阅读说明：本技术 磁铁构造体，磁铁构造体的制造方法以及旋转电机的制造方法 (Magnet structure, method for manufacturing magnet structure, and method for manufacturing rotating electric machine ) 是由 儿岛伸生 川岛伸也 于 2019-08-08 设计创作，主要内容包括：本发明提供一种实现了易于磁化的磁铁构造体，磁铁构造体的制造方法，以及旋转电机的制造方法。在根据本公开所涉及的磁铁构造体及其制造方法中，磁铁构造体具有具备多个磁铁构造部件的构造，并且层叠的多个磁铁构造部件受到约束器的约束。在这种磁铁构造体中，通过磁化工序可以将多个磁铁构造部件分别磁化。在磁化工序中，磁化对象为比磁铁构造体整体更小的磁铁构造部件。因此，可以使用比磁化整个磁铁构造体的磁化装置更小的磁化装置，并且可以更容易地进行磁铁构造体的磁化。(The invention provides a magnet structure body easy to magnetize, a manufacturing method of the magnet structure body, and a manufacturing method of a rotating motor. In the magnet structure and the method of manufacturing the same according to the present disclosure, the magnet structure has a structure including a plurality of magnet structural members, and the plurality of stacked magnet structural members are constrained by the constraining device. In such a magnet structure, the plurality of magnet structural members can be magnetized by the magnetizing step. In the magnetization step, the magnetization target is a magnet structural member smaller than the entire magnet structural body. Therefore, a smaller magnetizing device than the magnetizing device that magnetizes the entire magnet structure can be used, and the magnetization of the magnet structure can be performed more easily.)

1. A method of manufacturing a magnet structure, characterized in that,

a method for manufacturing a magnet structure used for a wind power generator and having a plurality of magnet structural members laminated together,

each of the magnet structural members includes a holding body having a pair of end surfaces parallel to each other, and a pair of magnets accommodated in the holding body and extending in parallel to a normal direction of the end surfaces as the magnets,

the pair of magnets are positioned so as to sandwich a reference line extending in the vertical direction on the end surfaces, and are inclined so as to approach each other toward the lower side of the reference line,

the manufacturing method comprises the following steps:

a magnetizing step of magnetizing each of the plurality of magnet structure members by using a tubular coil disposed so that a coil axis thereof is parallel to the reference line;

a lamination step of laminating the plurality of magnet structural members magnetized in the magnetization step so that end surfaces of the holder face each other, to obtain a laminated body of the magnet structural members; and

and a restraining step of restraining the laminated body of the magnet structural member obtained in the laminating step from a laminating direction by a restraint device.

2. A method of manufacturing a magnet structure according to claim 1, wherein the magnet structure is a magnet structure having a magnet core and a magnet core,

in the magnetizing step, the relative position between the magnet structural member and the coil in the direction of the reference line is changed for each of the plurality of magnet structural members, and the magnetization is performed a plurality of times.

3. A method for manufacturing a magnet structure according to claim 1 or 2, wherein the magnet structure is a magnet structure having a magnet core and a magnet core,

the cross-sectional shape of the coil is a rectangular ring shape.

4. A method for manufacturing a magnet structure according to any one of claims 1 to 3, wherein the magnet structure is a magnet structure having a magnet core,

in the laminating step, the respective magnet structural members are guided by a guide member extending in the laminating direction.

5. A method for manufacturing a magnet structure according to any one of claims 1 to 4, wherein the magnet structure is a magnet structure having a magnet core,

in the restraining step, a shaft penetrating the magnet structural members in the stacking direction is used as the restraint device.

6. A method for manufacturing a magnet structure according to any one of claims 1 to 4, wherein the magnet structure is a magnet structure having a magnet core,

in the restraining step, a case of a laminated body capable of accommodating the magnet structural member is used as the restraint device.

7. A method for manufacturing a magnet structure according to any one of claims 1 to 4, wherein the magnet structure is a magnet structure having a magnet core,

in the restraining step, a rail that extends in the stacking direction and engages with each of the magnet structural members is used as the restraint device.

