# Patent

## Title
Motor

## Abstract

A motor has a rotor core with a plurality of first non-magnetic layers and a plurality of second non-magnetic layers. The rotor core has a plurality of magnets. The first and second non-magnetic layers are positioned to cancel n-th order harmonics. Therefore, a specific order, for example 5-th order and 7-th order, harmonics component of a magnetic flux distribution waveform (induction voltage waveform) is reduced and unnecessary radial force and thrust force is prevented from occurrence, while sufficient magnetic flux is maintained.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This U.S. National stage application claims priority under 35 U.S.C. §119(a) to Japanese Patent Application No. 2003-191594, filed in Japan on Jul. 4, 2003, the entire contents of which are hereby incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to a motor comprising a rotor core in which multiple permanent magnets are embedded. More particularly, the present invention relates to a motor suitable for usage in which silence is required.
BACKGROUND ART
From the past, Silence in a motor is considered. There exist many techniques which intend to achieve silence by paying attention to the variation in attraction force in rotational direction due to rotational position such as cogging torque, mainly.
For example, Japanese Patent Publication Nos. 10-201147, 11-98731, and 2000-69695 each intends to reduce cogging torque.
Japanese Patent Publication No. 10-201147 realizes a motor with low vibration and low noise by reducing cogging torque by determining circumferential direction target position of permanent magnets in two layers to be a specific relationship which suits to a specific formula, the permanent magnets being embedded in the interior of the rotor core, as illustrated in FIG. 1.
Japanese Patent Publication No. 10-201147 pays attention to cogging torque, so that formula differs depending upon the cycle of cogging torque. Especially, the value of θ in FIG. 1 becomes greater when concentrated winding is employed, so that disadvantage arises in that permanent magnets disposed in outer peripheral side of the rotor cannot be made greater.
Further, an angle of aperture of a magnetic pole differs for every pole, so that unbalance is generated in rotational force. And, an induction voltage waveform becomes asymmetrical shape. Therefore, various abuse are expected such that increase in noise, affection in position detection accuracy and the like due to other cause.
Japanese Patent Publication No. 11-98731 intends to reduce cogging torque by varying the angle of aperture of the magnetic pole for every pole, as illustrated in FIG. 2.
But, an angle of aperture of a magnetic pole differs for every pole, so that unbalance is generated in rotational force. And, an induction voltage waveform becomes asymmetrical shape. Therefore, various abuse are expected such that increase in noise, affection in position detection accuracy and the like due to other cause.
Japanese Patent Publication No. 2000-69695 determines the punching holes for embedding permanent magnet which are equal to one another, and varies the shape of elongate hole section each provided to contact to the edge face of the permanent magnet. This corresponds to application of pseudo skew, and intends to reduction effect in cogging torque.
Piling different rotor cores in axial direction causes complicated arrangement of die. Force is generated in axial direction so that thrust vibration is possibly induced. Abuse cannot be ignored due to existence of pole which has extremely narrow angle of aperture in magnetic pole. For example, problems are exemplified such that increase in iron losses due to excessive concentration of magnetic flux, sufficient magnetic flux cannot reach edge section of permanent magnet during magnetization.
All of those techniques pay attention to cogging torque. When a motor is driven, more particularly when load is great, affection of cogging torque is small, and rather, affection of higher harmonics of induction voltage becomes greater if cogging torque is suppressed below a certain value. More particularly, when permanent magnet having stronger magnetic force is employed such as rare earth magnet, it is understood that the magnet is greatly affected by higher harmonics of induction voltage.
Japanese Patent Publication No. 2002-44888 can resolve the problem of the existence of extremely narrow angle of aperture in magnetic pole among the above problems. Specifically, an elongate hole section provided for contacting the edge face of the permanent magnet is divided in peripheral direction, as illustrated in FIG. 4, so that “auxiliary reinforcement rib” is provided. Japanese Patent Publication No. 2002-44888 intends to prevent deformation in the rotor.
The magnetic flux also flows through the “auxiliary reinforcement rib”. Therefore, sound may be increased depending upon the position of the “auxiliary reinforcement rib”.
As is described in the above, Japanese Patent Publication Nos. 10-201147, 11-98731, 2000-69695, and 2002-44888 do not successfully reduce cogging torque while sufficient permanent magnet magnetic flux is maintained and abuse in sound due to unbalance vibration and in sound due to thrust force is not generated. Also, they are not the measure which pays attention to specific harmonics of the induction voltage, for example fifth order harmonics and seventh order harmonics. Especially, they are not the arrangement for sufficiently reduce sound when the motor has a great load.
The present invention was made in view of the above problems.
It is an object of the present invention to provide a motor for reducing specific orders of magnetic flux distribution waveform, for example fifth order and seventh order, and for prevent generation of unnecessary radial force and thrust force while sufficient magnetic flux is maintained.
SUMMARY OF THE INVENTION
A motor of first aspect comprises a rotor core, plural permanent magnets embedded in the rotor core, wherein a peripheral direction edge section of each permanent magnet or non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet elongates in the vicinity between the poles to the vicinity of the rotor surface, and a second non-magnetic layer is provided in the vicinity of the surface of the rotor at the pole center side position with respect to the peripheral direction edge section of each permanent magnet or non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet, and wherein the non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet and the second non-magnetic layer are positioned to cancel n-th order harmonics (n is an odd number and is equal to or greater than 3) of the induction voltage.
A motor of second aspect employs an odd number order harmonics, the odd number being equal to or greater than 3 and other than multiples of 3, as the n-th order harmonics.
A motor of third aspect employs an odd number order harmonics, the odd number being equal to or greater than 13 and other than multiples of 3, as the n-th order harmonics.
A motor of fourth aspect employs 5-th order harmonics or 7-th order harmonics as the n-th order harmonics.
A motor of fifth aspect makes the peripheral direction edge section of each permanent magnet or non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet and the second non-magnetic layer independent from one another, and provides rotor core lying between them.
A motor of sixth aspect determines θ1 and θ2 to be

0<θ1<180/(5·Pn)

and

180/(5·Pn)≦θ2≦180×2/(5·Pn)

or

0<θ1<180/(7·Pn)

and

180/(7·Pn)≦θ2≦180×2/(7·Pn)

where θ1 represents an angle between the peripheral direction edge section of each permanent magnet or the pole center side edge section of rotor surface adjacent section of the non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet and the between poles, and θ2 represents an angle between pole center side edge section of the rotor surface adjacent section of the second non-magnetic layer and the between poles, and Pn represents a pole pair number.

