curvature of the
circumference C2, which connects the outer surfaces 13b of the
magnets 13, and thereby has a radius of curvature that is smaller
than the radius of curvature of the circumference C2. Thus, the
outer surface 12c is gradually distanced from the stator as the
circumferential ends become closer from the central part.
[0136] Here, the radius of the circumference C2 connecting the
outer surface 13b of each magnet 13 is represented by R, and the
radius of the outer surface 12c of each salient pole 12a is
represented by r1. In this case, when changing the ratio r1/R, the
surface magnetic flux density variation of the rotor 10E is shown
in FIG. 21, the torque is shown in FIG. 22, and the torque ripple
is shown in FIG. 23.
[0137] FIG. 21 shows the magnetic flux density variation when
changed the ratio to r1/R1=1, r1/R=0.5, and r1/R=0.3. The magnetic
flux density variation in the magnetic pole zone of the magnet 13
is small even if the ratio of r1/R is changed, and the magnetic
flux density variation forms a substantially trapezoidal shape with
a smooth curve. In contrast, the magnetic flux density variation in
the magnetic pole zone of the salient pole 12a greatly differs in
accordance with the ratio of r1/R. When the r1/R is 1, that is,
when the outer surface 12c of the salient pole 12a has the same
curvature as the circumference C2 connecting the outer surfaces 13b
of the magnets 13, the magnetic flux density near the ends of the
magnetic pole zone of the salient pole 12a projects out and varies
greatly, and the drop in the magnetic flux density is large near
the middle of the magnetic pole zone. When the ratio becomes
smaller, such as when r1/R=0.5 or r1/R=0.3 is satisfied, that is,
when the curvature of the outer surface 12c of the salient pole 12a
is greater than the circumference C2, a clearance between the
circumferential ends of the salient pole 12a and the stator is
enlarged. Thus, the projection variation rate of the magnetic flux
density near the ends of the magnetic pole zone of the salient pole
12a is small, and the drop rate of the magnetic flux density near
the middle of the magnetic pole zone also becomes small.
[0138] FIG. 22 shows the torque of the motor when the ratio r1/R is
changed. The magnitude of the torque is defined as 100% when r1/R=1
is satisfied, that is, when the curvature of the outer surface 12c
of the salient pole 12a is not changed. The torque becomes small,
although slightly, as the r1/R decreases (as the curvature of the
outer surface 12c of the salient pole 12a becomes greater than the
circumference C2). The torque is decreased by a small amount until
it becomes about 98.5% when the r1/R is 0.2, and the decreasing
amount becomes greater, although slightly, from when the ratio r1/R
is 0.2.
[0139] FIG. 23 shows the torque ripple when the ratio r1/R is
changed. The magnitude of the torque ripple is defined as 100% when
r1/R=1 is satisfied, that is, when the curvature of the outer
surface 12c of the salient pole 12a is not changed. The torque
ripple sufficiently decreases as the ratio r1/R decreases. The
torque ripple is decreased by a relatively small amount until it
becomes about 95% when the ratio r1/R is 0.8. However, the
decreasing amount becomes greater from when r1/R is 0.8, and the
torque ripple decreases to about 55% when the ratio r1/R is 0.3.
The decreasing amount of the torque ripple further increases from
when the ratio r1/R is 0.3. The torque ripple is particularly
greatly decreased from when the ratio r1/R is 0.8. This further
reduces torque pulsation.
[0140] Accordingly, in the rotor 10E of the sixth embodiment, the
curvature of the outer surface 12c of the salient pole 12a is set
so that the ratio r1/R is within a range of
0.2.ltoreq.r1/R.ltoreq.0.8. That is, in the sixth embodiment, the
arrangement of the clearance S between the magnet 13 and the
salient pole 12a suppresses sudden surface magnetic flux density
variation of the rotor 10E. Additionally, sudden surface magnetic
flux density variation is further suppressed while minimizing
torque decrease, and torque pulsation is further reduced.