8. A method of manufacturing a rotating electric machine,

a method for manufacturing a rotating electrical machine comprising a plurality of magnets and a plurality of stators, wherein a plurality of magnet structural members each containing a magnet are laminated,

each of the magnet structural members includes a holding body having a pair of end surfaces parallel to each other, and a pair of magnets accommodated in the holding body and extending in parallel to a normal direction of the end surfaces as the magnets,

the pair of magnets are positioned so as to sandwich a reference line extending in the vertical direction on the end surfaces, and are inclined so as to approach each other toward the lower side of the reference line,

the manufacturing method comprises the following steps:

a magnetizing step of magnetizing each of the plurality of magnet structure members by using a tubular coil disposed so that a coil axis thereof is parallel to the reference line;

a lamination step of laminating the plurality of magnet structural members magnetized in the magnetization step so that end surfaces of the holder face each other, to obtain a laminated body of the magnet structural members;

a restraining step of restraining the laminated body of the magnet structural member obtained in the laminating step from a laminating direction by a restraint device; and

and an arranging step of arranging the plurality of magnet structures and the plurality of stators obtained in the restraining step around a rotation axis.

9. A magnet structure characterized in that,

a magnet structure for a wind power generator,

the disclosed device is provided with:

a plurality of magnet structural members including a holding body having a pair of end surfaces parallel to each other, and a pair of magnets accommodated in the holding body and extending parallel to a normal direction of the end surfaces, the pair of magnets being positioned so as to sandwich a reference line extending in a vertical direction on the end surfaces, and being inclined so as to approach each other toward a lower side of the reference line;

and a restraint device for restraining the laminated body of the magnet structural members laminated such that the end surfaces of the holding body face each other from the laminating direction.

Technical Field

The present disclosure relates to a magnet structure, a method of manufacturing the magnet structure, and a method of manufacturing a rotating electrical machine.

Background

Japanese patent laying-open No. 2013-520149 (patent document 1) discloses a magnet structure for a wind turbine generator. In recent years, with the increase in size of wind power generators, there has been an increasing demand for magnet structures having high magnetic force, and with the increase in size of magnets included in the magnet structures, there has been a demand for the magnet structures themselves to be increased in size.

As a method of assembling the magnet structures, there are a method of assembling the magnet structures after magnetizing the magnets, and a method of assembling the magnet structures with magnets that are not magnetized and then magnetizing the magnet structures.

In the former method, particularly in the case of a large-sized magnet structure, since strong magnetic attraction and magnetic repulsion act on the magnet during the assembly operation, it is difficult to perform the operation safely.

In the latter method, since the magnet is not magnetized at the time of the assembling operation, the operation can be performed safely.

However, when a large-sized magnet structure is magnetized, it is difficult to sufficiently magnetize the magnet structure in practical use, and variation in magnetization tends to increase in the magnet. In order to magnetize a large-sized magnet structure sufficiently in practical use and suppress variation in magnetization in the magnets of the large-sized magnet structure, a large-sized magnetizer having a large power is required.

Disclosure of Invention

According to the present disclosure, a magnet structure that realizes easy magnetization, a method of manufacturing the magnet structure, and a method of manufacturing a rotating electrical machine are provided.

A method of manufacturing a magnet structure according to an aspect of the present disclosure is a method of manufacturing a magnet structure used in a wind turbine generator and in which a plurality of magnet structural members including magnets are stacked, each of the magnet structural members including a holding body having a pair of end surfaces parallel to each other, and a pair of magnets accommodated in the holding body and extending in parallel to a normal direction of the end surfaces are provided as the magnets, the pair of magnets being positioned so as to sandwich a reference line extending in an up-down direction on the end surfaces, and being inclined so as to approach each other toward a lower side of the reference line, the method including a magnetizing step of arranging each of the plurality of magnet structural members in a tubular coil so that a coil axis and the reference line are parallel to each other and magnetizing the coil; a laminating step of laminating the plurality of magnet structural members magnetized in the magnetizing step so that end surfaces of the holding body face each other, to obtain a laminated body of the magnet structural members; and a restraining step of restraining the laminated body of the magnet structural member obtained in the laminating step from the laminating direction by a restraint device.

