FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]
MOTOR, FAN, AND AIR CONDITIONER;
MITSUBISHI ELECTRIC CORPORATION, A CORPORATION ORGANISED AND
EXISTING UNDER THE LAWS OF JAPAN, WHOSE ADDRESS IS 7-3,
MARUNOUCHI 2-CHOME, CHIYODA-KU, TOKYO 100-8310, JAPAN
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE
INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.
2
DESCRIPTION

5 TECHNICAL FIELD
[0001]
The present disclosure relates to a motor, a fan, and an
air conditioner.
BACKGROUND ART
10 [0002]
A motor includes a rotor having a shaft, and a stator. A
bearing that supports the shaft is held by a bearing support
portion such as a bracket (for example, see Patent Document 1).
PRIOR ART REFERENCE
15 PATENT REFERENCE
[0003]
Patent Document 1: Japanese Utility Model Publication No.
60-141651 (FIG. 1)
SUMMARY OF THE INVENTION
20 PROBLEM TO BE SOLVED BY THE INVENTION
[0004]
Recently, a consequent pole rotor has been developed in
which a permanent magnet forms a magnet magnetic pole, and a part
of a rotor core forms a virtual magnetic pole. In the consequent
25 pole rotor, the magnet magnetic pole and the virtual magnetic
pole have different magnetic flux densities on the rotor surface,
and thus an excitation force in the radial direction is likely
to be applied to the rotor. As a result, a load in the radial
direction applied to a bearing that supports a shaft tends to
30 increase.
[0005]
If a large load in the radial direction is applied to the
bearing supporting the shaft, outer circumferential creep may
occur. The outer circumferential creep is a phenomenon in which
3
an outer ring of the bearing moves in the circumferential
direction relative to the bearing support portion. Since the
outer circumferential creep leads to wear of the bearing, it is
required to suppress the occurrence of the outer circumferential
5 creep.
[0006]
The present invention is made to solve the above-described
problem, and has an object to suppress the occurrence of the
outer circumferential creep.
10 MEANS OF SOLVING THE PROBLEM
[0007]
A motor according to the present disclosure includes a
rotor having a shaft, a rotor core surrounding the shaft from
outside in a radial direction about a center axis of the shaft,
15 and a permanent magnet attached to the rotor core, the permanent
magnet forming a magnet magnetic pole, a part of the rotor core
forming a virtual magnetic pole, a stator surrounding the rotor
from outside in the radial direction, a first bearing and a
second bearing supporting the shaft, a first bearing support
20 portion having an inner circumferential surface facing an outer
circumferential surface of the first bearing, and a second
bearing support portion having an inner circumferential surface
facing an outer circumferential surface of the second bearing.
One side of the shaft in a direction of the center axis is defined
25 as a load side to which a load is applied. Of the first bearing
and the second bearing, the first bearing is located on the load
side. A distance D1 from the center axis to the inner
circumferential surface of the first bearing support portion, a
distance D2 from the center axis to the inner circumferential
30 surface of the second bearing support portion, a distance d1 from
the center axis to the outer circumferential surface of the first
bearing, and a distance d2 from the center axis to the outer
circumferential surface of the second bearing satisfy D1-d1 <
D2-d2.
4
EFFECTS OF THE INVENTION
[0008]
In the present disclosure, since the distances D1, D2, d1,
and d2 satisfy D1-d1 < D2-d2, the outer ring of the first bearing
5 applied with a larger load in the radial direction is less likely
to move in the circumferential direction. Therefore, the
occurrence of the outer circumferential creep can be suppressed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009]
10 FIG. 1 is a longitudinal partial sectional view
illustrating a motor according to a first embodiment.
FIG. 2 is a cross-sectional view illustrating the motor
according to the first embodiment.
FIG. 3 is a cross-sectional view illustrating a rotor
15 according to the first embodiment.
FIG. 4 is a longitudinal partial sectional view
illustrating the motor according to the first embodiment.
FIG. 5(A) is a diagram illustrating a first bearing and a
first bearing support portion of the first embodiment, and FIG.
20 5(B) is a diagram illustrating a second bearing and a second
bearing support portion.
FIG. 6 is a view of a mold stator according to the first
embodiment as viewed from the load side.
FIG. 7 is an enlarged view illustrating a part of the motor
25 of FIG. 6.
FIG. 8 is a flux diagram illustrating the flow of magnetic
flux in the motor.
FIG. 9 is a schematic diagram illustrating a shaft, the
first bearing, and a bracket.
30 FIG. 10 is a diagram illustrating a configuration for
suppressing a shaft current in the first embodiment.
FIG. 11 is a sectional view illustrating the shaft and the
second bearing of the first embodiment.
FIG. 12 is a longitudinal partial sectional view
5
illustrating a motor according to a second embodiment.
FIG. 13(A) is a diagram illustrating a first bearing and
a second bearing of the second embodiment, and FIG. 13(B) is a
diagram illustrating another example of the first bearing and
5 the second bearing.
FIG. 14 is a longitudinal sectional view illustrating a
motor according to a third embodiment.
FIG. 15 is an enlarged longitudinal sectional view
illustrating a part of the motor according to the third
10 embodiment.
FIG. 16(A) is a diagram illustrating an air conditioner to
which the motor of each embodiment is applicable, and FIG. 16(B)
is a sectional view illustrating an outdoor unit of the air
conditioner.
15 MODE FOR CARRYING OUT THE INVENTION
[0010]
FIRST EMBODIMENT
(Configuration of Motor 100)
FIG. 1 is a longitudinal sectional view illustrating a
20 motor 100 according to the first embodiment. The motor 100 is
used, for example, for a fan of an air conditioner. The motor
100 is an interior permanent magnet (IPM) motor in which
permanent magnets 16 are embedded in a rotor 1.
[0011]
25 The motor 100 includes the rotor 1 having a shaft 15 which
is a rotary shaft, and a mold stator 4 surrounding the rotor 1.
The mold stator 4 includes a stator 5 provided to surround the
rotor 1, and a mold resin portion 40 covering the stator 5.