[0141] The rotor 10E of the sixth embodiment is used in an inner
rotor type motor. Accordingly, the area of the outer surfaces 12c
and 13b of the salient pole 12a and the magnet 13, that is, the
area of the surface facing towards the stator, is greater than the
inner surface. Further, the magnetic path that extends from the
magnet 13 through the rotor core 12 and out of the salient pole 126
is shortened thereby reducing magnetic loss. Thus, even when the
volume of the entire motor is the same as an outer rotor type
motor, the magnetic flux density formed with the stator is
increased and higher torque is obtained in comparison to the outer
rotor type in which the inner surface of the rotor core faces
toward the stator.
[0142] The sixth embodiment has the advantages described below.
[0143] (17) In the sixth embodiment, the salient pole 12a includes
the outer surface (surface) 12c, which has a curved shape of a
constant curvature. The ratio r1/R of the radius r1 of the outer
surface 12c and the radius R of the reference circumference C2 is
set within the range of 0.2.ltoreq.r1/R.ltoreq.0.8. In this range,
the two circumferential ends in the outer surface 12c of the
salient pole 12a are gradually distanced inward in the radial
direction in a curved manner from the reference circumference C2.
This enlarges the clearance from the stator as the circumferential
ends of the salient pole 12a become closer. Thus, the projection of
the magnetic flux density near the end of the magnetic pole zone of
the salient pole 12a decreases, and the dropping rate of the
magnetic flux density also decreases near the middle of the
magnetic pole zone. As a result, in addition to the arrangement of
the clearance S between the magnet 13 and the salient pole 12a
suppressing sudden magnetic flux density variation of the rotor
10E, sudden surface magnetic flux density variation is further
suppressed, and torque pulsation is further reduced. The ratio r1/R
of the radius r1 of the outer surface 12c of the salient pole 12a
and the radius R of the reference circumference C2 is set within
the range of 0.2.ltoreq.r1/R.ltoreq.0.8. Thus, torque ripple is
further reduced while suppressing torque decrease of the motor, and
torque pulsation is further reduced (see FIGS. 22 and 23). This
increases the motor output and reduces motor vibration.
Seventh Embodiment
[0144] A seventh embodiment will now be discussed with reference to
FIGS. 24 to 26.
[0145] In the sixth embodiment, the curvature of the entire outer
surface 12c of the salient pole 12a is optimized. In the seventh
embodiment, the curvature of the rounded shape of the corner 12d at
each of the two circumferential ends of the salient pole 12a is
optimized, as shown in FIG. 24. More specifically, the outer
surface 12c of the salient pole 12a is more distance from the
stator as the circumferential ends become closer from the central
part.
[0146] Here, the radius of the corner 12d of the salient pole 12a
is represented by r2, and the projecting length of the salient pole
12a from the circumference C1 connecting the inner surfaces 13a of
the magnets 13 is represented by h. In this case, when changing the
ratio r2/h, the torque of the rotor 10E is shown in FIG. 25, and
the torque ripple is shown in FIG. 26.
[0147] FIG. 25 shows the torque of the motor when changing r2/h.
The magnitude of the torque of the motor is defined as 100% when
r2/h is 0, that is, when the corner 12d is not rounded. The torque
gradually increases as r2/h increases and becomes maximum when r2/h
is approximately 0.6 and then gradually decreases. After the torque
becomes less than 100% when r2/h is approximately 0.9, the torque
further decreases until r2/h reaches 1.
[0148] FIG. 26 shows the torque ripple when changing r2/h. The
magnitude of the torque ripple is defined as 100% when r2/h is 0,
that is, when the corner 12d of the salient pole 12a is not
rounded. The torque ripple increases, although slightly, until r2/h
reaches 0.2, and becomes less than 100% after r2/h reaches 0.2. The
torque ripple becomes about 50% when r2/h is approximately 0.8 and
subtly varies from when r2/h reaches 0.9.