A motor of seventh aspect determines the angle θ1 to be 0<θ1<180/(5·Pn) or 0<θ1<180/(7·Pn), the angle θ2 to be the minimum value of 180/(5·Pn)≦θ2≦180×2/(5·Pn) or the minimum value of 180/(7·Pn)≦θ2≦180×2/(7·Pn).
A motor of eighth aspect determines θ5 and θ6 to be

0<θ5<180/(5·Pn)

and

180/(5·Pn)≦θ6≦180×2/(5·Pn)

where θ5 represents an angle between the peripheral direction edge section of each permanent magnet or the pole center side edge section of the rotor surface adjacent section of the non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet and the between poles, and θ6 represents an angle between pole center side edge section of the rotor surface adjacent section of the second non-magnetic layer and the between poles, and Pn represents a pole pair number, and determines θ7 and θ8 to be

0<θ7<180/(7·Pn)

and

180/(7·Pn)≦θ8≦180×2/(7·Pn)

where the rotor core section width has points of inflection, the rotor core section width being sandwiched by the peripheral direction edge section of each permanent magnet or non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet and the second non-magnetic layer and the rotor surface, θ7 and θ8 represent angles between the respective point of inflection and the between poles, and Pn represents a pole pair number, and determines the relationship of the angles θ5, θ6, θ7 and θ8 to be θ7<θ5<θ8<θ6.

A motor of ninth aspect determines the angle θ5 to be 0<θ5<180/(5·Pn), the angle θ7 to be 0<θ7<180/(7·Pn), the angle θ6 to be the minimum value of 180/(5·Pn)≦θ6≦180×2/(5·Pn), and the angle θ8 to be the minimum value of 180/(7·Pn)≦θ8≦180×2/(7 Pn).
A motor of tenth aspect employs a permanent magnet divided into multiple layers in radial direction as each of the permanent magnets.
A motor of eleventh aspect employs a permanent magnet divided into two layers in radial direction as each of the permanent magnets, and determines θ3 and θ4 to be

0<θ3<180/(5·Pn)

and

180/(5·Pn)≦θ4≦180×2/(5·Pn)

or

0<θ3<180/(7·Pn)

and

180/(7·Pn)≦θ4≦180×2/(7·Pn)

where θ3 represents an angle between the peripheral direction edge section of permanent magnet in inner side of the rotor or the pole center side edge section of rotor surface adjacent section of the non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet and the between poles, and θ4 represents an angle between the peripheral direction edge section of permanent magnet in outer side of the rotor or pole center side edge section of the rotor surface adjacent section of the non-magnetic layer continuous or adjacent to peripheral direction edge section of the permanent magnet and the between poles, and Pn represents a pole pair number.

A motor of twelfth aspect determines the angle θ3 to be 0<θ3<180/(5·Pn) or 0<θ3<180/(7·Pn), the angle θ4 to be the minimum value of 180/(5·Pn)≦θ4<180×2/(5·Pn) or the minimum value of 180/(7·Pn)≦θ4≦180×2/(7·Pn).
A motor of thirteenth aspect employs a permanent magnet divided into two layers in radial direction as each of the permanent magnets, and determines θ9 and θ10 to be

0<θ9<180/(5·Pn)

and

180/(5·Pn)≦θ10≦180×2/(5·Pn)

where θ9 represents an angle between the pole center side edge section of rotor surface adjacent section of the permanent magnet in inner side of the rotor and the between poles, and θ10 represents an angle between pole center side edge section of the rotor surface adjacent section of the permanent magnet in outer side of the rotor and the between poles, and Pn represents a pole pair number,

and determines θ11 and θ12 to be

0<θ11<180/(7·Pn)

and

180/(7·Pn)≦θ12≦180×2/(7·Pn)

where the rotor core section width has points of inflection, the rotor core section width being sandwiched by the peripheral direction edge section of permanent magnet on inner side of the rotor or non-magnetic layer continuous or adjacent to the peripheral direction edge section of permanent magnet and the peripheral direction edge section of permanent magnet on outer side of the rotor or non-magnetic layer continuous or adjacent to the peripheral direction edge section of permanent magnet, θ11 and θ12 represent angles between the respective point of inflection and the between poles, and Pn represents a pole pair number,

and determines the relationship of the angles θ9, θ10, θ11 and θ12 to be θ11<θ9<θ12<θ10.

A motor of fourteenth aspect determines the angle θ9 to be 0<θ9<180/(5·Pn), the angle θ11 to be 0<θ11<180/(7·Pn), the angle θ10 to be the minimum value of 180/(5·Pn)≦θ10≦180×2/(5·Pn), and the angle θ12 to be the minimum value of 180/(7·Pn)≦θ12≦180×2/(7·Pn). In this specification “pole” is used to represent N-poles or S-poles which are disposed at every approximately constant interval or constant angle. “magnetic pole” is used to represent an extent from which magnetic flux of the permanent magnet mainly flows.
The invention of first aspect comprises a rotor core, plural permanent magnets embedded in the rotor core, wherein a peripheral direction edge section of each permanent magnet or non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet elongates in the vicinity of between the poles to the vicinity of the rotor surface, and a second non-magnetic layer is provided in the vicinity of the surface of the rotor at the pole center side position with respect to the peripheral direction edge section of each permanent magnet or non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet, and wherein the non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet and the second non-magnetic layer are positioned to cancel n-th order harmonics (n is an odd number and is equal to or greater than 3) of the induction voltage. Therefore, n-th order harmonics component of the magnetic flux distribution waveform (induction voltage waveform) can be reduced and unnecessary radial force and thrust force can be prevented from occurrence, while sufficient magnetic flux can be maintained.
A motor of second aspect employs harmonics of an order of odd number and of equal to or greater than 3 other than multiples of 3, as the n-th order harmonics. Therefore, odd number order harmonics, the odd number being equal to or greater than 3 other than multiples of 3, of the magnetic flux distribution waveform (induction voltage waveform) can be reduced and unnecessary radial force and thrust force can be prevented from occurrence, while sufficient magnetic flux can be maintained.
A motor of third aspect employs harmonics of an order of odd number and of equal to or greater than 13 other than multiples of 3, as the n-th order harmonics. Therefore, odd number order harmonics, the odd number being equal to or greater than 13 other than multiples of 3, of the magnetic flux distribution waveform (induction voltage waveform) can be reduced and unnecessary radial force and thrust force can be prevented from occurrence, while sufficient magnetic flux can be maintained.
A motor of fourth aspect employs fifth order harmonics or seventh order harmonics as the n-th order harmonics. Therefore, 5-th order harmonics or 7-th order harmonics of the magnetic flux distribution waveform (induction voltage waveform) can be reduced and unnecessary radial force and thrust force can be prevented from occurrence, while sufficient magnetic flux can be maintained.
A motor of fifth aspect makes the peripheral direction edge section of each permanent magnet or non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet and the second non-magnetic layer independent from one another, and provides rotor core lying between them. Therefore, mechanical strength can be improved, and operation and effect similar to those of the fourth aspect can be realized.
A motor of sixth aspect determines θ1 and θ2 to be