[0012]
30 In the following description, the direction of the center
axis C1 of the shaft 15 is referred to as an "axial direction."
The circumferential direction about the center axis C1 is
referred to as a "circumferential direction" and is indicated by
an arrow R1 in FIG. 2 and other figures. The radial direction
6
about the center axis C1 is referred to as a "radial direction."
A sectional view in a plane parallel to the axial direction is
referred to as a "longitudinal sectional view," and a sectional
view in a plane orthogonal to the axial direction is referred to
5 as a "cross-sectional view."
[0013]
The shaft 15 receives a load on one side in the axial
direction. More specifically, the shaft 15 protrudes from the
mold stator 4 to the left side in FIG. 1, and, for example, an
10 impeller 505 of a fan (FIG. 16(A)) is attached to an attachment
portion 15a formed at the tip of the shaft 15 on the protruding
side. Thus, the protruding side of the shaft 15 is referred to
as a "load side" and the opposite side of the shaft 15 is referred
to as a "counter-load side."
15 [0014]
(Configuration of Mold Stator 4)
The mold stator 4 includes the stator 5 and the mold resin
portion 40, as described above. The mold resin portion 40 is
composed of a thermosetting resin such as a bulk molding compound
20 (BMC). Alternatively, the mold resin portion 40 may be composed
of a thermoplastic resin such as polybutylene terephthalate (PBT)
or polyphenylene sulfide (PPS).
[0015]
The mold resin portion 40 has attachment legs 45 on its
25 outer circumference. In this example, four attachment legs 45
are formed at equal intervals in the circumferential direction.
Holes 46 (FIG. 6) through which screws are inserted are formed
in the attachment legs 45. The attachment legs 45 are fixed to,
for example, a frame of an outdoor unit of the air conditioner
30 with screws inserted through the holes 46.
[0016]
The mold resin portion 40 has an opening 41 on the load
side. The rotor 1 is inserted into the hollow portion inside
the mold stator 4 through the opening 41. A bracket 6 serving
7
as a first bearing support portion is attached to the opening 41
of the mold resin portion 40. The bracket 6 is composed of a
metal such as a galvanized steel sheet. The bracket 6 is fitted
to an annular step portion 41a formed around the opening 41.
5 [0017]
The bracket 6 holds a first bearing 21 that supports the
shaft 15. A waterproof cap 9 for preventing water or the like
from entering the first bearing 21 is attached to the shaft 15
so as to surround the bracket 6 from outside.
10 [0018]
The mold resin portion 40 has a bearing support portion 42
serving as a second bearing support portion on the counter-load
side. The bearing support portion 42 of the mold resin portion
40 holds a second bearing 22 that supports the shaft 15.
15 [0019]
A circuit board 7 is disposed on the outer side of the
second bearing 22 in the radial direction. The circuit board 7
is covered with and held by the mold resin portion 40. A device
71 such as a power transistor for driving the motor 100, a
20 magnetic sensor, and the like are mounted on the circuit board
7. Lead wires 73 are wired on the circuit board 7. The lead
wires 73 on the circuit board 7 are drawn out to the outside of
the motor 100 through an outlet part 72 attached to an outer
circumferential portion of the mold resin portion 40.
25 [0020]
A heat dissipation plate 8 is provided so as to cover the
counter-load side of the mold resin portion 40. The heat
dissipation plate 8 is partially covered with the mold resin
portion 40 and partially exposed from the mold resin portion 40.
30 The heat dissipation plate 8 dissipates heat generated by the
motor 100 to the outside. It is also possible not to provide
the heat dissipation plate 8.
[0021]
(Configuration of Stator 5)
8
FIG. 2 is a cross-sectional view illustrating the motor
100. As illustrated in FIG. 2, the stator 5 includes a stator
core 50, an insulating portion 53 provided on the stator core
50, and coils 55 wound on the stator core 50 via the insulating
5 portion 53. The stator core 50 is formed by stacking a plurality
of electromagnetic steel sheets in the axial direction and fixing
them by crimping or the like. The thickness of each
electromagnetic steel sheet is, for example, 0.2 to 0.5 mm.
[0022]
10 The stator core 50 includes a yoke 51 in an annular shape
about the center axis C1 and a plurality of teeth 52 extending
inward in the radial direction from the yoke 51. The teeth 52
are arranged at equal intervals in the circumferential direction.
The number of teeth 52 is 12 in this example, but is not limited
15 to 12. Slots that are spaces for accommodating the coils 55 are
formed each between adjacent teeth 52.
[0023]
The insulating portion 53, which is made of, for example,
polybutylene terephthalate (PBT), is attached to the stator core
20 50. The insulating portion 53 is composed of a thermoplastic
resin such as PBT. The insulating portion 53 is obtained by
molding the thermoplastic resin integrally with the stator core
50 or assembling a molded body of the thermoplastic resin to the
stator core 50.
25 [0024]
(Configuration of Rotor 1)
FIG. 3 is a cross-sectional view illustrating the rotor 1.
As illustrated in FIG. 3, the rotor 1 includes the shaft 15, a
rotor core 10 surrounding the shaft 15 from outside in the radial
30 direction, and the plurality of permanent magnets 16 embedded in
the rotor core 10.
[0025]
The rotor core 10 is a member in an annular shape about
the center axis C1. The rotor core 10 is formed by stacking a
9
plurality of electromagnetic steel sheets in the axial direction
and fixing them by crimping or the like. The thickness of each
electromagnetic steel sheet is, for example, 0.2 to 0.5 mm.
[0026]
5 The rotor core 10 has a plurality of magnet insertion holes
11a. The magnet insertion holes 11a are arranged at equal
intervals in the circumferential direction and at equal distances
from the center axis C1. In this example, the number of the
magnet insertion holes 11a is five. The magnet insertion holes
10 11a are formed along the outer circumference of the rotor core
10.