[0149] Accordingly, the projecting length h of the salient pole 12a
and the radius r2 of the corner 12d in the rotor 10E of the seventh
embodiment are set so that r2/h is within a range of
0.2.ltoreq.r2/h.ltoreq.0.9. As a result, in the seventh embodiment,
sudden magnetic flux density variation is further suppressed
without lowering the torque of the motor as much as possible, and
torque pulsation is further reduced.
[0150] The seventh embodiment has the advantages described
below.
[0151] (18) In the seventh embodiment, the corners 12d located at
the two circumferential ends of the salient pole 12a are rounded,
and the ratio r2/h of the radius r2 of the corner 12d and the
projecting length h of the salient pole 12a is set within the range
of 0.2.ltoreq.r2/h.ltoreq.0.9. That is, when the salient pole 12a
is formed so that r2/h is within this range, the two
circumferential ends of the outer surface 12c of the salient pole
12a are gradually distanced inward in the radial direction in a
curved manner from the reference circumference C2. Thus, in the
same manner as the advantages of the sixth embodiment, sudden
magnetic flux density variation of the rotor 10E is further
suppressed, and torque pulsation is further reduced. Further, the
r2/h is set within the range of 0.2.ltoreq.r2/h.ltoreq.0.9. Thus,
the torque ripple is further reduced while suppressing a motor
torque decrease, and torque pulsation is further reduced (see FIGS.
25 and 26). This increases the motor output and reduces motor
vibration.
Eighth Embodiment
[0152] An eighth embodiment will now be discussed with reference to
FIGS. 27 to 31.
[0153] In the sixth and seventh embodiments, the curvatures of the
outer surface 12c and the corner 12d of the salient pole 12a are
optimized. In the seventh embodiment, the curvature of the outer
surface 13b of the magnet 13 is optimized, as shown in FIGS. 27 and
28. Specifically, the circumferential central part in the outer
surface 13b of the magnet 13, that is, at least part of the outer
surface 13b, lies along the circumference C2 connecting the outer
surfaces 12c of the salient poles 12a. The outer surface 13b of the
magnet 13 is more distanced from the stator from the
circumferential central part towards as the ends.
[0154] When changing the curvature of the outer surface 13b of each
magnet 13, the radius of the outer surface 13b is represented by
r3. When the curvature is not changed, the radius of the outer
surface 13b, that is, the circumference'C2 connecting the outer
surfaces 13b of the salient poles 12a is represented by R. When
changing the ratio r3/R of the radius r3 and the radius R, the
surface magnetic flux density variation of the rotor 10E is shown
in FIG. 29, the torque is shown in FIG. 30, and the torque ripple
is shown in FIG. 31. The outer surface 12c of the salient pole 12a
lies on the circumference C2 (r1/R=1).
[0155] FIG. 29 shows the magnetic flux density variation when the
ratio r3/R is changed to 1 and 0.6. The magnetic flux density in
the magnetic pole zone of the magnet 13 changes to a substantially
trapezoidal shape when the ratio r3/R is 1 but changes to a
substantially sinusoidal shape when r3/R is 0.6. Further, with
regard to the magnetic flux density in the magnetic pole zone of
the salient pole 12a, sudden magnetic flux density variation is
improved when the ratio r3/R is 0.6, that is, when the curvature of
the outer surface 13b of the magnet 13 is greater than the
curvature of the circumference C2, than when the ratio r3/R is 1,
that is, when the curvature of the outer surface 13b of the magnet
13 is the same as the curvature of the circumference C2.
[0156] FIG. 30 shows the torque of the motor when changing r3/R.
When the magnitude of the torque is defined as 100% when the ratio
r3/R is 1, the torque decreases as the ratio r3/R decreases. The
torque is decreased by a relatively small amount until the ratio
r3/R reaches 0.4 and is decreased by a large amount after the ratio
r3/R reaches 0.4.
[0157] FIG. 31 shows the torque ripple when changing r3/R. When the
magnitude of the torque ripple is defined as 100% when the ratio
r3/R is 1, the torque ripple decreases as the ratio r3/R decreases.