In the method of manufacturing a magnet structure, the magnet structure has a structure including a plurality of magnet structural members, and each of the plurality of magnet structural members is magnetized in the magnetizing step. The magnet structure is obtained by assembling a plurality of magnet structural members magnetized in the laminating step and the restraining step. Since the magnetization object in the magnetization step is a magnet structural member smaller than the entire magnet structure, it is possible to more easily perform magnetization using a smaller magnetization device than the magnetization device that magnetizes the entire magnet structure.

In the method of manufacturing a magnet structure according to another aspect, in the magnetizing step, the relative position between the magnet structure member and the coil in the direction of the reference line is changed for each of the plurality of magnet structure members, and the plurality of magnetizations are performed.

In order to bring the magnetization state of the magnet closer to the desired magnetization state, the relative position between the magnet structural member and the coil may be changed to repeat magnetization a plurality of times.

In the method for manufacturing a magnet structure according to the other aspect, the cross-sectional shape of the coil is a rectangular ring shape. In this case, the gap inside the coil when the magnet structural member is accommodated in the coil can be reduced, and an improvement in magnetization efficiency can be achieved.

In the method of manufacturing a magnet structure according to the other aspect, in the lamination step, the respective magnet structural members are guided by the guide member extending in the lamination direction. In this case, the magnet structure can be easily assembled.

In the method for manufacturing a magnet structure according to the other aspect, in the restraining step, a shaft that penetrates the magnet structure member in the stacking direction may be used as the restraint device; a case capable of housing a laminated body of magnet structural members; and a rail extending in the stacking direction and engaging with each of the magnet structural members.

A method of manufacturing a rotating electrical machine according to an aspect of the present disclosure is a method of manufacturing a rotating electrical machine including a plurality of stators and a magnet structure in which a plurality of magnet structural members including magnets are stacked, each of the magnet structural members including a holding body having a pair of end surfaces parallel to each other, and a pair of magnets accommodated in the holding body and extending parallel to a normal direction of the end surfaces as the magnets, the pair of magnets being positioned so as to sandwich a reference line extending in a vertical direction on the end surfaces, and being inclined so as to approach each other toward a lower side of the reference line, the method including: a magnetizing step of magnetizing each of the plurality of magnet structural members by using a tubular coil disposed so that a coil axis and a reference line are parallel to each other; a laminating step of laminating the plurality of magnet structural members magnetized in the magnetizing step so that end surfaces of the holding body face each other, to obtain a laminated body of the magnet structural members; a restraining step of restraining the laminated body of the magnet structural member obtained in the laminating step from the laminating direction by a restraint device; and an arrangement step of arranging the plurality of magnet structures and the plurality of stators obtained in the restraining step around the rotating shaft.

In the above method of manufacturing a rotating electric machine having a magnet structure, the magnet structure has a structure including a plurality of magnet structural members, and each of the plurality of magnet structural members is magnetized in the magnetizing step. The magnet structure is obtained by assembling a plurality of magnet structural members magnetized in the laminating step and the restraining step. In the arranging step, the plurality of magnet structures and the plurality of stators are arranged around the rotating shaft, thereby obtaining the rotating electric machine. In the magnetization step, the object to be magnetized is a magnet structural member smaller than the entire magnet structural body. Therefore, the magnet structure can be magnetized more easily by using a smaller magnetizing device than the magnetizing device for magnetizing the entire magnet structure.

A magnet structure according to an aspect of the present disclosure is a magnet structure for a wind turbine generator, including: a plurality of magnet structural members each having a holding body having a pair of end surfaces parallel to each other and a pair of magnets accommodated in the holding body and extending in parallel to a normal direction of the end surfaces, wherein the pair of magnets are positioned so as to sandwich a reference line extending in an up-down direction on the end surfaces and are inclined so as to approach each other toward a lower side of the reference line; and a restraint device for restraining the laminated body of the magnet structural components laminated in a manner that the end surfaces of the holding bodies face each other from the laminating direction.