0<θ1<180/(5·Pn)

and

180/(5·Pn)≦θ2≦180×2/(5·Pn)

or

0<θ1<180/(7·Pn)

and

180/(7·Pn)≦θ2≦180×2/(7·Pn)

where θ1 represents an angle between the peripheral direction edge section of each permanent magnet or the pole center side edge section of rotor surface adjacent section of the non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet and the between poles, and θ2 represents an angle between pole center side edge section of the rotor surface adjacent section of the second non-magnetic layer and the between poles, and Pn represents a pole pair number. Therefore, operation and effect similar to those of fourth aspect or fifth aspect can be realized by taking symmetry into consideration.

A motor of seventh aspect determines the angle θ1 to be 0<θ1<180/(5·Pn) or 0<θ1<180/(7·Pn), the angle θ2 to be the minimum value of 180/(5·Pn)≦θ2≦180×2/(5·Pn) or the minimum value of 180/(7·Pn)≦θ2≦180×2/(7·Pn). Therefore, silencing can be realized, and operation and effect similar to those of fourth aspect or fifth aspect can be realized.
A motor of eighth aspect determines θ5 and θ6 to be

0<θ5<180/(5·Pn)

and

180/(5·Pn)≦θ6≦180×2/(5·Pn)

where θ5 represents an angle between the peripheral direction edge section of each permanent magnet or the pole center side edge section of the rotor surface adjacent section of the non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet and the between poles, and θ6 represents an angle between pole center side edge section of the rotor surface adjacent section of the second non-magnetic layer and the between poles, and Pn represents a pole pair number,

and determines θ7 and θ8 to be

0<θ7<180/(7·Pn)

and

180/(7·Pn)≦θ8≦180×2/(7·Pn)

where the rotor core section width has points of inflection, the rotor core section width being sandwiched by the peripheral direction edge section of each permanent magnet or non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet and the second non-magnetic layer and the rotor surface, θ7 and θ8 represent angles between the respective point of inflection and the between poles, and Pn represents a pole pair number,

and determines the relationship of the angles θ5, θ6, θ7 and θ8 to be θ7<θ5<θ8<θ6. Therefore, operation and effect similar to those of fourth aspect or fifth aspect can be realized by taking symmetry into consideration.

A motor of ninth aspect determines the angle θ5 to be 0<θ5<180/(5·Pn), the angle θ7 to be 0<θ7<180/(7·Pn), the angle θ6 to be the minimum value of 180/(5·Pn)≦θ6≦180×2/(5·Pn), and the angle θ8 to be the minimum value of 180/(7·Pn)≦θ8≦180×2/(7·Pn). Therefore, silencing can be realized, and operation and effect similar to those of fourth aspect or fifth aspect can be realized.
A motor of tenth aspect employs a permanent magnet divided into multiple layers in radial direction as each of the permanent magnets. Therefore, operation and effect similar to those of first to fourth aspect can be realized even when the permanent magnet is divided into multiple parts, some parts corresponding to inner side of the rotor and other parts corresponding to outer side of the rotor.
A motor of eleventh aspect employs a permanent magnet divided into two layers in radial direction as each of the permanent magnets, and determines θ3 and θ4 to be

0<θ3<180/(5·Pn)

and

180/(5·Pn)≦θ4≦180×2/(5·Pn)

or

0<θ3<180/(7·Pn)

and

180/(7·Pn)≦θ4≦180×2/(7·Pn)

where θ3 represents an angle between the peripheral direction edge section of permanent magnet in inner side of the rotor or the pole center side edge section of rotor surface adjacent section of the non-magnetic layer continuous or adjacent to the peripheral direction edge section of each permanent magnet and the between poles, and θ4 represents an angle between pole center side edge section of the rotor surface adjacent section of the peripheral direction edge section of permanent magnet in outer side of the rotor or non-magnetic layer continuous or adjacent to peripheral direction edge section of the permanent magnet and the between poles, and Pn represents a pole pair number. Therefore, operation and effect similar to those of tenth aspect can be realized by taking symmetry into consideration.