The torque ripple is decreased by a relatively small amount until
the ratio r3/R reaches 0.8 at which the torque ripple is about 80%.
However, the torque ripple is decreased by a large amount from when
the ratio r3/R reaches 0.8, and the torque ripple decreases to
about 50% when the ratio r3/R reaches 0.6. The torque ripple
becomes sufficiently small from when the ratio r3/R is 0.6. In
particular, the torque ripple is greatly decreased from when the
ratio r3/R is 0.8. Thus, torque pulsation is further reduced.
[0158] Accordingly, in the rotor 10E of the eighth embodiment, the
curvature of the outer surface 13b of the magnet 13 is set so that
the ratio r3/R is within a range of 0.4.ltoreq.r3/R.ltoreq.0.8.
Thus, in the eighth embodiment as well, sudden magnetic flux
density variation is further suppressed without lowering the torque
of the motor as much as possible, and torque pulsation is further
suppressed.
[0159] The eighth embodiment has the advantages described
below.
[0160] (19) In the eighth embodiment, the magnet 13 has a curved
shape, in which the entire outer surface (surface) 13b has a
constant curvature. The ratio r3/R of the radius r3 of the outer
surface 13b and the radius R of the reference circumference C2 is
set within the range of 0.4.ltoreq.r3/R.ltoreq.0.8. That is, the
magnet 13 is formed so that the r3/R is within this range so that
the two circumferential ends of the outer surface 13b are gradually
distanced in a curved manner from the reference circumference C2.
Thus, in the same manner as the advantages of the sixth embodiment,
sudden magnetic flux density variation of the rotor 10E is further
suppressed, and the torque pulsation is further reduced. Since the
r3/R is set within the range of 0.4.ltoreq.r3/R.ltoreq.0.8, the
torque ripple is further reduced while suppressing torque decrease
of the motor, and torque pulsation is further reduced (see FIGS. 30
and 31). This increases the motor output and reduces motor
vibration.
[0161] The sixth to eighth embodiments may be modified as
below.
[0162] The numerical ranges in the sixth to eighth embodiments may
be changed as required in accordance with the situation or the
like.
[0163] The curvature of the entire outer surface 12c of the salient
pole 12a is optimized in the sixth embodiment. The curvature of the
corner 12d of the salient pole 12a is optimized in the seventh
embodiment. The curvature of the entire outer surface 13b of the
magnet 13 is optimized in the eighth embodiment. These forms may be
combined. For example, the curvatures of the salient pole 12a and
the magnet 13 may both be optimized.
[0164] The sixth to eighth embodiments are applied to the rotor 10E
including fourteen magnetic pole portions, seven salient poles 12a
and seven magnets 13. However, the quantity of the magnetic pole
portions of the rotor 10E may be changed as required. The quantity
of the magnetic pole portions in the stator may be changed
accordingly.
[0165] The first to eighth embodiments are applied to the rotors
10A to 10E used in an inner rotor type motor but may be applied as
a rotor for an outer rotor type motor. In such a case, the opposing
relationship of the rotor and the stator in the radial direction is
reversed.
Ninth Embodiment
[0166] A ninth embodiment will now be discussed with reference to
FIGS. 32 and 33. The same reference numerals are given to those
components that are the same as the corresponding components of the
first embodiment. Such components will not be described in
detail.
[0167] FIGS. 32 and 33 show an inner rotor type brushless motor M.
The motor M of the ninth embodiment uses a rotor 10F including
seven N-pole magnets 13, which are arranged along a circumferential
direction of the rotor core 12, and salient poles 12a, which are
formed integrally with the rotor core 12 and arranged between
adjacent ones of the magnets 13 in the circumferential direction.
The salient poles 12a function as S pole. In other words, the rotor
10F is a so-called consequent pole type having fourteen magnetic
pole portions. The stator 20 includes twelve teeth 21a in the same
manner as the first embodiment.