[0027]
Each magnet insertion hole 11a extends linearly in a
direction orthogonal to a line in the radial direction (referred
15 to as a magnetic pole center line) passing through a pole center,
i.e., the center of the magnet insertion hole 11a in the
circumferential direction. However, the magnet insertion hole
11a is not limited to such a shape, and may extend, for example,
in a V-shape.
20 [0028]
Flux barriers 11b which are holes are formed at both ends
of each magnet insertion hole 11a in the circumferential
direction. Thin portions are formed between the flux barriers
11b and the outer circumference of the rotor core 10. To suppress
25 the leakage flux between adjacent magnetic poles, the thickness
of the thin portion is desirably the same as the thickness of
each electromagnetic steel sheet of the rotor core 10.
[0029]
The permanent magnets 16 are inserted into the magnet
30 insertion holes 11a. Each permanent magnet 16 is in the form of
a flat plate and has a rectangular cross-sectional shape in a
plane orthogonal to the axial direction. The permanent magnet
16 is composed of a rare earth magnet. More specifically, the
permanent magnet 16 is composed of a neodymium sintered magnet
10
containing Nd (neodymium)-Fe (iron)-B (boron).
[0030]
The permanent magnets 16 are arranged so that the same
magnetic poles (for example, N poles) face the outer
5 circumferential side of the rotor core 10. In the rotor core 10,
magnetic poles (for example, S poles) opposite to the permanent
magnets are formed in the regions each between the permanent
magnets adjacent to each other in the circumferential direction.
[0031]
10 Thus, the rotor 1 includes five magnet magnetic poles P1
formed by the permanent magnets 16 and five virtual magnetic
poles P2 formed by the rotor core 10. Such a configuration is
referred to as a consequent pole type. Hereinafter, when the
term "magnetic pole" is simply used, it refers to either the
15 magnetic pole P1 or the virtual pole P2. The rotor 1 has 10
magnetic poles.
[0032]
Although the number of poles of the rotor 1 is 10 in this
example, the number of poles of the rotor 1 may be four or any
20 larger even number. Although one permanent magnet 16 is disposed
in each magnet insertion hole 11a in this example, two or more
permanent magnets 16 may be disposed in each magnet insertion
hole 11a. The magnetic poles P1 may be S poles, and the virtual
poles P2 may be N poles.
25 [0033]
The outer circumference of the rotor core 10 has a socalled flower shape in a plane orthogonal to the axial direction.
In other words, the outer circumference of the rotor core 10 has
a maximum outer diameter at the pole center of each of the
30 magnetic poles P1 and P2 and a minimum outer diameter at each
inter-pole portion M, and extends in an arc shape from the pole
center to the inter-pole portion M. The shape of the outer
circumference of the rotor core 10 is not limited to the flower
shape, but may be a circular shape.
11
[0034]
In the rotor core 10, crimping portions 14 are provided on
the inner side of the magnet insertion holes 11a in the radial
direction. The crimping portions 14 are portions by which the
5 electromagnetic steel sheets constituting the rotor core 10 are
fixed.
[0035]
A resin part 30 is provided between the inner circumference
of the rotor core 10 and the shaft 15. The resin part 30 is
10 composed of, for example, a resin such as polybutylene
terephthalate (PBT). The resin part 30 has an annular inner
cylindrical portion 31 fixed to the shaft 15, an annular outer
cylindrical portion 33 fixed to the inner circumference of the
rotor core 10, and a plurality of ribs 32 connecting the inner
15 cylindrical portion 31 and the outer cylindrical portion 33.
[0036]
The shaft 15 is fixed inside the inner cylindrical portion
31 of the resin part 30. The ribs 32 are arranged at equal
intervals in the circumferential direction and extend radially
20 outward in the radial direction from the inner cylindrical
portion 31. Hollow portions are formed each between the ribs 32
adjacent to each other in the circumferential direction. In this
example, the number of ribs 32 is half the number of poles, and
the positions of the ribs 32 in the circumferential direction
25 coincide with the pole centers of the virtual magnetic poles P2,
but the number and arrangement of the ribs 32 are not limited to
the examples described above.
[0037]
With reference to FIG. 1 again, a sensor magnet 17 is
30 disposed on the counter-load side of the rotor core 10. The
sensor magnet 17 is held by the resin part 30. The magnetic
field of the sensor magnet 17 is detected by a magnetic sensor
mounted on the circuit board 7, whereby the rotational position
of the rotor 1 is detected.
12
[0038]
(Bearings 21 and 22 and Their Support Structures)
Nest, the bearings 21 and 22 that rotatably support the
shaft 15 and a supporting structure for the bearings 21 and 22
5 will be described. FIG. 4 is a longitudinal partial sectional
view illustrating the motor 100. The shaft 15 is rotatably
supported by the first bearing 21 and the second bearing 22, as
described above. The first bearing 21 is disposed on the load
side, and the second bearing 22 is disposed on the counter-load
10 side.
[0039]
The first bearing 21 includes an inner ring 21a, an outer
ring 21b, and a plurality of rolling elements 21c. The inner
ring 21a is fixed to the shaft 15 by press-fitting. The outer
15 ring 21b is fixed to a cylindrical portion 61 (described below)
of the bracket 6 by gap-fitting. The rolling elements 21c are,
for example, balls and are disposed between the inner ring 21a
and the outer ring 21b. Each of the inner ring 21a, the outer
ring 21b, and the rolling elements 21c is composed of a metal.
20 [0040]
The second bearing 22 includes an inner ring 22a, an outer
ring 22b, and a plurality of rolling elements 22c. The inner
ring 22a is fixed to the shaft 15 by press-fitting. The outer
ring 22b is fixed to the bearing support portion 42 of the mold
25 resin portion 40 by gap-fitting. The rolling elements 22c are,
for example, balls and are disposed between the inner ring 22a
and the outer ring 22b. Each of the inner ring 22a, the outer
ring 22b, and the rolling elements 22c is composed of a metal.