In the above magnet structural member, the magnet structural member has a structure including a plurality of magnet structural members, and the plurality of stacked magnet structural members are restrained by a restraint device. In such a magnet structure, since the magnetization can be performed in the form of a magnet structural member smaller than the entire magnet structure, the magnetization can be performed more easily by using a smaller magnetization device than the magnetization device for magnetizing the entire magnet structure.

Drawings

Fig. 1 is a schematic perspective view illustrating a magnet structure according to an embodiment of the present disclosure.

Fig. 2 is a schematic perspective view showing the magnet structural member shown in fig. 1.

Fig. 3 is a front view showing the magnet structural member shown in fig. 2.

Fig. 4 is a diagram showing a laminated structure of magnets included in the magnet structural member shown in fig. 2.

Fig. 5 is a flowchart illustrating a method of manufacturing the magnet structure shown in fig. 1.

Fig. 6 is a diagram showing a mode of the magnetization process in the flowchart of fig. 5.

Fig. 7 is a diagram showing a form of the laminating step of the flowchart of fig. 5.

Fig. 8 is a schematic configuration diagram illustrating a generator according to an embodiment of the present disclosure.

Fig. 9 is a diagram showing a coil of a different form from that of fig. 6.

Fig. 10 is a schematic perspective view showing a magnet structure having a different form from that of fig. 1.

Fig. 11 is a front view showing a magnet structure member of a different form from that of fig. 3.

Detailed Description

Various embodiments and examples will be described below with reference to the accompanying drawings. In the drawings, the same or corresponding portions are denoted by the same reference numerals, and redundant description will be omitted.

As shown in fig. 1, a magnet structure 1 according to the embodiment includes a laminated body 3 in which a plurality of magnet structural members 2 are laminated. In the present embodiment, the laminated body 3 has 9 magnet structural members 2, and the 9 magnet structural members 2 are arranged along one direction (X direction in fig. 1).

As shown in fig. 2, each magnet structural member 2 includes a pair of magnets 10 and a holder 20.

The holder 20 is made of a magnetic material such as a laminated electromagnetic steel sheet. The holding body 20 has a substantially rectangular parallelepiped outer shape. The holding body 20 has a first end face 20a and a second end face 20b that are parallel to each other, and these end faces 20a and 20b face each other in the thickness direction of the holding body 20.

In the following description, a facing direction in which the first end surface 20a and the second end surface 20b of the holder 20 face each other is referred to as an X-axis direction, a vertical direction of the holder 20 is referred to as a Z-axis direction, and a direction orthogonal to the X-axis direction and the Z-axis direction is referred to as a Y-direction.

The holder 20 has an upper surface 20c and a lower surface 20d facing each other in the Z direction. The holder 20 has a first side surface 20e and a second side surface 20f facing each other in the Y direction.

Regarding the outer dimension of the holder 20 (i.e., the outer dimension of the magnet structural member 2), as an example, the X-direction dimension (length) is 120mm, the Y-direction dimension (width) is 220mm, and the Z-direction dimension (height) is 110 mm. The weight of the holder 20 is, for example, 15 kg.

The holding body 20 has substantially the same sectional shape over the entire length thereof. Specifically, as shown in fig. 3, in a Y-Z plane orthogonal to the X axis, there are a cross-sectional shape and an end face shape that are linearly symmetrical with respect to a reference line Z1 parallel to the Z axis. In other words, the holder 20 has a reference line Z1 that bisects the cross-sectional shape and the end surface shape.

The pair of magnets 10 is made of a magnetic material such as neodymium magnet. Each of the pair of magnets 10 has an elongated prism-like shape and extends in the X direction. The pair of magnets 10 are accommodated in the holder 20 so as to be exposed to both end surfaces 20a and 20b of the holder 20. There is substantially no gap between the pair of magnets 10 and the holder 20.

As shown in fig. 4, each of the pair of magnets 10 has a structure in which a plurality of rectangular plate-shaped single magnets 10a are stacked. In the present embodiment, six single magnets 10a are stacked to form one magnet 10. The dimensions of the individual single-piece magnets 10a are, for example, 100mm for the long side length L1, 50mm for the short side length L2, and 20mm for the thickness L3. The weight of each of the individual magnets 10a is 800g as an example.