[0168] The magnet 13 has a circumferential length that is slightly
longer than that of the salient pole 12a. The magnet 13 has a
curved shape, the thickness (dimension in the radial direction) of
which is constant in the circumferential direction. Accordingly,
the inner surface 13a and the outer surface 13b of the magnet 13
are parallel. The fixation surface 12b of the rotor core 12 to
which the inner surface 13a of the magnet 13 is fixed has a curved
shape conforming to the inner surface 13a. A clearance (gap in the
circumferential direction) S1 is formed between a magnet 13 and
salient pole 12a that are arranged adjacent to each other in the
circumferential direction. The outer surface 13b of each magnet 13
has a curved shape with a curvature that allows for the outer
surfaces 13b of the other magnets 13 to be arranged on the same
circumference.
[0169] The salient pole 12a has a circumferential length that is
slightly shorter than that of the magnet 13. The salient pole 12a
projects outward in the radial direction from the peripheral
portion of the rotor 12 in an arcuate manner. Further, the salient
pole 12a projects further outward in the radial direction from the
outer surface 13b of the magnet 13. The outer surface 12c of the
salient pole 12a has a curved shape with a larger curvature than
the outer surface 13b of the magnet 13. The circumferential central
part of the outer surface 12c is bulged outward from the two ends.
The ends of the outer surface 12c are located outward in the radial
direction from the outer surface 13b of the magnet 13. That is, the
clearance S2 between the rotor 10F and the stator 20 in the portion
of the salient pole 12a is less than the clearance S2 in the
portion of the magnet 13. Further, the clearance S2 is gradually
enlarged from the circumferential central part towards the ends of
the outer surface 12c of the salient pole 12a.
[0170] A hooking groove 12f is formed in a distal portion in each
of the two side surfaces of the salient pole 12a (portion located
slightly before the distal corner of the salient pole 12a). A cover
member 14 is attached to the two hooking grooves 12f formed in the
side surfaces of the adjacent salient poles 12a that face toward
each other. The cover member 14, which has a curved shape
conforming to the outer surface 13b of the magnet 13, contacts the
outer surface 13b. The cover member 14 has a length longer than the
circumferential length between the adjacent salient poles 12a. The
cover member 14 has two circumferential ends 14a, which are fitted
into the hooking grooves 12f in the axial direction of the rotor
10F, for example, and fixed extending between the adjacent salient
poles 12a. Such a cover member 14 is formed from a sheet of a
nonmagnetic metal material such as stainless steel (SUS) or copper
alloy that does not inhibit the magnetic field of the magnet 13.
The cover member 14 prevents the magnet 13 from being separated
from the fixation surface 12b. The cover member 14 is also arranged
in correspondence with each magnet 13 so as to prevent chipped
parts of the magnet 13 from scattering.
[0171] In the ninth embodiment, the salient pole 12a is projected
out relative to the magnet 13. That is, the magnet 13 is arranged
inward in the radial direction from the salient pole 12a, and the
cover member 14 is arranged in the space formed by the inward
arrangement. Accordingly, the cover member 14 covering the magnet
13 is arranged so as not to project outward in the radial direction
from the salient pole 12a. That is, the salient pole 12a is not
covered by the cover member 14 since the cover member 14 is
obviously not necessary for the salient pole 12a. In addition, the
arrangement of the cover member 14 minimizes the clearance S2, that
is, the magnetic distance between the salient pole 12a and the
stator 20b. Thus, the magnetic resistance between the salient pole
12a and the stator 20 remains small, and a decrease in the motor
output is suppressed.
[0172] The ninth embodiment has the advantages described below.
[0173] (20) The rotor 10F of the ninth embodiment is formed so that
the salient pole 12a projects outward in the radial direction
relative to the magnet 13. The cover member 14, which covers the
magnet 13, is hooked to the distal sides of the side surfaces that
face toward each other in the adjacent salient poles 12a so as not
to project outward in the radial direction from the salient pole
12a. That is, the salient pole 12a is not covered by the cover
member 14, and the cover member 14 does not project outward in the
radial direction from the salient pole 12a. This allows for the
clearance S2 between the salient pole 12a portion and the stator 20
to be very small. Thus, the magnetic resistance between the salient
pole 12a and the stator 20 remains small, and an output decreased
of the motor M is suppressed.