[0041]
30 FIG. 5(A) is a sectional view illustrating the first
bearing 21 and the bracket 6. The bracket 6 has a cylindrical
portion 61 surrounding the first bearing 21 and a flange portion
62 extending outward in the radial direction from the cylindrical
portion 61. The inner circumferential surface 61a of the
13
cylindrical portion 61 faces an outer circumferential surface
21d of the outer ring 21b of the first bearing 21 (also referred
to as the outer circumferential surface 21d of the first bearing
21).
5 [0042]
An annular fitting portion 63 is formed on the outer
circumference of the flange portion 62, and the fitting portion
63 is fitted to the step portion 41a (FIG. 4) of the mold resin
portion 40. The bracket 6 is fixed to the mold resin portion 40
10 by fitting the fitting portion 63 to the step portion 41a.
[0043]
The bracket 6 further has an end surface portion 64 facing
the end surface of the first bearing 21 in the axial direction.
A shaft insertion hole 65 through which the shaft 15 passes is
15 formed at the center of the end surface portion 64. A washer 66
that urges the outer ring 21b of the first bearing 21 in the
axial direction is disposed between the end surface portion 64
and the first bearing 21.
[0044]
20 The distance from the center axis C1 to the outer
circumferential surface 21d of the outer ring 21b of the first
bearing 21 is defined as a distance d1. The distance from the
center axis C1 to the inner circumferential surface 61a of the
cylindrical portion 61 of the bracket 6 is defined as a distance
25 D1. The distance D1 is larger than the distance d1.
[0045]
The difference (D1-d1) between the distance D1 and the
distance d1 is a gap between the outer circumferential surface
21d of the outer ring 21b of the first bearing 21 and the inner
30 circumferential surface 61a of the cylindrical portion 61 of the
bracket 6 and is, for example, 5 μm.
[0046]
FIG. 5(B) is a sectional view illustrating the second
bearing 22 and the bearing support portion 42. The bearing
14
support portion 42 has an inner circumferential surface 42a
surrounding the second bearing 22 and an end surface 42b in
contact with the outer ring 22b of the second bearing 22 in the
axial direction. The inner circumferential surface 42a of the
5 bearing support portion 42 faces an outer circumferential surface
22d of the outer ring 22b of the second bearing 22 (also referred
to as the outer circumferential surface 22d of the second bearing
22).
[0047]
10 The distance from the center axis C1 to the outer
circumferential surface 22d of the outer ring 22b of the second
bearing 22 is defined as a distance d2. The distance from the
center axis C1 to the inner circumferential surface 42a of the
bearing support portion 42 is defined as a distance D2. The
15 distance D2 is larger than the distance d2.
[0048]
The difference (D2-d2) between the distance D2 and the
distance d2 is a gap between the outer circumferential surface
22d of the outer ring 22b of the second bearing 22 and the inner
20 circumferential surface 42a of the bearing support portion 42
and is, for example, 10 μm.
[0049]
In the first embodiment, D1-d1 < D2-d2 is satisfied. That
is, the gap on the outer circumferential side of the outer ring
25 21b of the first bearing 21 on the load side is narrower than
the gap on the outer circumferential side of the outer ring 22b
of the second bearing 22 on the counter-load side.
[0050]
FIG. 6 is a view of the mold stator 4 as viewed from the
30 load side. In FIG. 6, the rotor 1 is not yet inserted into the
mold stator 4, and thus the bearing support portion 42 is exposed
through the opening 41 of the mold resin portion 40.
[0051]
FIG. 7 is an enlarged view illustrating the central portion
15
in the radial direction of the mold stator 4 illustrated in FIG.
6. FIG. 7 illustrates both a circle representing the inner
circumferential surfaces 61a and 42a of the bearing support
portions 6 and 42 and a circle representing the outer
5 circumferential surfaces 21d and 22d of the outer rings 21b and
22b of the bearings 21 and 22.
[0052]
(Operation)
Next, the operation of the first embodiment will be
10 described. FIG. 8 is a flux diagram illustrating a flux flow in
the motor 100 including the consequent pole rotor 1.
[0053]
The consequent pole rotor 1 has the magnet magnetic poles
P1 at which the permanent magnets 16 are provided and the virtual
15 magnetic poles P2 at which the permanent magnets 16 are not
provided, as described above. The magnetic flux density on the
surface of the rotor 1 is higher at the magnet magnetic poles P1
and is lower at the virtual magnetic poles P2.
[0054]
20 As a result, the force acting between the magnet magnetic
poles P1 and the teeth 52 is larger than the force acting between
the virtual magnetic poles P2 and the teeth 52, and an excitation
force in the radial direction is applied to the rotor 1. The
excitation force in the radial direction applied to the rotor 1
25 is applied to the shaft 15.
[0055]
FIG. 9 is a schematic view illustrating the shaft 15, the
first bearing 21, and the bracket 6 holding the first bearing
21. In this regard, the gap (D1–d1) between the outer
30 circumferential surface 21d of the outer ring 21b of the first
bearing 21 and the inner circumferential surface 61a of the
bracket 6 is shown exaggerated in FIG. 9.
[0056]
The inner ring 21a of the first bearing 21 is fixed to the
16
shaft 15 by press-fitting, while the outer ring 21b is fixed to
the bracket 6 by gap-fitting. Thus, there is a difference
between the circumferential length of the outer circumferential
surface 21d of the outer ring 21b of the first bearing 21 and
5 the circumferential length of the inner circumferential surface
61a of the bracket 6.
[0057]
When the shaft 15 rotates in the direction indicated by
the arrow R2 in a state in which the load Fr in the radial
10 direction is applied to the first bearing 21, the outer ring 21b
moves in the circumferential direction relative to the inner
circumferential surface 61a of the bracket 6 as indicated by the
arrow F1 due to the load Fr in the radial direction and the
difference in the circumferential lengths. This phenomenon is
15 referred to as outer circumferential creep.
[0058]
In particular, the weight of the impeller 505 attached to
the shaft 15 is applied to the first bearing 21 disposed on the
load side in addition to the excitation force in the radial
20 direction generated by the rotor 1. Thus, the load Fr in the
radial direction applied to the first bearing 21 is larger than
the load Fr in the radial direction applied to the second bearing
22.
