Interior permanent magnet electric motor including a rotor having circumferential surface portions with defined curve profiles

• US 7,843,101 B2
• Filed: 11/27/2006
• Issued: 11/30/2010
• Est. Priority Date: 12/01/2005
• Status: Active Grant

• Current Assignee: Aichi Electric Company Limited
• Original Assignee: Aichi Electric Company Limited
• Inventors: Suzuki, Mitsuhiro, Ito, Isao, Kuroko, Masashi, Mano, Shoji
• Primary Examiner(s): Leung; Quyen
• Assistant Examiner(s): Andrews; Michael
• Application Number:
  US11/563,305
• Publication Number:
  US 20070126304A1
• Time in Patent Office: 1,464 Days
• Field of Search: 310/156.56, 310/156.55, 310/156.48, 310/156.01, 310/156.33, 310/156.46, 310/156.53, 310/156.57, 310/156.58, 324/147, 324/146, 417/410.1, 417/423.1
• US Class Current: 310/156.56
• CPC Class Codes: H02K 1/2766 having a flux concentration effect
• CPC Class Codes: H02K 1/28 Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
• CPC Class Codes: H02K 29/03 with a magnetic circuit specially adapted for avoiding torque ripples or self-starting problems

Abstract

A rotary shaft 60 having an outside diameter larger than the bore diameter of a rotary shaft insert hole 59 of a rotor 50 is inserted into the rotary shaft insert hole 59. A magnet insert hole 51a1 is provided in a main magnetic pole [a] of the rotor 50. Permanent magnets 52a1 to 52a3 are inserted into the magnet insert hole 51a1 such that a gap is formed between the permanent magnets 52a1 to 52a3 and the magnet insert hole 51a1. A semi-tubular rivet insert hole 55a and interlocks 57a1, 57a2 elongated in the radial direction of the rotor are disposed radially outward of the magnet insert hole 51a in the rotor. A semi-tubular rivet 56a is inserted into the semi-tubular rivet insert hole 55a such that a gap is formed between the semi-tubular rivet 56a and the semi-tubular rivet insert hole 55a. Passage holes 58ab, 58da are provided in the auxiliary magnetic poles [ab], [da].

Claims

1. An interior permanent magnet motor, having a stator and a rotor, the rotor having main magnetic poles and auxiliary magnetic poles which alternate in a circumferential direction when viewed in cross section perpendicular to the axial direction of the rotor, each of the main magnetic poles having a magnet insert hole for receiving a permanent magnet, the magnet insert hole extending in the axial direction of the rotor, the rotor having a rotary shaft insert hole for receiving a rotary shaft and a semi-tubular rivet insert hole for receiving a semi-tubular rivet, the insert holes extending in the axial direction of the rotor, the rotary shaft having an outside diameter larger than a bore diameter of the rotary shaft insert hole, wherein:

an outer circumferential surface of the rotor is formed of first outer circumferential surface portions and second outer circumferential surface portions which are alternately directly connected in the circumferential direction, wherein each of the first outer circumferential surface portions each has a first curve profile which bulges radially outward and intersects with a d-axis of the assigned main magnetic pole, and each of the second outer circumferential surface portions has a second curve profile which bulges radially outward and intersects with a q-axis of the assigned auxiliary magnetic pole, as viewed in cross section perpendicular to the axial direction of the rotor, wherein the first curve profile has a circular arc shape having its center of curvature on a center of the rotor on the d-axis and having a radius of R_d, and the second curve profile has a circular arc shape having its center of curvature on a point on the q-axis displaced from the center of the rotor away from the assigned second outer circumferential surface portion, and having a radius R_q larger than the radius R_d, such that the maximum width of a gap between the second outer circumferential surface portion and the inside surface of the stator is larger than the maximum width of a gap between the first outer circumferential surface portion and the inside surface of the stator,

the semi-tubular rivet insert hole is disposed in each of the auxiliary magnetic poles,

the permanent magnet is inserted into the magnet insert hole such that a gap is formed between the magnet insert hole and the permanent magnet,

the semi-tubular rivet is inserted into the semi-tubular rivet insert hole such that a gap is formed between the semi-tubular rivet insert hole and the assigned semi-tubular rivet, and

the rotor has an outer surface contour which is not significantly changed at boundaries between the first and second outer circumferential surface portions, such that flow of magnetic flux is prevented from abrupt change when the boundaries between the first and second outer circumferential surface portions pass by teeth of the stator.

2. The interior permanent magnet motor as defined in claim 1, wherein a passage hole is formed in each of the auxiliary magnetic poles and extends in the axial direction of the rotor.

3. The interior permanent magnet motor as defined in claim 2, wherein the passage hole is disposed radially inward of the semi-tubular rivet insert hole in the rotor.