[0174] (21) In the ninth embodiment, the cover member 14, which is
formed from a sheet of a nonmagnetic metal material, is hooked to
the hooking grooves 12, which are arranged in the distal sides of
the salient poles 12a, to cover the magnet 13. That is, the heights
(radial position) of the outer surface 13b of the magnet 13, which
is covered by the cover member 14, and the distal end of the
salient pole 12a are close. This allows for the hooking groove 12f
for locking the cover member 14 to be arranged in the distal end of
the salient pole 12a. In the ninth embodiment, the cover member 14
is just deformed into a curved shape. This simplifies the shape of
the cover member 14 and facilitates processing.
[0175] The ninth embodiment may be modified as described below.
[0176] In the ninth embodiment, the cover member 14 is fitted into
and fixed to the hooking grooves 12f arranged in the distal
portions of the salient pole 12a. However, the fixation of the
cover member 14 is not limited to such a structure.
[0177] For example, as shown in FIG. 34, the side surfaces of two
salient poles 12a that face toward each other may each include a
semicircular hooking hole 12e arranged in a basal portion (basal
end corner of the salient pole 12a). A cover member 14 has two end
portions defining side walls 14b, which extend toward the basal end
of the salient pole 12a while covering the two circumferential ends
of the magnet 13. The distal end (inward end in the radial
direction) of each side wall 14b is bent at an acute angle to form
a hooking piece 14c. The hooking piece 14c has a distal end
inserted into and hooked to the hooking hole 12e so that the cover
member 14 is attached to the rotor core 12. The cover member 14 is
attached from the outer side in the radial direction of the magnet
13. Specifically, the hooking piece 14c is resiliently deformed and
inserted into the clearance S1 between the salient pole 12a and the
magnet 13. The hooking piece 14c returns to its original form in
the hooking hole 12e and thereby attaches the cover member 14. The
cover member 14 may be attached from the axial direction by
inserting the lock piece 14c into the lock hole 12e.
[0178] When the cover member 14 is attached using the structure
described above, formation of the hooking hole 12e is necessary.
The basal end corner of the salient pole 12a in which the hooking
hole 12e is located is a portion in which the magnetic flux density
variation is large and the magnetic flux amount is relatively
small. Thus, the magnetic influence resulting from the formation of
the hole is small. Further, the clearance S1 between the basal end
of the salient pole 12a and the radially inward portion of the
magnet 13 is enlarged. This decreases magnetic flux leakage.
[0179] The hooking groove 12f and the hooking hole 12e are formed
in the salient pole 12a to hook the cover member 14, as described
above. However, the salient pole 12a may include a projection. The
cover member 14 may be hooked not only to the salient pole 12a but
also to the fixation surface 12b.
[0180] For example, as shown in FIG. 35, a nonmagnetic resin
material that covers the magnet 13 may be molded integrally molded
with the rotor core 12 (fixed to the rotor core 12). This forms a
resin cover 15 that does not project outward in the radial
direction from the distal portion of the salient pole 12a. This
reduces the number of components in the rotor 10. Further, the
resin cover 15 may be formed in advance and be attached to the
rotor 10F in the same manner as the cover member 14.
[0181] Although not particularly discussed in the ninth embodiment,
the cover member 14 may be formed discretely for each magnet 13.
However, for example, the cover members 14 may be formed integrally
by coupling the cover members 14, which correspond to the magnet
13, at one side in the axial direction of the rotor 10E.
[0182] The ninth embodiment is applied to the rotor 10F including
fourteen magnetic pole portions, seven salient poles 12a and seven
magnets 13. However, the quantity of the magnetic pole portions may
be changed as required. Further, the number of magnetic pole
portions in the stator side may be changed accordingly.
* * * * *