[0059]
25 In the first embodiment, the bearings 21 and 22 and the
bearing support portions 6 and 42 are configured so that the
distances D1, D2, d1, and d2 satisfy D1-d1 < D2-d2. That is,
the gap on the outer circumferential side of the outer ring 21b
of the first bearing 21 is narrower than the gap on the outer
30 circumferential side of the outer ring 22b of the second bearing
22.
[0060]
Thus, the outer ring 21b of the first bearing 21 is less
likely to move in the circumferential direction in the bracket
17
6. That is, it is possible to suppress the occurrence of the
outer circumferential creep of the first bearing 21 to which the
larger radial load Fr is applied.
[0061]
5 It is conceivable that the relationship D1-d1 < D2-d2 is
satisfied, for example, when the distances D1 and D2 satisfy D1
< D2 or when the distances d1 and d2 satisfy d1 > d2.
[0062]
For example, if the inner diameter of the cylindrical
10 portion 61 of the bracket 6 is made smaller than the inner
diameter of the bearing support portion 42, the distances D1 and
D2 satisfy D1 < D2. In such a case, as long as D1-d1 < D2-d2 is
satisfied, a large/small relationship between the distances d1
and d2 does not matter. For example, the distances d1 and d2
15 may be the same (d1 = d2). With this configuration, the bearings
21 and 22 can be made to have the same outer diameter, and thereby
the manufacturing cost can be reduced.
[0063]
If the outer diameter of the outer ring 21b of the first
20 bearing 21 is larger than the outer diameter of the outer ring
22b of the second bearing 22, the distances d1 and d2 satisfy d1
> d2. In such a case, as long as D1-d1 < D2-d2 is satisfied, a
large/small relationship between the distances D1 and D2 does
not matter. For example, the distances D1 and D2 may be the same
25 (D1 = D2). With this configuration, the cylindrical portion 61
of the bracket 6 and the bearing support portion 42 can be made
to have the same inner diameter, and thereby the manufacturing
cost can be reduced.
[0064]
30 As illustrated in FIGS. 5(A) and 5(B), the distance e1 from
the center axis C1 to the inner circumferential surface of the
inner ring 21a of the first bearing 21 and the distance e2 from
the center axis C1 to the inner circumferential surface of the
inner ring 22a of the second bearing 22 are the same. In other
18
words, the inner diameter (2 × e1) of the first bearing 21 and
the inner diameter (2 × e2) of the second bearing 22 are the
same.
[0065]
5 Thus, in the shaft 15, the outer diameter of the portion
supported by the first bearing 21 can be made equal to the outer
diameter of the portion supported by the second bearing 22. Thus,
the manufacturing cost can be reduced.
[0066]
10 (Configuration for Suppressing Shaft Current)
Suppression of a shaft current in the motor 100 will now
be described. When the motor 100 is driven by an inverter, the
carrier frequency is set to a frequency higher than the audible
frequency in order to suppress noise accompanying switching.
15 However, as the carrier frequency increases, a voltage called a
shaft voltage is generated in the shaft 15 by the high-frequency
induction.
[0067]
When the shaft voltage increases, the potential difference
20 between the inner rings 21a and 22a and the outer rings 21b and
22b of the bearings 21 and 22 supporting the shaft 15 increases,
and the current is likely to flow to the shaft 15 through the
bearings 21 and 22. Such a current is referred to as a shaft
current. When the shaft current is generated, damage known as
25 electrolytic corrosion occurs on the raceway surfaces of the
inner rings 21a and 22a, the raceway surfaces of the outer rings
21b and 22b, and the rolling surfaces of the rolling elements
21c and 22c.
[0068]
30 FIG. 10 is a schematic diagram for describing a current
flow when the shaft current is generated. As indicated by the
arrows in FIG. 10, there are a path A1 flowing from the stator
5 to the shaft 15 via the bracket 6 and the first bearing 21, a
path A2 flowing from the stator 5 to the shaft 15 via the circuit
19
board 7 and the second bearing 22, and a path A3 flowing from
the stator 5 to the shaft 15 via the rotor core 10.
[0069]
In the first embodiment, an insulator 18 is provided
5 between the shaft 15 and the second bearing 22, as illustrated
in FIG. 11. More specifically, the outer diameter of an end
portion 15b on the counter-load side of the shaft 15 is reduced,
and the cylindrical insulator 18 is attached to the end portion
15b. The insulator 18 is composed of a thermoplastic resin such
10 as BMC.
[0070]
Since the shaft 15 and the second bearing 22 can be
electrically insulated from each other by the insulator 18, the
flow of the current through the path A2 can be suppressed.
15 [0071]
In the rotor 1, since the resin part 30 is disposed between
the rotor core 10 and the shaft 15, the current flow from the
rotor core 10 to the shaft 15 can be suppressed. That is, the
current flow through the path A3 can be suppressed.
20 [0072]
Of the three current paths A1, A2, and A3, the current flow
through the paths A2 and A3 is suppressed, so that the current
flow through the path A1 is also suppressed. This makes it
possible to suppress the generation of the shaft current and the
25 occurrence of the electrolytic corrosion in the bearings 21 and
22.
[0073]
Since the insulator 18 is attached to the end portion 15b
of the shaft 15, the end portion 15b of the shaft 15 can be
30 worked to be thin and the cylindrical insulator 18 can be attached
to the end portion 15b. Thus, the manufacturing cost can be
reduced.
[0074]
The insulator 18 may be provided not only between the shaft
20
15 and the second bearing 22 but also between the shaft 15 and
the first bearing 21. It is also possible to provide the
insulators 18 between the shaft 15 and the first bearing 21 and
between the shaft 15 and the second bearing 22.
