The object of the invention is an electric machine according to the preamble part of Claim 1 , and a permanent magnet for an electric magnet according to the preamble part of Claim 10, as well as a method for manufacturing a permanent magnet according to the preamble part of Claim 13.

Permanent magnets are commonly used for establishing a magnetic field in electric machinery. In permanent magnet electric machines, permanent magnets have been fitted in a rotor that is at an air gap distance from the electric machine's stator. The permanent mag- nets are used for establishing a magnetic field, and the magnetic flux of the field goes over the air gap to the stator. The permanent magnets are fitted either on the rotor's surface, or inside the rotor's magnetically conductive frame. The air gap between the rotor and the stator may be parallel to the electric machine's shaft, or perpendicular to the shaft, in which case the air gap is radial. In electric machines with a radial air gap, the rotor is either inside or outside the stator.

The invention is particularly related to surface-fitted permanent magnets, and electric machines that have been magnetized with permanent magnets and which have a radial air gap. A permanent magnet consists of one or more permanent magnet pieces in the direction of the electric machine's shaft, and each pole of the electric machine has one or more parallel permanent magnet pieces next the circumferential direction of the electric machine. The electric machine may have an external rotor or an internal rotor, and the permanent magnets are fitted on the rotor surface that is towards the stator. The electric machine may be designed to function either as a generator or a motor. Moreover, the electric machine has a considerably large number of poles, at least ten, but the number of poles may be many dozens, up to over a hundred poles. The electric machine's typical number of slots per pole per phase is one or two.

In electric machines the aim is to establish in the air gap a magnetic flux density that varies as evenly as possible in the electric machine's magnetic pole area. The magnetic flux density is the highest in the middle of the magnetic pole, decreases ideally according to the sinusoidal curve when moving towards the pole's edge, and is zero on the pole edge. If the air gap influx distribution deviates extensively from the pure sinusoidal form, the harmonic waves in the distribution cause torque vibration. Particularly in permanent magnet electric machines, in which the number of slots per pole per phase is one or two and which have a large number of poles, idling creates a cogging torque due to the permeance fluctuation caused by the stator tooth. Under load, the current flowing in the stator winding results in a flux that causes torque ripple. The cogging torque and the torque ripple caused by the current are summed under load. The dimensioning guideline is that during idling, the cogging torque may not exceed 1% of the nominal torque. On the other hand, under nominal load, the torque ripple may not exceed 2% of the nominal torque.

Powerful permanent magnets such as NdFeBo [neodymium-iron-boron] magnets based on rare earth metals are commonly used in permanent magnet electric machines. They preferably provide a sufficient magnetic field, but are relatively fragile, and it is difficult, time- consuming and expensive to process them exactly to the intended shape.

Fastening permanent magnets on the rotor's curved surface requires processing. Either the rotor surface must be processed straight piece by piece, or the lower surface of the perma- nent magnet must be processed concave. Besides the gluing used for the fitting, permanent magnets often also have to be fastened with fastening means between the poles. The fastening means take up valuable space from the permanent magnet itself in the circumferential direction of the rotor.

Permanent magnet dimensions' impact on the performance of the electric machine is a complicated problem where several factors affect the outcome, often in a conflicting manner. Therefore, an optimal outcome is the combined effect of many factors.

A permanent magnet electric machine is previously known from the published patent application JP 01-234038 where permanent magnets, their cross-section being the shape of a hexagon, have been fitted on the rotor surface. The rotor's outer circumference has been processed straight at the poles, in which case the cross-section of the rotor frame is a polygon. The permanent magnets have been shaped so that there is a straight middle section on the upper surface of the permanent magnet. The middle section is as small as possible in order to achieve a minimal cogging torque.

The purpose of the invention is to develop a new permanent magnet structure solution and a new permanent magnet rotor where the above-mentioned problems have been removed, which is inexpensive to manufacture and which meets the electric machine requirements both during idling and under load. In order to achieve this, the permanent magnet electric machine is characterized by the features specified in the characteristics section of Claim 1. The permanent magnet according to the invention is characterized by the features specified in the characteristics section of Claim 10. The method for making the permanent magnet electric machine is characterized by the features specified in the characteristics section of Claim 13. The characteristics of some preferred embodiments of the invention are defined in the dependent claims.