A motor of twelfth aspect determines the angle θ3 to be 0<θ3<180/(5·Pn) or 0<θ3<180/(7·Pn), the angle θ4 to be the minimum value of 180/(5·Pn)≦θ4≦180×2/(5·Pn) or the minimum value of 180/(7·Pn)≦θ4≦180×2/(7·Pn). Therefore, silencing can be realized, and operation and effect similar to those of tenth aspect can be realized.
A motor of thirteenth aspect employs a permanent magnet divided into two layers in radial direction as each of the permanent magnets, and determines θ9 and θ10 to be

0<θ9<180/(5·Pn)

and

180/(5·Pn)≦θ10≦180×2/(5·Pn)

where θ9 represents an angle between the pole center side edge section of rotor surface adjacent section of the permanent magnet in inner side of the rotor and the between poles, and θ10 represents an angle between pole center side edge section of the rotor surface adjacent section of the permanent magnet in outer side of the rotor and the between poles, and Pn represents a pole pair number,

and determines θ11 and θ12 to be

0<θ11<180/(7·Pn)

and

180/(7·Pn)≦θ12≦180×2/(7·Pn)

where the rotor core section width has points of inflection, the rotor core section width being sandwiched by the peripheral direction edge section of permanent magnet on inner side of the rotor or non-magnetic layer continuous or adjacent to the peripheral direction edge section of permanent magnet and the peripheral direction edge section of permanent magnet on outer side of the rotor or non-magnetic layer continuous or adjacent to the peripheral direction edge section of permanent magnet, θ11 and θ12 represent angles between the respective point of inflection and the between poles, and Pn represents a pole pair number,

and determines the relationship of the angles θ9, θ10, θ11 and θ12 to be θ11<θ9<θ12<θ10. Therefore, operation and effect similar to those of tenth aspect can be realized by taking symmetry into consideration.

A motor of fourteenth aspect determines the angle θ9 to be 0<θ9<180/(5·Pn), the angle θ11 to be 0<θ11<180/(7·Pn), the angle θ10 to be the minimum value of 180/(5·Pn)≦θ10≦180×2/(5·Pn), and the angle θ12 to be the minimum value of 180/(7·Pn)≦θ12≦180×2/(7·Pn). Therefore, silencing can be realized, and operation and effect similar to those of tenth aspect can be realized.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating an example of a prior motor;
FIG. 2 is a schematic diagram illustrating another example of a prior motor;
FIG. 3 is a schematic diagram illustrating a further example of a prior motor;
FIG. 4 is a schematic diagram illustrating a further example of a prior motor;
FIG. 5 is a diagram illustrating magnetic flux density distribution in peripheral direction on rotor surface;
FIG. 6 is a cross-sectional view illustrating a rotor of a motor of first embodiment according to the present invention;
FIG. 7 is a diagram illustrating a relationship between the magnetic flux density distribution on the rotor surface and the non-magnetic layer;
FIG. 8 is a diagram illustrating characteristics of 5-th order harmonics, 7-th order harmonics with respect to θ1 when θ2=23°;
FIG. 9 is a diagram illustrating characteristics of 5-th order harmonics, 7-th order harmonics with respect to θ2 when θ1=6°;
FIG. 10 is a schematic diagram illustrating a stator having distributed winding;
FIG. 11 is a schematic diagram illustrating a stator having concentrated winding;
FIG. 12 is a schematic diagram illustrating a modified example of the rotor of first embodiment;
FIG. 13 is a schematic diagram illustrating another modified example of the rotor of first embodiment;
FIG. 14 is a schematic diagram illustrating a rotor of the motor of second embodiment according to the present invention;
FIG. 15 is a schematic diagram illustrating a modified example of the rotor of second embodiment;
FIG. 16 is a schematic diagram illustrating a rotor of the motor of third embodiment according to the present invention;
FIG. 17 is a diagram illustrating magnetic flux density distribution on rotor surface;
FIG. 18 is a diagram illustrating comparison of the induction voltage waveform for a case where second non-magnetic layer does not exist, and the induction voltage waveform for a case where third embodiment is employed;
FIG. 19 is a diagram illustrating higher harmonics component of noise for a case the motor is driven as the motor for compressor;
FIG. 20 is a schematic diagram illustrating a modified example of the rotor of third embodiment; and
FIG. 21 is a schematic diagram illustrating a rotor of the motor of fourth embodiment according to the present invention.



BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, referring to the attached drawings, we explain a motor of an embodiment according to the present invention in detail.
In the following embodiment, we explain a case which cancels 5-th order harmonics and/or 7-th order harmonics of an induction voltage. But, it is of course possible that other harmonics can be canceled.
First, a general example of a motor is described.
Magnetic flux density distribution in peripheral direction of the rotor surface of the motor is symmetric for every pole. When each pole has approximately same shape to one another, magnetic flux density becomes zero for between poles.
Therefore, the magnetic flux density distribution in peripheral direction of the rotor surface becomes a distribution which makes 1 pole pair to be fundamental wave, and includes odd number order thereof For example, when a simple rectangular wave is applied Fourier expansion, odd number order components such as third order, 5-th order, 7-th order, and 9-th order, are overlapped to the fundamental wave, as is illustrated in FIG. 5. Wherein, 3n-th order harmonics vibration addition forces (where n: 1, 2, 3, 4, . . . ) such as third order and 9-th order harmonics vibration addition forces are in synchronism to one another so that a mode of resonance having a number which is the same to the stator pole number, such that hexagon mode of resonance for the stator having 6 poles. The mode of resonance of higher order generally exceed the audible range greatly so that the mode of resonance hardly becomes noise.
Further, 5-th order and 7-th order have characteristics which is greater in amplitude, easier in becoming sound, and more difficult to be cut-off because of low frequency, in comparison to eleventh or more orders. Therefore, we will pay attention to 5-th order harmonics and 7-th order harmonics.
The following two points may be made to be premises when the 5-th order harmonics and 7-th order harmonics are taken measure to meet with.
1) Every order component becomes zero due to the symmetry of magnetic flux density waveform on the rotor surface.
2) Higher harmonics component can be zero-cross at the location where varying in magnetic flux begins suddenly such as beginning of magnetic pole and the like.
First Embodiment
Hereinafter, the first embodiment is described with reference to the drawings.
FIG. 6 is a schematic diagram illustrating an arrangement of a rotor of a motor of the first embodiment according to the present invention.
This rotor 1 comprises multiple permanent magnets 3 (in this embodiment, the rotor has 4 poles, therefore 4 permanent magnets 3) which are embedded in the interior of the rotor core 2.
Further, non-magnetic layers 4 (hereinafter, referred to as “first non-magnetic layer”), each being continuous to the peripheral direction edge section of each permanent magnet 3, each elongates in vicinity of the between poles to the vicinity of the rotor surface. And, a second non-magnetic layer 5 is provided at a location which is a pole center side location of the first non-magnetic layer 4 and which is in vicinity of the rotor surface. Wherein, the non-magnetic layer is a through hole or an air layer.
The first non-magnetic layer 4 and second non-magnetic layer 5 are independent from one another. An auxiliary reinforcement rib 2a made of rotor core is interposed between both non-magnetic layers.
An angle θ1 between the pole center side edge section of rotor surface adjacent section and the between poles of the first non-magnetic layer 4, and an angle θ2 between the pole center side edge section of rotor surface adjacent section and the between poles of the second non-magnetic layer 5 are determined to be