5 [0075]
(Effects of Embodiment)
As described above, the motor 100 of the first embodiment
includes the consequent pole rotor 1, the stator 5 surrounding
the rotor 1 from outside in the radial direction, the first
10 bearing 21 and the second bearing 22 supporting the shaft 15 of
the rotor 1, the bracket 6 (first bearing support portion) having
the inner circumferential surface 61a facing the outer
circumferential surface 21d of the first bearing 21, and the
bearing support portion 42 (second bearing support portion)
15 having the inner circumferential surface 42a facing the outer
circumferential surface 22d of the second bearing 22. The first
bearing 21 is located on the load side, and the second bearing
22 is located on the counter-load side. The distance D1 from
the center axis C1 to the inner circumferential surface 61a of
20 the bracket 6, the distance D2 from the center axis C1 to the
inner circumferential surface 42a of the bearing support portion
42, the distance d1 from the center axis C1 to the outer
circumferential surface 21d of the first bearing 21, and the
distance d2 from the center axis C1 to the outer circumferential
25 surface 22d of the second bearing 22 satisfy D1−d1 < D2−d2.
[0076]
With this configuration, a gap on the outer circumferential
side of the first bearing 21 applied with a larger load in the
radial direction is made smaller than a gap on the outer
30 circumferential side of the other second bearing 22, and thus
the outer ring 21b of the first bearing 21 can be made less
likely to move in the circumferential direction. In this way,
the occurrence of the outer circumferential creep can be
suppressed, and the performance of the motor 100 can be improved.
21
[0077]
When the distance D1 is smaller than the distance D2, the
first bearing 21 and the second bearing 22 having the same outer
diameter can be used, and thus the manufacturing cost can be
5 reduced.
[0078]
When the distance d1 is larger than the distance d2, the
cylindrical portion 61 of the bracket 6 and the bearing support
portion 42 can be formed to have the same inner diameter, and
10 thus the manufacturing cost can be reduced.
[0079]
Since the bracket 6 is composed of a metal and the bearing
support portion 42 is composed of a resin, the first bearing 21
to which a larger load in the radial direction is applied can be
15 held by the bracket 6 with high positional accuracy. When the
bearing support portion 42 is composed of a resin, the
manufacturing cost can be reduced.
[0080]
Since the inner diameter of the first bearing 21 and the
20 inner diameter of the second bearing 22 are the same, the outer
diameter of the portion of the shaft 15 held by the first bearing
21 and the outer diameter of the portion of the shaft 15 held by
the second bearing 22 can be made the same, and thus the
manufacturing cost can be reduced.
25 [0081]
Since the insulator 18 is provided between the shaft 15
and at least one of the first bearing 21 and the second bearing
22, the generation of the shaft current can be suppressed, and
the occurrence of the electrolytic corrosion of the bearings 21
30 and 22 can be suppressed.
[0082]
Since the resin part 30 is provided between the rotor core
10 and the shaft 15, the generation of the shaft current can be
suppressed, and the occurrence of the electrolytic corrosion in
22
the bearings 21 and 22 can be suppressed.
[0083]
SECOND EMBODIMENT
Next, the second embodiment will be described. FIG. 12 is
5 a longitudinal partial sectional view illustrating a motor 100A
according to the second embodiment. The motor 100A of the second
embodiment differs from the motor 100 of the first embodiment in
the material of the rolling elements of the first bearing 21 or
the rolling elements of the second bearing 22.
10 [0084]
As illustrated in FIG. 12, the insulator 18 (FIG. 11)
described in the first embodiment is not provided between the
shaft 15 and the second bearing 22. That is, the inner
circumferential surface of the second bearing 22 is in contact
15 with the surface of the shaft 15.
[0085]
FIG. 13(A) is an enlarged view illustrating the first
bearing 21 and the second bearing 22 of the second embodiment.
The first bearing 21 of the second embodiment includes an inner
20 ring 21a, an outer ring 21b, and a plurality of rolling elements
21e.
[0086]
The rolling elements 21e of the first bearing 21 are
composed of a ceramic. An example of the ceramic is alumina
25 (Al2O3). However, besides alumina, any ceramic having strength
required for the rolling element and insulating property can be
used.
[0087]
The structures of the inner ring 21a and the outer ring
30 21b of the first bearing 21 are as described in the first
embodiment. The structure of the second bearing 22 is as
described in the first embodiment.
[0088]
Since the rolling elements 21e of the first bearing 21 are
23
composed of a ceramic, the inner ring 21a and the outer ring 21b
can be electrically insulated from each other. That is, the
current flow through the path A1 described in the first
embodiment can be suppressed.
5 [0089]
As described in the first embodiment, the current flow
through the path A3 is suppressed by the resin part 30 disposed
between the rotor core 10 and the shaft 15.
[0090]
10 Of the three current paths A1, A2, and A3, the current flow
through the paths A1 and A3 is suppressed, so that the current
flow through the path A2 is also suppressed. This makes it
possible to suppress the generation of the shaft current and the
occurrence of the electrolytic corrosion in the bearings 21 and
15 22.
[0091]
Since the first bearing 21 on the load side receives a
large load in the radial direction, an oil film of a lubricating
oil around the rolling elements 21e tends to become thin. As
20 the oil film is thinned, electrolytic corrosion is more likely
to occur due to conduction. As the rolling elements 21e of the
first bearing 21 is composed of a ceramic, the occurrence of the
electrolytic corrosion can be suppressed even when the oil film
is thinned.
25 [0092]
In this example, the rolling elements 21e of the first
bearing 21 are composed of a ceramic and the rolling elements
21c of the second bearing 22 are composed of a metal. However,
it is sufficient that the rolling elements 21e of at least one
30 of the bearings 21 and 22 are made of a ceramic.
[0093]
For example, as illustrated in FIG. 13(B), both the rolling
elements 21e of the first bearing 21 and the rolling elements
22e of the second bearing 22 may be composed of a ceramic. With
24
this configuration, the shaft current can be more effectively
suppressed, and the effect of suppressing the occurrence of the
electrolytic corrosion can be enhanced.
[0094]
5 The insulator 18 may be provided between the shaft 15 and
the second bearing 22 as described in the first embodiment.
[0095]
The motor 100A of the second embodiment is configured in
a similar manner to the motor 100 of the first embodiment, except
10 for the points described above.