The solution according to the invention will simultaneously achieve both the required sinusoidal distribution of the air gap flow, and the inexpensive manufacturing and finishing of permanent magnets. Ensuring the sinusoidality is particularly important in multi-pole electric machines where the winding's number of slots per pole and phase is one or two. hi these cases, the harmful impact of slot harmonics is emphasized. It is technically difficult to manufacture a permanent magnet that is purely sinusoidal with regard to its top surface. Instead, it is relatively easy to process three straight plane surfaces. The number of work stages does not essentially increase, since the surface of the permanent magnet must in any case be finished into its intended form after compression.

To be able to reliably fasten the permanent magnets fitted on the rotor's outer surface, the permanent magnet's lower surface and the outer surface of the rotor core must be compatible. Due to their large size, electric machines with a large number of poles and with a large diameter are difficult to handle and process so that a straight surface could be achieved in them. On the other hand, permanent magnet material is fragile and therefore difficult to process in a precise curved shape. According to an embodiment of the invention, a washer is fitted between the rotor's circumferential surface and the permanent magnet. The lower surface of the washer corresponds to the rotor surface shape, and the upper surface against the permanent magnet is straight.

The method according to the invention takes into account both the magnitude of the slot harmonics torque both during idling and under load, and minimizes its impact so that the electric machine requirements are not exceeded in either situation.

According to a preferred embodiment, the permanent magnet is fitted with connecting de- vices, and the connecting lugs of the devices extend over the top surface of the permanent magnets. The arrangement is simple to implement and does not require processing or addi- tional shaping of the permanent magnet piece. It is possible to minimize the amount of possibly electrically conductive material in the same air gap area.

In the following, the invention will be described in detail by referring to the drawings, where:

- Figure 1 is a partial illustration of an electric machine according to the invention,

- Figure 2 is a partial illustration of a second electric machine according to the invention,

- Figure 3 is a partial illustration of a third electric machine according to the invention,

- Figure 4 illustrates the cogging torque fluctuations and the torque ripple fluctuations as a function of the magnet's bevel,

- Figure 5 illustrates the cogging torque fluctuations and the torque ripple fluctuations as a function of the magnet's thickness,

- Figure 6 illustrates the cogging torque fluctuations and the torque ripple fluctua- tions as a function of the magnet's width,

- Figure 7 illustrates the cogging torque fluctuations and the torque ripple fluctuations as a function of the width of the magnet's middle area.

Figure 1 is a partial illustration of a permanent magnet synchronous machine where the rotor 4 is inside the stator 2 at the air gap's δ distance from the stator. The stator has been manufactured of magnetically conductive plates, and slots 3 have been formed in it for stator windings (not illustrated). The stator teeth 5 are between the slots. In this case, the number of slots per pole per phase of the electric machine is one, which means that a three- phase machine has three slots per pole. The rotor consists of the rotor's magnetic frame that has been formed from magnetically conductive sheets, for example by piling them as a sheet pack which is the length of the rotor. The rotor's magnetic frame has been fastened, directly or via the rotor center, onto the synchronous machine's shaft, which has been fitted with a bearing to the electric machine's frame in a well-known manner. According to the synchronous machine's number of poles, a number of permanent magnets 8, comprising the rotor's magnetic poles, have been fastened onto the outer circumference 6 of the rotor's magnetic frame. In the lengthwise direction of the synchronous machine, there are several separate permanent magnets 8 so that they essentially cover the length of the entire rotor. The permanent magnets 8 include the undersurface 10 which is against the washer 12 fitted on the outer surface of the rotor's magnetic frame. The lower surface of the washer 12 is slightly curved, corresponding to the curvature of the outer circumference 6 of the rotor's magnetic frame. The washer 12 has a straight upper surface, and the permanent magnet is against the surface. The permanent magnet's 8 upper surface against the air gap δ and the stator consists of three parts, the middle part 14 and two side parts 16 and 18. The upper surface's middle part 14 is essentially parallel to the permanent magnet's lower surface 10, which means that the permanent magnet is of an even thickness at the middle part 14. At the permanent magnet's middle part 14, the distance between the stator's inner surface and the permanent magnet - that is, the machine's air gap length D - is essentially equal. Only the curvature of the stator's inner surface slightly changes the air gap at the permanent magnet's middle part 14, but its impact is minor in a multi-pole machine with a large diameter. The permanent magnet's upper surface's edge parts 16 and 18 have been slightly bevelled in the example in Figure 1 so that the thickness of the permanent magnet at the edge is about a quarter smaller than in the middle part. The distance between the permanent magnet's edge part and the stator's inner surface is 2D; that is, two times the air gap at the permanent magnet. The permanent magnet's middle part length in the circumferential direction of the machine may vary by machine.