0<θ1<180/(5·Pn)

and

180/(5·Pn)≦θ2≦180×2/(5·Pn)

or

0<θ1<180/(7·Pn)

and

180/(7·Pn)≦θ2≦180×2/(7·Pn)

when the pole pair number is Pn. The above formulae correspond to reduction in 5-th order harmonics and reduction in 7-th order harmonics. When the reduction of n-th order harmonics (n is odd number and is equal to or greater than 3) is to be carried out, n is employed instead 5 and 7. Similar operation should be carried out for following formulae. In this embodiment, the pole pair number Pn=2. Formulae of upper two rows are used for reducing the 5-th order harmonics. Specifically, it is better that θ1=9°, θ2=18°.

The principle for reducing sound of the motor having the above arrangement is described in the following.
For example, since 5-th order harmonics is intended to be reduced and the pole pair number is 2, when θ1=0°, and θ2=18°, the phases are shifted by 180° so as to cancel from one another. But, θ1=0° is difficult for the arrangement where the permanent magnets are embedded in the interior of the rotor core. Consequently, it is sufficient that θ1<18° due to symmetry. When 7-th order harmonics is to be reduced, formulae of lower two rows are used, and it is better that θ1<12.9°, 12.9°≦θ2≦25.7°. For maximizing the torque, θ2 is increased as great as possible so as to increase the magnetic flux interlinking to the permanent magnet.
FIG. 7 illustrates a relationship between the magnetic flux density distribution on the rotor surface and the non-magnetic layers 4 and 5, of this embodiment. In some portion of the non-magnetic layers 4 and 5, the magnetic flux density increases or decreases, and in remaining portion of the non-magnetic layers 4 and 5, the magnetic flux density is approximately constant. Therefore, changing in magnetic flux becomes steep from pole center side edge section of the rotor surface adjacent portion of respective non-magnetic layers 4 and 5. Consequently, zero-cross points of higher harmonics components appear for respective points. For the second non-magnetic layer 5, it corresponds to 1 wave length of the 5/7-th order harmonics from the between poles, and it is thought that the zero-cross point becomes the between poles due to symmetry. For the first non-magnetic layer 4, it corresponds to half wave length of the 5/7-th order harmonics from the between poles, and it is thought that the zero-cross point becomes the between poles due to symmetry. Therefore, 5/7-th order harmonics due to respective non-magnetic layers 4 and 5 are shifted by half wave length from one another, so that they are canceled one another.
FIG. 8 illustrates characteristics of 5-th order harmonics and 7-th order harmonics with respect to θ1 when θ2=23°, while FIG. 9 illustrates characteristics of 5-th order harmonics and 7-th order harmonics with respect to θ2 when θ1=6°.
It is understood from FIGS. 8 and 9, greater reduction effect of 5-th order harmonics and 7-th order harmonics can be realized by determining the angle θ1, and θ2 to satisfy the above formulae.
Wherein, the width of the rotor core sandwiched by the first non-magnetic layer 4, second non-magnetic layer 5 and the rotor surface (hereinafter, referred to as “first bridge 2b1” and “second bridge 2b2”) are constant. It is desirable that the width is made smaller for preventing magnetic flux leakage.
Further, there also exist a rotor rib (auxiliary reinforcement rib) 2a serving as the magnetic path between the first non-magnetic layer 4 and second non-magnetic layer 5. Sufficient effect cannot be obtained by passing the magnetic flux of the permanent magnet through the auxiliary reinforcement rib 2a. 
The permanent magnet and non-magnetic layer need not be in continuous to one another. They may adjacent to one another by a short distance.
The stator of the motor according to the present invention may have distributed winding as illustrated in FIG. 10, or may have concentrated winding as illustrated in FIG. 11. Especially, 5-th order harmonics and 7-th order harmonics become extremely greater for concentrated winding, therefore application of the present invention is effective.
FIGS. 12 and 13 illustrate schematic diagram illustrating modified examples of FIG. 6.
FIG. 12 is a modified example in which rotor core 2c exist in vicinity of both side of the permanent magnet of the rotor of FIG. 6. When the first and second non-magnetic layers 6 and 7 are disposed for canceling the higher harmonics wave of the magnetic flux flowing out from the surface, sufficient effect can be obtained.
FIG. 13 is a modified example in which the permanent magnet layer exist to a region adjacent to the rotor surface. When the second non-magnetic layer 8 is disposed for canceling the higher harmonics wave of the magnetic flux flowing out from the surface, sufficient effect can similarly be obtained. In this case, it is necessary to magnetize the permanent magnet so that the magnet flux at the permanent magnet edge section does not flow out in normal direction of the rotor.
Second Embodiment
FIG. 14 is a schematic diagram illustrating a rotor of a motor of a second embodiment according to the present invention.
In the rotor 11, permanent magnets are embedded in the interior of the rotor core 12. Permanent magnets for each pole is divided into 2 layers in radial direction (13: permanent magnet at inner side of the rotor, and 14: permanent magnet at outer side of the rotor). Further, peripheral direction edge sections 13a, and 14a of each of the permanent magnets 13, and 14 elongate in the vicinity to the between poles to the vicinity of the rotor surface.
The peripheral direction edge sections 13a and 14a of the permanent magnet 13 at inner side of the rotor and of the permanent magnet 14 at outer side of the rotor are independent from one another. A so-called q-axis magnetic flux path 12a made of rotor core is interposed between them.
Due to the existence of the q-axis magnetic flux path 12a, q-axis inductance Lq can be made to be greater so that the reluctance torque can be utilized in greater part, and that the magnetic flux of the permanent magnet can be increased without increasing the rotor in size.
An angle θ3 between the pole center side edge section of the peripheral direction edge section 13a of the permanent magnet 13 in inner side of the rotor and the between poles, and an angle θ4 between the pole center side edge section of the peripheral direction edge section 14a of the permanent magnet 14 in inner side of the rotor and the between poles are determined to be

0<θ3<180/(5·Pn)

and

180/(5·Pn)≦θ4≦180×2/(5·Pn)

or

0<θ3<180/(7·Pn)

and

180/(7·Pn)≦θ4≦180×2/(7·Pn)

when the pole pair number is Pn.