As shown in fig. 2, the pair of magnets 10 are arranged so as to sandwich the reference line Z1 of the holding body 20. Hereinafter, for convenience of explanation, of the pair of magnets 10, the magnet located on the first side surface 20e side of the reference line Z1 is referred to as a first magnet 11, and the magnet located on the second side surface 20f side of the reference line Z1 is referred to as a second magnet 12.

Each of the first magnet 11 and the second magnet 12 has a rectangular cross-sectional shape and an end face shape in a Y-Z plane orthogonal to the X axis. The first magnet 11 and the second magnet 12 have a cross-sectional shape and an end surface shape that are linearly symmetrical with respect to a reference line Z1 parallel to the Z axis in a Y-Z plane orthogonal to the X axis. The first magnet 11 and the second magnet 12 are arranged obliquely so as to form a V-shape, and are inclined so as to approach each other toward the lower side of the reference line Z1 (from the upper surface 20c toward the lower surface 20 d).

Here, the first magnet 11 and the second magnet 12 have first surfaces 11a and 12a facing the reference line Z1 side and second surfaces 11b and 12b opposite to the first surfaces 11a and 12a as surfaces corresponding to the long sides of the single magnet 10 a. Then, the first and second magnets 11, 12 are inclined such that the first surfaces 11a, 12a and the second surfaces 11b, 12b approach each other as they go below the reference line Z1.

Since the first magnet 11 and the second magnet 12 are linearly symmetrical with respect to the reference line Z1, the inclination angle with respect to the reference line Z1 is also the same. When the angle formed by the Z-axis direction and the normal direction D is defined as the inclination angle θ, the inclination angle θ may be selected within a range of 30 ° to 70 °, and is 52 ° as an example.

The holder 20 is provided with a pair of through holes 23A and 23B. Each of the pair of through holes 23A, 23B extends in the X direction from the first end face 20a to the second end face 20B, and penetrates the holder 20. The pair of through holes 23A and 23B are arranged to sandwich the reference line Z1 of the holder 20. Hereinafter, for convenience of explanation, in the pair of magnets 10, the through-hole located on the first side surface 20e side of the reference line Z1 is referred to as a first through-hole 23A, and the through-hole located on the second side surface 20f side of the reference line Z1 is referred to as a second through-hole 23B.

Any one of the first through-hole 23A and the second through-hole 23B has a square sectional shape and an end face shape in a Y-Z plane perpendicular to the X axis. Further, the first through-hole 23A and the second through-hole 23B have a cross-sectional shape and an end surface shape that are linearly symmetrical with respect to a reference line Z1 parallel to the Z axis in a Y-Z plane perpendicular to the X axis. The pair of through holes 23A and 23B are located between the pair of magnets 10. More specifically, the first through-hole 23A is located between the first magnet 11 and the reference line Z1, and the second through-hole 23B is located between the second magnet 12 and the reference line Z1.

Further, the first side surface 20e and the second side surface 20f of the holder 20 are provided with notches 21a and 21b extending in the thickness direction of the holder, respectively. The cutout portions 21a, 21b have a cross-sectional shape and an end face shape that are linearly symmetrical with respect to the reference line Z1, and both have a cross-sectional shape and an end face shape that are substantially rectangular in shape. In addition, since the cutout portions 21a, 21b are linearly symmetrical with respect to the reference line Z1, they are provided at the same height position in the Z direction (i.e., the up-down direction).

As shown in fig. 1, the magnet structure 1 includes a pair of restraint plates 4A and 4B and two shafts 4C and 4D as a restraint device 4 that restrains the stacked body 3 of the magnet structural member 2 in the stacking direction. The pair of constraining plates 4A and 4B are disposed so as to sandwich the stacked body 3 from both sides in the stacking direction. Either one of the two shafts 4C, 4D is provided so as to penetrate the stacked body 3 and the pair of constraining plates 4A, 4B. To fasten the laminated plate 3 and the pair of constraining plates 4A, 4B, washers and nuts are mounted on respective both end portions of the two shafts 4C and 4D. The two shafts 4C and 4D are constituted by a first shaft 4C inserted into the first through hole 23A of the holder 20 and a second shaft 4D inserted into the second through hole 23B of the holder 20. The first shaft 4C and the second shaft 4D are square rod-shaped members having a sectional dimension equal to or slightly smaller than that of the through holes 23A, 23B. The pair of restraining plates 4A, 48 and the two shafts 4C, 4D are made of, for example, structural steel.