4. The interior permanent magnet motor as defined in claim 2, wherein an interlock is provided at least either in the main magnetic pole or in the auxiliary magnetic pole and elongated in the radial direction of the rotor.

5. The interior permanent magnet motor as defined in claim 4, wherein the interlock is disposed radially outward of the semi-tubular rivet insert hole in the rotor.

6. The interior permanent magnet motor as defined in claim 1, wherein an interlock is provided at least either in the main magnetic pole or in the auxiliary magnetic pole and elongated in the radial direction of the rotor.

7. The interior permanent magnet motor as defined in claim 6, wherein the interlock is provided both in the main magnetic pole and in the auxiliary magnetic pole and a passage hole is formed in the main magnetic pole.

8. The interior permanent magnet motor as defined in claim 6, wherein the interlock is provided in the auxiliary magnetic pole and located radially outward of the semi-tubular rivet insert hole in the rotor.

9. The interior permanent magnet motor as defined in claim 8, wherein a passage hole is formed in the main magnetic pole.

10. The interior permanent magnet motor as defined in claim 1, wherein a recess is formed in the second outer circumferential surface portion and in a position to face an end wall of the magnet insert hole which is adjacent to the outer circumferential surface of the rotor.

11. A compressor driven by a motor, wherein the interior permanent magnet motor as defined in claim 1 is used as the motor.

12. A motor vehicle equipped with a motor, wherein the interior permanent magnet motor as defined in claim 1 is used as the motor.

13. An interior permanent magnet motor, having a stator and a rotor, the rotor having main magnetic poles and auxiliary magnetic poles which alternate in a circumferential direction when viewed in cross section perpendicular to the axial direction of the rotor, each of the main magnetic poles having a magnet insert hole for receiving a permanent magnet, the magnet insert hole extending in the axial direction of the rotor, the rotor having a rotary shaft insert hole for receiving a rotary shaft, a semi-tubular rivet insert hole for receiving a semi-tubular rivet and a passage hole, said holes extending in the axial direction of the rotor, the rotary shaft having an outside diameter larger than a bore diameter of the rotary shaft insert hole, wherein:

an outer circumferential surface of the rotor is formed of first outer circumferential surface portions and second outer circumferential surface portions which are alternately directly connected in the circumferential direction, wherein each of the first outer circumferential surface portions has a first curve profile which bulges radially outward and intersects with a d-axis of the assigned main magnetic pole, and each of the second outer circumferential surface portions has a second curve profile which bulges radially outward and intersects with a q-axis of the assigned auxiliary magnetic pole, as viewed in cross section perpendicular to the axial direction of the rotor, wherein the first curve profile has a circular arc shape having its center of curvature on a center of the rotor on the d-axis and having a radius of R_d, and the second curve profile has a circular arc shape having its center of curvature on a point on the q-axis displaced from the center of the rotor away from the assigned second outer circumferential surface portion, and having a radius R_q larger than the radius R_d, such that the maximum width of a gap between the second outer circumferential surface portion and the inside surface of the stator is larger than the maximum width of a gap between the first outer circumferential surface portion and the inside surface of the stator,

the semi-tubular rivet insert hole is disposed in each of the main magnetic poles of the rotor and located radially outward of the magnet insert hole in the rotor,

the passage hole is formed in each of the auxiliary magnetic poles,

the permanent magnet is inserted into the magnet insert hole such that a gap is formed between the magnet insert hole and the permanent magnet,

the semi-tubular rivet is inserted into the semi-tubular rivet insert hole such that a gap is formed between the semi-tubular rivet insert hole and the semi-tubular rivet, and

the rotor has an outer surface contour which is not significantly changed at boundaries between the first and second outer circumferential surface portions, such that flow of magnetic flux is prevented from abrupt chancre when the boundaries between the first and second outer circumferential surface portions pass by teeth of the stator.

14. The interior permanent magnet motor as defined in claim 13, wherein an interlock is provided at least either in the main magnetic pole or in the auxiliary magnetic pole and elongated in the radial direction of the rotor.

15. The interior permanent magnet motor as defined in claim 14, wherein the interlock is disposed radially outward of the semi-tubular rivet insert hole or the passage hole in the rotor.

16. The interior permanent magnet motor as defined in claim 13, wherein a recess is formed in the second outer circumferential surface portion and in a position to face an end wall of the magnet insert hole which is adjacent to the outer circumferential surface of the rotor.

17. A compressor driven by a motor, wherein the interior permanent magnet motor as defined in claim 13 is used as the motor.

18. A motor vehicle equipped with a motor, wherein the interior permanent magnet motor as defined in claim 13 is used as the motor.