[0096]
As described above, in the second embodiment, at least one
of the first bearing 21 and the second bearing 22 for holding
the shaft 15 includes rolling elements composed of a ceramic.
15 Therefore, the shaft current can be effectively suppressed, and
the effect of suppressing the occurrence of the electrolytic
corrosion can be enhanced.
[0097]
THIRD EMBODIMENT
20 Next, the third embodiment will be described. FIG. 14 is
a longitudinal partial sectional view illustrating a motor 100B
according to the third embodiment. The motor 100B of the third
embodiment is different from the motor 100 of the first
embodiment in that the motor 100B includes a bearing support
25 member 80 made of a metal and serving as a second bearing support
portion and does not include the heat dissipation plate 8 (FIG.
1).
[0098]
The bearing support member 80 is provided so as to cover
30 the counter-load side of the mold stator 4. The bearing support
member 80 is composed of a metal. More specifically, the bearing
support member 80 is composed of a hot-dip zinc-aluminummagnesium alloy plated steel sheet. A hot-dip zinc-aluminummagnesium alloy plated steel sheet is advantageous in that it
25
can be subjected to press-working and has high dimensional
accuracy.
[0099]
The bearing support member 80 may alternatively be composed
5 of an aluminum alloy such as ADC12 (JIS H5302). Since the
aluminum alloy such as ADC12 can be processed by die casting,
the degree of freedom of the shape is higher as compared with
when extrusion molding or the like is used.
[0100]
10 The bearing support member 80 has a flange portion 81
positioned on the outer side in the radial direction of the
second bearing 22 and a plate-like portion 82 positioned on the
counter-load side of the second bearing 22.
[0101]
15 FIG. 15 is an enlarged view illustrating a part of the
bearing support member 80. An inner circumferential surface 83
in contact with the outer circumferential surface 22d of the
outer ring 22b of the second bearing 22 is formed in the flange
portion 81 of the bearing support member 80. An end surface 84
20 in contact with the end surface in the axial direction of the
outer ring 22b and a facing surface 85 facing the end surface in
the axial direction of the inner ring 22a with a space
therebetween are formed on the plate-like portion 82.
[0102]
25 The bearing support member 80 is held by the mold resin
portion 40. The outer circumferential side of the flange portion
81 of the bearing support member 80 is covered with the mold
resin portion 40. The bearing support member 80 is separated
from the circuit board 7, and the mold resin portion 40 is
30 provided between the bearing support member 80 and the stator 5.
That is, the bearing support member 80, the circuit board 7, and
the stator 5 are not in contact with one another.
[0103]
Since the bearing support member 80 is composed of a metal,
26
the inner circumferential surface 83 of the bearing support
member 80 can be formed with high dimensional accuracy as is the
case with the inner circumferential surface 61a of the bracket
6. Therefore, D1-d1 < D2-d2 described in the first embodiment
5 is satisfied, and the gap (D2-d2) on the outer circumferential
side of the second bearing 22 can be narrowed, and thus the
occurrence of the outer circumferential creep can be suppressed.
[0104]
Since a part of the bearing support member 80 is covered
10 with the mold resin portion 40 and is not in contact with the
circuit board 7 and the stator 5, the generation of the shaft
current can be suppressed.
[0105]
Since the bearing support member 80 is in contact with the
15 outer ring 22b but is not in contact with the inner ring 22a,
the current flow between the inner ring 22a and the outer ring
22b can be suppressed.
[0106]
Since the bearing support member 80 is composed of a metal
20 and a portion of the bearing support member 80 is exposed from
the mold resin portion 40, the bearing support member 80 can also
achieve a heat dissipation effect of dissipating heat generated
in the coils 55 or the circuit board 7 to the outside.
[0107]
25 Except for the points described above, the motor 100B of
the third embodiment is configured in a similar manner to the
motor 100 of the first embodiment.
[0108]
As described above, in the third embodiment, since the
30 metal bearing support member 80 (second bearing support portion)
holds the second bearing 22, the gap on the outer circumferential
side of the second bearing 22 can be narrowed, and the occurrence
of the outer circumferential creep of the second bearing 22 can
be suppressed.
27
[0109]
In the first embodiment, the bracket 6 serving as the first
bearing support portion is composed of a metal, and the bearing
support portion 42 serving as the second bearing support portion
5 is composed of a resin. In the third embodiment, both the
bracket 6 and the bearing support member 80 are composed of a
metal. However, both the first bearing support portion and the
second bearing support portion may be composed of a resin such
as BMC. Alternatively, the first bearing support portion may be
10 composed of a resin, and the second bearing support portion may
be composed of a metal.
[0110]
(Air Conditioner)
Next, an air conditioner to which the above-described
15 motors 100, 100A, and 100B of the first to third embodiments are
applicable will be described. FIG. 16(A) is a diagram
illustrating the configuration of an air conditioner 500 to which
the motor 100 of the first embodiment is applied. The air
conditioner 500 includes an outdoor unit 501, an indoor unit 502,
20 and a refrigerant pipe 503 connecting the units 501 and 502.
[0111]
The outdoor unit 501 includes an outdoor fan 510 such as
a propeller fan, a compressor 504, and a heat exchanger 507. The
outdoor fan 510 includes an impeller 505 and a motor 100 for
25 driving the impeller 505. The configuration of the motor 100 is
as described above in the first embodiment.
[0112]
FIG. 16(B) is a sectional view of the outdoor unit 501.
The motor 100 is attached to a frame 509 disposed inside a housing
30 508 of the outdoor unit 501 by screws 48. The impeller 505 is
attached to the shaft 15 of the motor 100 via a hub 506.
[0113]
In the outdoor fan 510, the impeller 505 is rotated by the
rotation of the motor 100 and blows air to the heat exchanger
28
507. During the cooling operation of the air conditioner 500,
the heat released when the refrigerant compressed in the
compressor 504 is condensed in the heat exchanger 507 (condenser)
is released to the outside of the room by the air blowing by the
5 outdoor fan 510.