Next, a method of manufacturing the magnet structure 1 will be described with reference to fig. 5 to 7.

As shown in the flowchart of fig. 5, in the production of the magnet structure 1, each of the plurality of magnet structural members 2 is magnetized in the magnetizing step S1. Specifically, as shown in fig. 6, the magnet structural member 2 containing the non-magnetized magnet 10 is disposed in the tubular coil 30, and the magnetization of the magnet structural member 2 is performed using the coil 30. At this time, by extending the coil 30 in the Z direction, the axis of the coil 30 is parallel to the reference line Z1 of the holder 20 of the magnet structural member 2. In the present embodiment, the coil 30 has a rectangular tubular shape and has a rectangular annular cross section. The X-Y sectional dimension of the hole defined by the inner surface 30a of the coil 30 is designed to be the same as or slightly larger than the X-Y sectional dimension of the magnet structural member 2. Therefore, when the magnet construction member 2 is accommodated in the coil 30, only a slight gap exists in the coil in the X-Y section.

In the magnetizing step S1, a current is caused to flow through the coil 30 by using a magnetizing power supply (not shown in the drawings), thereby generating a magnetizing magnetic field and magnetizing the first magnet 11 and the second magnet 12 of the magnet structural member 2. In the present embodiment, the first surface 11a of the first magnet 11 is magnetized so as to have an N-pole and the second surface 11b so as to have an S-pole, and the first surface 12a of the second magnet 12 is magnetized so as to have an N-pole and the second surface 12b so as to have an S-pole.

In the magnetization step S1, the relative position between the magnet structural member 2 and the coil 30 is changed in the vertical direction (Z direction, reference line Z1 direction), and magnetization can be performed a plurality of times (for example, twice). It is known that the magnitude of the magnetic field generated in the coil 30 varies depending on the position. Therefore, in order to bring the magnetization state of the magnet 10 closer to the desired magnetization state, it is effective to repeat the magnetization a plurality of times by changing the relative position between the magnet structural member 2 and the coil 30.

Next, in the laminating step S2, the plurality of magnet structural members 2 magnetized in the magnetizing step S1 are laminated such that the end surfaces 20a and 20b of the respective holders 20 face each other, and a laminated body 3 is obtained. In the laminating process S2, as a guide member, a rail 5 as shown in fig. 7 may be used. The rail 5 is an elongated member extending in the X direction, and is made of a non-magnetic material. As the nonmagnetic material, for example, stainless steel, resin, or a combination thereof can be used. Further, as the resin, polyacetal resin having good surface smoothness or the like can be used. A pair of engaging portions 5a and 5b are provided on the rail 5 at positions corresponding to the cutout portions 21a and 21b of the holder 20 of each magnet structural member 2. The engagement portions 5a and 5b enter the notch portions 21a and 21b in the Y-Z cross section. Each magnet structural member 2 is guided by the engaging portions 5a and 5b of the rail 5 at the notch portions 21a and 21b so as to be slidable in the X direction, but is restricted from moving in the Y direction or the Z direction. In the magnet structural member 2 after the magnet 10 is magnetized, it may be difficult to stack a plurality of magnet structural members 2 because a relatively large magnetic attraction force and a relatively large magnetic repulsion force are generated. Since the magnet structural members 2 are moved only in the X direction by using the rails 5, a large force can be applied from the X direction, so that the laminated body 3 in which the magnet structural members 2 are closely arranged with each other is more easily obtained. That is, the magnet structure 1 can be easily assembled by using the rail 5.