In this embodiment, the pole pair number Pn=2. Formulae of upper two rows are used for reducing the 5-th order harmonics. Specifically, it is better that θ1=9°, θ2=18°. Of course, formulae of lower two rows are used for reducing the 7-th order harmonics.
The principle for reducing sound of the motor having the above arrangement is similar to that of the first embodiment. Thus the description is omitted.
FIG. 15 is a schematic diagram illustrating a modified example of this embodiment.
This modified example employs planar permanent magnets instead the curved permanent magnets.
Therefore, sound can be reduced when this modified example is employed.
Third Embodiment
FIG. 16 is a schematic diagram illustrating an arrangement of a rotor of a motor of third embodiment according to the present invention.
In the rotor 31, multiple permanent magnets 33 (in this embodiment, the rotor is of 4 poles, so 4 permanent magnets) are embedded in the interior of the rotor core 32.
A non-magnetic layer 34 (hereinafter, referred to as “first non-magnetic layer”) elongates in vicinity of between poles to the vicinity of the rotor surface, the non-magnetic layer 34 being continuous to the peripheral direction edge section of each permanent magnet 33. Further, a second non-magnetic layer 35 is provided in pole center side of the first non-magnetic layer 34 and in vicinity of the rotor surface. Wherein, the non-magnetic layer is a through hole or an air layer.
An angle between the pole center side edge section of adjacent section to the rotor surface of the first non-magnetic layer 34 and the between poles is expressed with θ5, while an angle between the pole center side edge section of adjacent section to the rotor surface of the second non-magnetic layer 35 and the between poles is expressed with θ6.
The first non-magnetic layer 34 and second non-magnetic layer 35 are independent from one another. An auxiliary reinforcement rib 32a made of rotor core is interposed between them.
Further, the width of the rotor core section (hereinafter, referred to as “first bridge 32b1”, and “second bridge 32b2”) has points of inflection 36a and 36b, the rotor core section being sandwiched by the first non-magnetic layer 34, second non-magnetic layer 35 and the rotor surface. Angles between respective point of inflection 36a and 36b and between poles are expressed with θ7 and θ8. The angles θ5, θ6, θ7 and θ8 are determined to be

0<θ5<180/(5·Pn)

and

180/(5·Pn)≦θ6≦180×2/(5·Pn)

and

0<θ7<180/(7·Pn)

and

180/(7·Pn)≦θ8≦180×2/(7·Pn)

and

θ7<θ5<θ8<θ6.

In this embodiment, the pole pair number Pn is 2, so that the angles are determined to be θ6=18°, θ8=12.9°, θ5=9°, θ7=6.4°.
Wherein, the points of inflection 36a and 36b are crossing points of extents where the widths of the first bridge 32b1 and second bridge 32b2 are constant and extents where the widths of the first bridge 32b1 and second bridge 32b2 are gradually increasing. The change in magnetic flux density distribution on the rotor surface becomes steep at these points.
The magnetic flux density distribution on the rotor surface of this embodiment is illustrated in FIG. 17.
As is apparent from FIG. 17 and the description of the first embodiment, 7-th order harmonics is canceled by the points of inflection 36a and 36b, while 5-th order harmonics is canceled by pole center side edge section of the section adjacent to the rotor surface and by pole center side edge section of the section adjacent to the rotor surface of the second non-magnetic layer 35.
FIG. 18 illustrates a comparison in induction voltage waveforms, one for a case where the second non-magnetic layer 35 does not exist, the other for this embodiment. Table 1 illustrates a comparison in amplitude of higher harmonics components. Further, higher harmonics component of noise when the motor is driven as a motor for compressor is illustrated in FIG. 19.









TABLE 1









percentage with respect



to fundamental wave










Without
With


Induction voltage
non-magnetic layer
non-magnetic layer





5-th order harmonics
8.24
0.01


7-th order harmonics
2.68
0.03









Further, the shapes of the non-magnetic layer 34 and 35 are not limited to the shapes of this embodiment. It may be good that, for example, as is illustrated in FIG. 20, the widths of the bridges 37b1 and 37b2 are separated into small width sections 37b11, 37b21 and large width sections 37b12, 37b22, and that varying points of the small width sections 37b11, 37b21 and the large width sections 37b12, 37b22 are considered to be points of inflection 38a, 38b. 
Fourth Embodiment
FIG. 21 is a schematic diagram illustrating an arrangement of a rotor of a motor of fourth embodiment according to the present invention.
In the rotor 41, permanent magnets are embedded in the interior of the rotor core 42. The permanent magnets are divided into two layers in radial direction for every pole (43: permanent magnet at inner side of the rotor, and 44: permanent magnet at outer side of the rotor). Further, the peripheral direction edge section 43a, 44a of each permanent magnet 43, 44 elongates in the vicinity between poles to the vicinity of the rotor surface. The peripheral direction edge sections 43a, 44a of the permanent magnet 43 at the inner side of the rotor and the permanent magnet 44 at the outer side of the rotor are independent from one another. A so-called q-axis magnetic flux path 42a made of rotor core is interposed between them.
Due to the existence of the q-axis magnetic flux path 42a, the q-axis inductance Lq can be made greater. Therefore, reluctance torque of greater part can be used, and the magnetic flux of the permanent magnet can be increased without increase of the rotor in size.
Further, the peripheral direction edge section 43a of the permanent magnet 43 at the inner side of the rotor elongates in the vicinity between poles to the vicinity of the rotor surface, and the peripheral direction edge section 44a of the permanent magnet 44 at the outer side of the rotor also elongates in the vicinity between poles to the vicinity of the rotor surface. Wherein, air layers and the like may exist at the peripheral direction edge sections 43a, 44a of the permanent magnets 43, 44. An angle between the pole center side edge section of the peripheral direction edge section 43a of the permanent magnet 43 at the inner side of the rotor and between poles is expressed with θ9, and an angle between the pole center side edge section of the peripheral direction edge section 44a of the permanent magnet 44 at the outer side of the rotor and between poles is expressed with θ10.
Further, the width of the rotor core section (hereinafter, referred to as “first bridge 42b1”, and “second bridge 42b2”) has points of inflection 46a and 46b, the rotor core section being sandwiched by the peripheral direction edge section 43a of the permanent magnet 43 at the inner side of the rotor, the peripheral direction edge section 44a of the permanent magnet 44 at the outer side of the rotor and the rotor surface. Angles between respective point of inflection 46a, 46b and between poles are expressed with θ11 and θ12. The angles θ9, θ10, θ11 and θ12 are determined to be

