Rotor core manufacturing device and rotor core manufacturing method

Abstract

The present invention provides a rotor core manufacturing device and a rotor core manufacturing method, which are capable of appropriately inserting a cylindrical core rod into the center hole of a laminated iron core when the laminated iron core is inserted into the insertion recess of a first mold. The device comprises: a first mold; a second mold that is engaged with the first mold and, together with the first mold, molds the laminated iron core and seals the laminated iron core; a resin injection portion that is provided in the second mold and uses a molding machine to inject resin material into the magnet insertion hole of the laminated iron core into which the magnet is inserted; and a guide plate that has a through hole for the core rod provided in the first mold to pass through and is installed at one end of the laminated iron core so that the center hole of the laminated iron core and the through hole are connected. The guide plate has an opening diameter of the through hole on one surface side of the laminated iron core on the one end side and substantially the same as the diameter of the center hole, and an opening diameter of the through hole on the other surface side of the through hole on the first mold side is larger than the opening diameter on the one surface side.

Description

Technical Field

[0001] The present invention relates to a manufacturing device and a manufacturing method of a rotor core. Background Art

[0002] For example, Figure 1 As shown, for the IPM type rotor core (embedded magnet type rotor core) 1, its structure includes: a laminated iron core 2 obtained by stacking multiple core components (thin plate-shaped components) formed by punching electromagnetic steel plates, a permanent magnet 3 inserted and accommodated in a magnet insertion hole 2c formed from one end 2a to the other end 2b in the axis O1 direction of the laminated iron core 2, and a resin material 4 injected into the magnet insertion hole 2c to bury and fix the permanent magnet 3.

[0003] For example, Figure 2 As shown, for the SPM type rotor core (surface magnet type rotor core) 5, it is constructed to include: a laminated iron core 2, permanent magnets 3 arranged at equal intervals along the circumferential direction on the outer peripheral side of the laminated iron core 2, a cylindrical shell component 6 that surrounds and covers the laminated iron core 2 together with the permanent magnets 3, and a resin material 4 that is injected between the shell component 6 and the laminated iron core 2 to bury and fix the permanent magnets 3.

[0004] The laminated core 2 is provided with a center hole (shaft hole) 2 d formed to penetrate from one end 2 a to the other end 2 b on the axis O1 and to fit a shaft of the rotor.

[0005] On the other hand, for example, Figure 4 As shown, the manufacturing apparatus for the rotor cores 1 and 5 includes: a first mold 7 having a fitting recess 7a for fitting the laminated core 2 (or the laminated core 5 (or the laminated core 5 (or the laminated core 5 (or the laminated core 5 (or the laminated core 2 (or the laminated core 2 (or the laminated core 2 (or the laminated core 2 (or the laminated core 2 (or the laminated core 2 (or the laminated core 2 (or the laminated core 2 (or the laminated core 2 (or the laminated core 2 (or the laminated core 2 (( ( ...

[0006] like Figure 4 、 Figure 5 As shown, when manufacturing the rotor cores 1 and 5, after the first mold 7 and the second mold 8 are molded together to seal the laminated core 2, the rotor core 1 and 5 are manufactured. Figure 6As shown, an injection molding machine is used to inject resin material 4 from the resin injection portion 9 into the magnet insertion hole 2c (or between the housing member 6 and the laminated core 2). Figure 7 As shown, the first mold 7 and the second mold 8 are opened at an appropriate time, and the rotor core 1 (5) is demolded and taken out. In this way, the rotor core 1 (5) in which the permanent magnets 3 are embedded and fixed by the resin material 4 is manufactured.

[0007] Patent Document 1: Re-publication of WO2016 / 147211 Summary of the Invention

[0008] Problems to be solved by the invention

[0009] However, in the conventional manufacturing apparatus of the rotor core 1, 5 (and the manufacturing method of the rotor core), when the laminated core 2 is fitted into the fitting recess 7a provided in the first mold 7, it is difficult to fit the cylindrical core rod 10 into the center hole 2d of the laminated core 2 having a shape substantially identical to that of the core rod 10. In addition, depending on the circumstances, one end portion 2a of the laminated core 2 may collide with the core rod 10, which may result in manufacturing defects (see Figure 4 ).