Then, in the restraining step S3, the laminated body 3 of the magnet structural member 2 laminated on the rail 5 in the laminating step S2 is restrained by the restrainer 4 as shown in fig. 1. The restraint device 4 restrains the laminated body 3 from the X direction and suppresses the movement of the magnet structural member 2 in the X direction. After the laminated body 3 is constrained by the constraining device 4, the rail 5 is taken out of the laminated body 3, and the magnet structure 1 shown in fig. 1 is obtained. The rail 5 may be retained as a restraint for restraining the stacked body 3 from the X direction, and in this case, the rail 5 is one of the members constituting the magnet structure 1.

The magnet structure 1 obtained by the above-described manufacturing method can be applied to a generator 50 shown in fig. 8.

The generator 50 is a generator constituted by a part of a huge wind power generator of, for example, several hundred meters. The generator 50 includes a plurality of magnet structures 1, and further includes a rotating shaft 52 and a plurality of stators 54. The generator 50 is an outer rotor type generator in which a plurality of magnet structures 1 are arranged as a rotor around a plurality of stators 54 fixed to the outer periphery of a rotating shaft 52. Each magnet structure 1 is disposed such that the upper surface of the holding body 20 faces the inside in the radial direction of the generator 50. Each magnet structure 1 is disposed close to the stator 54 so that the stator 54 is located within the magnetic field range of the magnet structure 1. The polarities of the radially inner surfaces of the magnet structures 1 are alternately reversed along the circumferential direction of the rotating shaft 52. The diameter of the generator 50 is, as an example, 10 m. For example, the magnet structure 1 may have 120 poles, and the stator may have 144 poles. The magnet structure 1 may be applied to an inner rotor generator.

The manufacturing method of the generator 50 further includes the disposing step in steps S1 to S3 of the manufacturing method of the magnet structure 1. In the disposing step, the plurality of magnet structures 1 and the plurality of stators 54 obtained in the restraining step S3 are disposed around the rotating shaft 52.

Such as a large magnet structure 1 for a wind power generator, the size and weight of which can be relatively large. For example, a large magnet structure incorporated in a large wind power generator of several hundred meters in size has a length of several tens of centimeters and a weight of several tens of kilograms. In order to manufacture such a large-sized magnet structure, it is conceivable to magnetize the magnet alone and then assemble it into the magnet structure, but at the time of assembly operation, strong magnetic attraction force or magnetic repulsion force acts on the magnet, and therefore, it is difficult to perform safe operation. According to the method of assembling the unmagnetized magnets into the magnet structure and then magnetizing the entire magnet structure as in the above-described method of manufacturing the magnet structure 1, the magnets are not yet magnetized at the time of the assembly operation, and therefore, the operation can be performed safely.

As described above, in the magnet structure 1 and the method of manufacturing the same, the magnet structure 1 has a structure including the plurality of magnet structural members 2, and the plurality of stacked magnet structural members 2 are constrained by the constraining device 4. Therefore, the plurality of magnet structural members 2 are integrated as the magnet structure 1. In the magnet structure 1, in the magnetizing step S1, the object to be magnetized is the magnet structural member 2 smaller than the entire magnet structure 1. Therefore, a smaller magnetizing apparatus than the magnetizing apparatus for magnetizing the entire magnet structure 1 can be used, and the magnet structure 1 can be easily magnetized. In addition, since the magnetization object in the magnetization step S1 is the magnet structural member 2 smaller than the entire magnet structure 1, it is possible to realize a higher magnetization and practically sufficient magnetization (so-called full magnetization) as compared with the case of magnetizing the entire magnet structure 1. In the magnetizing step S1, since the plurality of magnet structural members 2 are magnetized, the respective magnet structural members 2 can be uniformly magnetized, and variation in magnetization of the magnet 10 in the magnet structure 1 can be suppressed.

Further, in the above-described method of manufacturing the magnet structure 1, since the coil 30 having a rectangular ring-shaped cross-sectional shape is used for magnetization, the gap inside the coil is small when the magnet structural member 2 is accommodated in the coil 30. Therefore, the magnetizing magnetic field generated in the coil 30 is effectively utilized, the magnetizing efficiency is improved, and power saving of the magnetizing power supply is realized.