0<θ9<180/(5·Pn)

and

180/(5·Pn)≦θ10≦180×2/(5·Pn)

and

0<θ11<180/(7·Pn)

and

180/(7·Pn)≦θ12≦180×2/(7·Pn)

and

θ11<θ9<θ12<θ10.

In this embodiment, the pole pair number Pn is 2, so that the angles are determined to be θ10=18°, θ12=12.9°, θ9=9°, θ11=6.4°.
The sound reduction operation and effect in this embodiment is similar to those of the third embodiment, therefore description is omitted.
The invention of first aspect has characteristic effect such that odd number order harmonics, the odd number being equal to or greater than 3, of the magnetic flux distribution waveform (induction voltage waveform) can be reduced and unnecessary radial force and thrust force can be prevented from occurrence, while sufficient magnetic flux can be maintained.
The invention of second aspect has characteristic effect such that odd number order harmonics, the odd number being equal to or greater than 3 other than multiples of 3, can be reduced, and that effect similar to those of first aspect can be realized.
The invention of third aspect has characteristic effect such that odd number order harmonics, the odd number being equal to or greater than 13 other than multiples of 3, can be reduced, and that effect similar to those of first aspect can be realized.
The invention of fourth aspect has characteristic effect such that 5-th order harmonics or 7-th order harmonics can be reduced, and that effect similar to those of second aspect can be realized.
The invention of fifth aspect has characteristic effect such that mechanical strength can be improved, and that effect similar to those of fourth aspect can be realized.
The invention of sixth aspect has characteristic effect such that effects similar to those of fourth aspect or fifth aspect can be realized by taking symmetry into consideration.
The invention of seventh aspect has characteristic effect such that silencing can be realized, and that effects similar to those of fourth aspect or fifth aspect can be realized.
The invention of eighth aspect has characteristic effect such that effects similar to those of fourth aspect or fifth aspect can be realized by taking symmetry into consideration.
The invention of ninth aspect has characteristic effect such that silencing can be realized, and that effects similar to those of fourth aspect or fifth aspect can be realized.
The invention of tenth aspect has characteristic effect such that effects similar to those of one of first aspect to fourth aspect can be realized even when the permanent magnet is divided into multiple parts, some parts corresponding to inner side of the rotor and other parts corresponding to outer side of the rotor.
The invention of eleventh aspect has characteristic effect such that effects similar to those of tenth aspect can be realized by taking symmetry into consideration.
The invention of twelfth aspect has characteristic effect such that silencing can be realized, and that effects similar to those of tenth aspect can be realized.
The invention of thirteenth aspect has characteristic effect such that effects similar to those of tenth aspect can be realized by taking symmetry into consideration.
The invention of fourteenth aspect has characteristic effect such that silencing can be realized, and that effects similar to those of tenth aspect can be realized.

## Claims

1. A rotor comprising:
a rotor core having a rotor surface;
a plurality of permanent magnets embedded in the rotor core with each of the permanent magnets defining a pole of the rotor, each pole of the rotor having a pole center;
a plurality of first non-magnetic layers being located between adjacent pairs of the permanent magnets along the rotor surface, each first non-magnetic layer being continuous or adjacent to a peripheral edge section of one of the permanent magnets in a vicinity between the poles and a vicinity of the rotor surface; and
a plurality of second non-magnetic layers being located in a vicinity of the rotor surface at pole center side positions with respect to the first non-magnetic layers,
the first non-magnetic layers and the second non-magnetic layers being positioned to cancel 5-th order harmonics or 7-th order harmonics of an induction voltage, and
the first non-magnetic layers and the second non-magnetic layers being independent from one another, and the rotor core being interposed between them, wherein
an angle θ1 being measured between a pole center side edge section, in the vicinity of the rotor surface, of the first non-magnetic layer and a position between the poles, and
an angle θ2 being measured between a pole center side edge section, in the vicinity of the rotor surface, of the second non-magnetic layer and the position, wherein


0<θ1<180/(5·Pn) and 180/(5·Pn)≦θ2≦180×2/(5·Pn)



or



0≦θ1<180/(7·Pn) and 180/(7·Pn)≦θ2≦180×2/(7·Pn)

where a pole pair number is Pn.

2. The rotor as set forth in claim 1, wherein the angle θ1 and the angle θ2 satisfy either


0<θ1<180/(5·Pn) and θ2=180/(5·Pn)



or



0<θ1<180/(7·Pn) and θ2=180/(7·Pn).

3. The rotor as set forth in claim 1, wherein
each of the permanent magnets is divided into multiple layers in a radial direction.

4. The rotor as set forth in claim 3, wherein
each of the permanent magnets is divided into two layers in a radial direction,
an angle θ3 is measured between a pole center side edge section, in the vicinity of a rotor surface, of the first non-magnetic layer continuous or adjacent to the permanent magnet in an inner side of the rotor and a position between the poles, and
an angle θ4 is measured between a pole center side edge section, in the vicinity of the rotor surface, of the first non-magnetic layer continuous or adjacent to the permanent magnet in an outer side of the rotor and the position between the poles, wherein


0<θ3<180/(5·Pn) and 180/(5·Pn)≦θ4≦180×2/(5·Pn)



or



0<θ3<180/(7·Pn) and 180/(7·Pn)≦θ4≦180×2/(7·Pn)

where a pole pair number is Pn.