[0114]
The indoor unit 502 (FIG. 16(A)) includes an indoor fan
520 which is, for example, a cross flow fan, and a heat exchanger
523. The indoor fan 520 includes an impeller 521 and a motor
10 522 for driving the impeller 521.
[0115]
In the indoor fan 520, the impeller 521 is rotated by the
rotation of the motor 522 and blows air into the room. During
the cooling operation of the air conditioner 500, the air
15 deprived of heat when the refrigerant evaporates in the heat
exchanger 523 (evaporator) is blown into the room by the air
blowing by the indoor fan 520.
[0116]
In the motor 100 described in the first embodiment, the
20 outer circumferential creep is suppressed. Thus, the operation
of the outdoor fan 510 can be stabilized for a long period of
time, and thus the reliability of the air conditioner 500 can be
improved.
[0117]
25 The motor 100 of the first embodiment is used for the
outdoor fan 510 in this example, but it is sufficient that the
motor 100 of the first embodiment is used for at least one of
the outdoor fan 510 and the indoor fan 520. In place of the
motor 100 of the first embodiment, any of the motors 100A and
30 100B of the second and third embodiments may be used.
[0118]
The motors 100, 100A, and 100B described in the first to
third embodiments may also be mounted on electrical equipment
other than the fan of an air conditioner.
29
[0119]
Although the preferred embodiments of the present
invention have been described above in detail, the present
invention is not limited to the above-described embodiments, and
5 various improvements or modifications can be made without
departing from the gist of the present invention.
DESCRIPTION OF REFERENCE CHARACTERS
[0120]
1 rotor; 4 mold stator; 5 stator; 6 bracket (first bearing
10 support portion); 7 circuit board; 8 heat dissipation plate; 9
waterproof cap; 10 rotor core; 15 shaft; 16 permanent magnet; 18
insulator; 21 first bearing; 21a inner ring; 21b outer ring;
21c rolling element; 21d outer circumferential surface; 21e
rolling element; 22 second bearing; 22a inner ring; 22b outer
15 ring; 22c rolling element; 22d outer circumferential surface;
22e rolling element; 30 resin part; 31 inner cylindrical portion;
32 rib; 33 outer cylindrical portion; 40 mold resin portion; 41
opening; 42 bearing support portion (second bearing support
portion); 42a inner circumferential surface; 42b end surface; 45
20 attachment leg; 50 stator core; 55 coil; 61 cylindrical portion;
61a inner circumferential surface; 62 annular portion; 63 fitting
portion; 64 end surface portion; 71 drive circuit; 72 outlet
part; 73 lead wire; 80 bearing support member (second bearing
support portion); 81 flange portion; 82 plate-like portion; 83
25 inner circumferential surface; 84 end surface; 85 opposing
surface; 100, 100A, 100B motor; 500 air conditioner; 501 outdoor
unit; 502 indoor unit; 503 refrigerant pipe; 505 impeller; 509
frame; 510 outdoor fan; 520 indoor fan.

We Claim:
1. A motor comprising:
a rotor having a shaft, a rotor core surrounding the shaft
5 from outside in a radial direction about a center axis of the
shaft, and a permanent magnet attached to the rotor core, the
permanent magnet forming a magnet magnetic pole, a part of the
rotor core forming a virtual magnetic pole;
a stator surrounding the rotor from outside in the radial
10 direction;
a first bearing and a second bearing supporting the shaft;
and
a first bearing support portion having an inner
circumferential surface facing an outer circumferential surface
15 of the first bearing; and
a second bearing support portion having an inner
circumferential surface facing an outer circumferential surface
of the second bearing,
wherein one side of the shaft in a direction of the center
20 axis is defined as a load side to which a load is applied;
wherein, of the first bearing and the second bearing, the
first bearing is located on the load side; and
wherein a distance D1 from the center axis to the inner
circumferential surface of the first bearing support portion, a
25 distance D2 from the center axis to the inner circumferential
surface of the second bearing support portion, a distance d1 from
the center axis to the outer circumferential surface of the first
bearing, and a distance d2 from the center axis to the outer
circumferential surface of the second bearing satisfy D1-d1 <
30 D2-d2.
2. The motor according to claim 1, wherein D1 < D2 is further
satisfied.
31
3. The motor according to claim 2, wherein d1 = d2 is further
satisfied.
4. The motor according to claim 1 or 2, wherein d1 > d2 is
5 further satisfied.
5. The motor according to claim 4, wherein D1 = D2 is further
satisfied.
10 6. The motor according to any one of claims 1 to 5, wherein
the first bearing support portion is composed of a metal, and
wherein the second bearing support portion is composed of
a resin.
15 7. The motor according to any one of claims 1 to 5, wherein
the first bearing support portion is composed of a metal, and
wherein the second bearing support portion is composed of
a metal.
20 8. The motor according to claim 7, further comprising a mold
resin portion holding the first bearing support portion and the
second bearing support portion.
9. The motor according to any one of claims 1 to 8, wherein
25 the first bearing and the second bearing have a same inner
diameter.
10. The motor according to any one of claims 1 to 9, further
comprising an insulator provided between the shaft and at least
30 one of the first bearing and the second bearing.
11. The motor according to any one of claims 1 to 10, wherein
the rotor has a resin part between the rotor core and the shaft.
32
12. The motor according to any one of claims 1 to 11, wherein
at least one of the first bearing and the second bearing has a
rolling element composed of a ceramic.
5 13. The motor according to claim 12, wherein the first bearing
has a rolling element composed of a ceramic.
14. The motor according to claim 12, wherein each of the first
bearing and the second bearing has a rolling element composed of
10 a ceramic.
15. A fan comprising:
the motor according to any one of claims 1 to 14; and
an impeller rotated by the motor.
15
16. An air conditioner comprising:
an outdoor unit; and
an indoor unit connected to the outdoor unit via a
refrigerant pipe,
20 wherein at least one of the outdoor unit and the indoor
unit has the fan according to claim 15.