The coil used in the magnetization step S1 is not limited to the rectangular ring-shaped coil 30, and may have other shapes as long as it is tubular. For example, a circular tubular coil 30A as shown in fig. 9 may be used. The coil 30A has an annular X-Y cross-sectional shape. Even when the coil 30A is used in the magnetizing process S1, the same or equivalent magnetization as the above-described coil 30 can be performed.

The guide member used in the laminating step S2 is not limited to the rail 5, and may be another member as long as it can extend in the laminating direction and guide the magnet structural member 2. For example, the shafts 4C and 4D of the above-described restraint 4 may also be used as guide members instead of the rail 5 or together with the rail 5.

The restrainer used in the restraining step S3 is not limited to the restrainer 4 and the rail 5, and may be any other member as long as it can restrain the stacked body 3 of the magnet structural member 2 in the stacking direction. For example, an open top surface housing 6, as shown in fig. 10, may be used as the restraint. The housing 6 is designed to have the same size as or slightly larger than the outer size of the magnet structure 1, depending on the size of the hole defined by the inner surface 6 a. Therefore, by accommodating the laminated body 3 of the magnet structural member 2 in the case 6, the laminated body 3 is restrained in the X direction and the Y direction. When the housing 6 serves as a restraint, the housing 6 is one of the members constituting the magnet structure 1. The case 6 may be made of nonmagnetic stainless steel such as SUS304 (stainless steel containing 18% chromium and 8% nickel).

The magnet structural member 2 may be a magnet structural member 2A of the type shown in fig. 11. The magnet structural member 2A is different from the above-described magnet structural member 2 in that it includes the center magnet 13, and the other points are the same as or similar to the magnet structural member 2. The center magnet 13 is accommodated in the holding body 20, as with the first magnet 11 and the second magnet 12, and extends in the thickness direction (X direction) of the holding body 20. Further, the center magnet 13 is located on a reference line Z1 in a Y-Z plane orthogonal to the X axis, and has a linearly symmetrical shape with respect to a reference line Z1. In the present embodiment, the center magnet 13 has a rectangular cross-sectional shape and an end surface shape that are linearly symmetrical with respect to the reference line Z1. The center magnet 13 is, as an example, a single magnet having a width (length in the Y direction) of 30mm, a height (length in the Z direction) of 20mm, and a thickness (length in the X direction) of 20mm, and is constituted by overlapping six pieces like the magnet 10. The weight of the single piece magnet of the center magnet 13 is 110g as an example. The center magnet 13 has a first surface 13a facing upward from the reference line Z1 and a second surface 13b facing downward from the reference line Z1. The center magnet 13 may be magnetized such that the first surface 13a is an N-pole and the second surface 13b is an S-pole.

Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above-described embodiments, and various modifications may be made. For example, the number of magnet structural members included in the magnet structure is not limited to nine, and may be increased or decreased as appropriate. The number of magnets in each magnet structure member is, for example, one or four or more, and may be increased or decreased as appropriate. In addition, the first magnet and the second magnet may not be linearly symmetrical with respect to the reference line Z1. Further, the first magnet and the second magnet may have different sectional shapes. The cross-sectional shape and the end face shape of the first magnet and the second magnet may be arcuate curved convexly (or concavely) with respect to the reference line Z1. When the cross-sectional shape and the end face shape of the magnet are arcuate, the magnet can be regarded as a rectangle having the smallest dimension including the arcuate shape, and the normal direction D, the inclination angle θ, and the like are defined. The first magnet and the second magnet may be embedded in the holding body. In addition, the cross-sectional shape and the end face shape of the center magnet may have a triangular shape, a trapezoidal shape or an arcuate shape. Further, in the above-described embodiments, the description has been made of the method of manufacturing the generator as one kind of the rotating electric machine, but the present disclosure may also be applied to the method of manufacturing the motor as one kind of the rotating electric machine.

Further, the number of shafts is not limited to two, and may be one or three or more. The sectional shape of the shaft is not limited to a square, and may be a rectangle or a circle.