5. The rotor as set forth in claim 4, wherein the angle θ3 and the angle θ4 satisfy either


0<θ3<180/(5·Pn) and θ4=180/(5·Pn)



or



0<θ3<180/(7·Pn) and θ4=180/(7·Pn).

6. The rotor as set forth in claim 3, wherein
each of the permanent magnets is divided into two layers in a radial direction, and an angle θ9 between a pole center side edge section, in the vicinity of the rotor surface, of the permanent magnet in an inner side of the rotor and a position between the poles, and
an angle θ10 is measured between a pole center side edge section, in the vicinity of the rotor surface, of the permanent magnet in an outer side of the rotor and the position between the poles, wherein


0<θ9<180/(5·Pn) and 180/(5·Pn)≦θ10≦180×2/(5·Pn)

where a pole pair number is Pn,

a rotor core section width has points of inflection, the rotor core section width being sandwiched by the first non-magnetic layer continuous or adjacent to the permanent magnet on the inner side of the rotor and the first non-magnetic layer continuous or adjacent to the permanent magnet on the outer side of the rotor, and
angles θ11 and θ12 are measured between respective points of inflection and the position between the poles, wherein


0<θ11<180/(7·Pn) and 180/(7·Pn)≦θ12≦180×2/(7·Pn)

where a pole pair number is Pn, and
a relationship of the angles θ9, θ10, θ11 and θ12 is θ11<θ9<θ12<θ10.

7. The rotor as set forth in claim 6, wherein
the angle θ9 is 0<θ9<180/(5·Pn), the angle θ11 is 0<θ11<180/(7·Pn), the angle θ10 is 180/(5·Pn), and the angle θ12 is 180/(7·Pn).

8. A rotor comprising:
a rotor core having a rotor surface;
a plurality of permanent magnets embedded in the rotor core with each of the permanent magnets defining a pole of the rotor, each pole of the rotor having a pole center;
a plurality of first non-magnetic layers being located between adjacent pairs of the permanent magnets along the rotor surface, each first non-magnetic layer being continuous or adjacent to a peripheral edge section of one of the permanent magnets in a vicinity between the poles and a vicinity of the rotor surface; and
a plurality of second non-magnetic layers being located in a vicinity of the rotor surface at pole center side positions with respect to the first non-magnetic layers,
the first non-magnetic layers and the second non-magnetic layers being positioned to cancel 5-th order harmonics or 7-th order harmonics of an induction voltage,
the first non-magnetic layers and the second non-magnetic layers being independent from one another, and the rotor core being interposed between them,
an angle θ5 being measured between a pole center side edge section, in the vicinity of the rotor surface, of the first non-magnetic layer and a position between the poles,
an angle θ6 being measured between a pole center side edge section, in the vicinity of the rotor surface, of the second non-magnetic layer and the position between the poles, wherein


0<θ5<180/(5·Pn) and 180/(5·Pn)≦θ6≦180×2/(5·Pn)

where a pole pair number is Pn,

a rotor core section width has points of inflection, the rotor core section width being sandwiched by the first non-magnetic layers and the second non-magnetic layers and the rotor surface, and
angles θ7 and θ8 being measured between respective points of inflection and the position between the poles, wherein


0<θ7<180/(7·Pn) and 180/(7·Pn)≦θ8≦180×2/(7·Pn)

where a pole pair number is Pn, and
a relationship of the angles θ5, θ6, θ7 and θ8 is θ7<θ5<θ8<θ6.

9. The rotor as set forth in claim 8, wherein
the angle θ5 is 0<θ5<180/(5·Pn), the angle θ7 is 0<θ7<180/(7·Pn),the angle θ6 is 180/(5·Pn), and the angle θ8 is 180/(7·Pn).

10. The rotor as set forth in claim 8 wherein
each of the permanent magnets is divided into multiple layers in a radial direction.

11. The rotor as set forth in claim 10, wherein
each of the permanent magnets is divided into two layers in a radial direction,
an angle θ3 is measured between a pole center side edge section, in the vicinity of the rotor surface, of the first non-magnetic layer continuous or adjacent to the permanent magnet in an inner side of the rotor and a position between the poles, and
an angle θ4 is measured between a pole center side edge section, in the vicinity of the rotor surface, of the first non-magnetic layer continuous or adjacent to the permanent magnet in an outer side of the rotor and the position between the poles, wherein


0<θ3<180/(5·Pn) and 180/(5·Pn)≦θ4≦180×2/(5·Pn)



or



0<θ3<180/(7·Pn) and 180/(7·Pn)≦θ4≦180×2/(7·Pn)

where a pole pair number is Pn.

12. The rotor as set forth in claim 11, wherein
the angle θ3 and the angle θ4 satisfy either


0<θ3<180/(5·Pn) and θ4=180/(5·Pn)



or



0<θ3<180/(7·Pn) and θ4=180/(7·Pn).

13. The rotor as set forth in claim 10, wherein
each of the permanent magnets is divided into two layers in a radial direction, and an angle θ9 between a pole center side edge section, in the vicinity of the rotor surface, of the permanent magnet in an inner side of the rotor and a position between the poles, and
an angle θ10 is measured between a pole center side edge section, in the vicinity of the rotor surface, of the permanent magnet in an outer side of the rotor and the position between the poles, wherein


0<θ9<180/(5·Pn) and 180/(5·Pn)≦θ10≦180×2/(5·Pn)

where a pole pair number is Pn,

a rotor core section width has points of inflection, the rotor core section width being sandwiched by the first non-magnetic layer continuous or adjacent to the permanent magnet on the inner side of the rotor and the first non-magnetic layer continuous or adjacent to the permanent magnet on the outer side of the rotor, and
angles θ11 and θ12 are measured between respective points of inflection and the position between the poles, wherein


0<θ11<180/(7·Pn) and 180/(7·Pn)≦θ12≦180×2/(7·Pn)

where a pole pair number is Pn, and
a relationship of the angles θ9, θ10, θ11 and θ12 is θ11<θ9<θ12<θ10.

14. The rotor as set forth in claim 13, wherein
the angle θ9 is 0<θ9<180/(5·Pn), the angle θ11 is 0<θ11<180/(7·Pn), the angle θ10 is 180/(5·Pn), and the angle θ12 is 180/(7·Pn).