Connecting devices 20 have been fitted on both sides of the permanent magnets 8. The devices have connecting lugs 22, extending over the permanent magnets' edge parts 16 and 18. The connecting lugs 22 press the permanent magnets against the rotor surface. Prefera- bly, the permanent magnets have been glued onto the washer that is glued onto the rotor surface. At their middle section 24, the connecting devices have been fastened with bolts 26 to the rotor frame. The connecting device is made of a non-magnetic material, such as aluminum or steel, or a suitable composite material. The connecting device's 20 middle part is slightly narrower than the space remaining between the permanent magnets. More- over, the connecting device's edge 28 is slightly slanted in regard to the permanent magnet's 8 vertical edge 9. In this case, a gap remains between the connecting lug and the vertical surface of the permanent magnet's edge, which makes for easier fitting and leaves the edge surface of the permanent magnet free. The connecting device is preferably slightly flexible. The connecting device 20 and its fastening bolt 26 are as low as possible so that the air gap area will remain free. This improves the flow of cooling air between the permanent magnets.

Figure 2 illustrates another embodiment pursuant to the invention, with a permanent mag- net synchronous machine implemented with an external rotor. The stator has been manufactured of magnetically conductive plates, and slots 33 have been formed in it for stator windings (not illustrated). The stator teeth 55 are between the slots. In this case, the number of slots per pole per phase of the electric machine is two, which means that a three- phase machine has six slots per pole. The rotor 34 is outside the stator 32, at the air gap's δ distance from the stator. The rotor consists of the rotor's magnetic frame that has been formed as circle-like to surround the stator 32, and has been made of magnetically conductive sheets, for example by piling them as a sheet pack which is the length of the rotor. The rotor 34 has been fitted with a bearing to the electric machine's frame in a well-known way. According to the synchronous machine's number of poles, a number of permanent magnets 38, comprising the rotor's magnetic poles, have been fastened onto the inner circumference 36 of the rotor's magnetic frame. In the lengthwise direction of the synchronous machine, there are several separate permanent magnets 38 so that they essentially cover the length of the entire rotor. The permanent magnets 38 include the undersurface 40 which is against the washer 42 fitted on the inner surface of the rotor's magnetic frame. The lower surface of the washer 42 against the rotor is slightly curved, corresponding to the curvature of the inner circumference 36 of the rotor's magnetic frame. The washer 42 has a straight upper surface, and the permanent magnet is against the surface. The permanent magnet's 38 top surface against the air gap δ and the stator 32 consists of three parts: the middle part 44 and two side parts 46 and 48. The top surface's middle part 44 is essen- tially parallel to the permanent magnet's undersurface 40, which means that the permanent magnet is of an even thickness at the middle part 44. hi this case, the one-pole permanent magnet 38 includes three pieces parallel in the circumferential direction of the electric machine, piece 41 in the middle and pieces 43 at the edges. The cross-section of piece 41 is a rectangle, and the cross-sections of pieces 43 are trapezoids. At the permanent magnet's middle part 44, the distance between the stator's inner surface and the permanent magnet, that is, the machine's air gap length D is essentially equal. Only the curvature of the stator's outer surface slightly changes the air gap at the permanent magnet's middle part 44, but its impact is minor in a multi-pole machine with a large diameter. The permanent magnet's top surface's edge parts 46 and 48 have slightly been bevelled in the example in Figure 2 so that the thickness of the permanent magnet at the edge is about a quarter smaller than in the middle part. The distance between the permanent magnet's edge part and the stator's outer surface is 2D; that is, two times the air gap at the middle part of the permanent magnet. The permanent magnet's middle part length in the circumferential direction of the machine may vary by machine.

The top surface towards the permanent magnet's stator and the air gap is coated with a protective layer 45, extending at least over the top surface's middle part and edge parts. The protective layer 45 may also cover the vertical surface 39 of the permanent magnet's edge. The protective layer 45 acts as mechanical reinforcement and mechanical protection, and corrosion protection for the relatively fragile permanent magnet 38. Moreover, the protective layer provides heat insulation, preventing the permanent magnets from heating as a result of the heat from the stator. In this way, the operating temperature of the permanent magnets remains within the rated values, in which case their efficiency is at their best. In addition, permanent magnets of a lower thermal class can be used, which reduces the costs. The preferable material of the protective layer 45 is non-magnetic and electrically non- conductive, such as a suitable composite material.

Connecting devices 50 have been fitted on both sides of the permanent magnets 38. The devices have connecting lugs 52, extending over the permanent magnets' edge parts 46 and 48. At their middle section 54, the connecting devices have been fastened with bolts 56 to the rotor frame. The fastening bolt 56 extends through the rotor frame. In the connecting device's middle part 54, a threaded hole has been formed - the fastening bolt 56 is screwed into the hole. The connecting device is made of a non-magnetic material, such as aluminum or steel, or a suitable composite material. The connecting device's 50 middle part is slightly narrower than the space remaining between the permanent magnets. Moreover, the connecting device's edge 58 is slightly slanted in regard to the permanent magnet's 38 vertical edge 39. In this case, a gap remains between the connecting lug and the vertical surface of the permanent magnet's edge, which makes for easier fitting and leaves the edge surface of the permanent magnet free. As the head of the fastening bolt 56 is outside the rotor, the connecting device's inner surface between the lugs remains free. This improves the flow of cooling air between the permanent magnets. Figure 3 illustrates the third embodiment of the invention, and when applicable, the same reference numbers for the same parts as in Figures 1 and 2 have been used. The rotor's outer surface and the position of the permanent magnets have been illustrated as straightened in order to clarify the dimensions presented later on. The permanent magnet pieces have been formed so that their width is about 85% of the pole distribution, in which case the permanent magnet's width corresponds to approximately 150 electric degrees. The horizontal surface of the permanent magnet's top part is about 50% of the pole distribution, which corresponds to about 90 electric degrees.

Figure 3 uses the reference marking Bl for indicating the permanent magnet's width in the circumferential direction of the rotor, and the reference marking B2 for indicating the width of the horizontal part of the permanent magnet's top part. Correspondingly, Hl refers to the height of the permanent magnet, and H2 refers to the depth of the permanent magnet's bevel at the permanent magnet's edge. As a function of these values, Figures 4 to 7 illustrate the cogging torque fluctuation during idling and correspondingly the torque ripple under load.

In the example in Figure 3, the permanent magnets have been fastened to the rotor core by means of the fastening beam 60 and the bolts 62 fitted to the beam. The permanent magnets 38 have been fastened to the washer 42, and the protective layer 45 has been fitted on them. The washer 42 is slightly broader than the permanent magnet 38, and the fastening beam 62 presses against it, fastening the permanent magnets to the rotor.

Graph 70 in Figure 4 illustrates the cogging torque fluctuation during idling as a function of the bevel's depth H2, and graph 72 illustrates the torque ripple change when the electric machine is under load. The torques are peak-to-peak values and relative values; that is, percentages of the nominal torque. Graph 74 in Figure 5 illustrates the cogging torque fluc- tuation during idling as a function of the permanent magnet's thickness Hl, and graph 76 illustrates the torque ripple change when the electric machine is under load.

Correspondingly, graph 80 in Figure 6 illustrates the cogging torque fluctuation during idling as a function of the permanent magnet's width Bl, and graph 82 illustrates the torque ripple change when the electric machine is under load. Graph 84 in Figure 7 illustrates the cogging torque fluctuation during idling as a function of the permanent magnet's even top part B2, and graph 86 illustrates the torque ripple change when the electric machine is under load.

In Figures 4 to 7, it can be seen that the conditions for maintaining the cogging torque during idling and the torque ripple under load within the allowed limits are partly conflicting, which means that changing one dimension of the permanent magnet on the basis of one criterion results in a worse situation with regard to another criterion. According to the invention, cogging torque and torque ripple values will be calculated for a number of different dimensions and then an alternative meeting both conditions will be chosen.

The embodiments presented in Figures 1, 2 and 3 illustrate some preferred embodiments which will be used for implementing the idea of the invention. Several alternative solutions are possible, such as mutually replacing the corresponding parts in Figures 1 and 2. It must especially be observed that both in case of an external and an internal rotor, the permanent magnet may be fully identical both in dimensions and shape. The connecting lugs and their fastening bolts are also inter-replaceable, and, for example, the fastening bolt going through the figure's rotor frame may be used in case of an internal rotor, when the rotor has a hollow structure. The permanent magnets' connecting devices may comprise separate devices corresponding to adjacent permanent magnets, or devices connecting many consecutive permanent magnet pairs in the direction of the shaft.

In the above, the invention has been described with the help of certain embodiments. How- ever, the description should not be considered as limiting the scope of patent protection; the embodiments of the invention may vary within the scope of the following claims.