[0010] Solutions for solving problems

[0011] A technical solution of the rotor core manufacturing device disclosed in the present invention includes: a first mold, which has: an interlocking recess for interlocking with a laminated iron core with a magnet inserted in a magnet insertion hole, or a laminated iron core with a magnet and a shell component installed on the outer circumference and holding the laminated iron core; and a cylindrical core rod, which is used to interlock with a center hole formed through the laminated iron core along the axial direction; a second mold, which is engaged with the first mold and, together with the first mold, closes the mold of the laminated iron core and seals the laminated iron core; a resin injection part, which is provided in the first mold or the second mold A tool is used to inject resin material into the magnet insertion hole or between the shell component and the laminated iron core using a forming machine; and a guide plate, which has a through hole for the core rod to pass through at the center of the axis, so that the through hole and the center hole are connected and can be detachably installed on one end part of the laminated iron core in the axial direction on the side of the first mold. For the guide plate, the opening diameter of the through hole on one surface side of the one end side of the laminated iron core is approximately the same as the diameter of the center hole, and the opening diameter of the through hole on the other surface side of the first mold is larger than the opening diameter of the one surface side.

[0012] A technical solution of the manufacturing method of the rotor core disclosed in the present invention includes: a guide plate installation process, in which a guide plate having a through hole in the center of the axis is detachably installed on an axial end portion of the laminated iron core in which a magnet is inserted into the magnet insertion hole, or on an axial end portion of the laminated iron core in which a magnet and a shell component are installed on the outer circumference in a manner so that the through hole and the center hole formed by passing through the laminated iron core in the axial direction are connected; a first mold installation process, in which a cylindrical rod-shaped core rod provided in the first mold is passed through the through hole of the guide plate to the center hole of the laminated iron core and the laminated iron core is fitted in the fitting recess of the first mold for configuration; a second mold installation process, in which the second mold is joined to the first mold and fitted with the The first mold is used to close the laminated iron core together and seal the laminated iron core; and a resin injection process is performed, in which resin material is injected into the magnet insertion hole, or between the shell component and the laminated iron core through the resin injection part provided in the first mold or the second mold; for the guide plate, the opening diameter of the through hole on one end side and one surface side of the laminated iron core is approximately the same as the diameter of the center hole, and the opening diameter of the through hole on the other surface side on the first mold side is larger than the opening diameter on the one surface side. In the first mold installation process, the core rod is inserted into the through hole while being guided by the guide surface located on the inner surface of the through hole.

[0013] Effects of the Invention

[0014] In the above-mentioned technical solution, when the guide plate is installed on one end portion of the laminated iron core on the side of the first mold, the laminated iron core is embedded in the embedding recess of the first mold, and the opening diameter of the through hole of the guide plate on one surface side close to one end portion of the laminated iron core is approximately the same as the diameter of the center hole, and the opening diameter of the through hole on the other surface side close to the first mold is larger than the opening diameter on one surface side.

[0015] This allows the core rod of the first die to be inserted from the side of the guide plate where the through-hole has a larger opening diameter, and the core rod is guided by the inner surface of the guide plate's through-hole while being inserted into the center hole of the laminated core. Consequently, when the laminated core is fitted into the first die, the core rod can be inserted and inserted into the center hole of the laminated core more easily, reliably, and accurately than before, thereby improving rotor core manufacturing efficiency and quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a perspective view showing a rotor core (IPM type rotor core) according to one embodiment.

[0017] Figure 2This is a perspective view showing a rotor core (SPM type rotor core) according to one embodiment.

[0018] Figure 3 It is a cross-sectional view showing a manufacturing apparatus and a manufacturing method of a rotor core (IPM type rotor core) according to one embodiment.

[0019] Figure 4 It is a cross-sectional view showing a conventional rotor core (IPM type rotor core) manufacturing apparatus and manufacturing method.

[0020] Figure 5 It is a cross-sectional view showing a conventional rotor core (IPM type rotor core) manufacturing apparatus and manufacturing method.

[0021] Figure 6 It is a cross-sectional view showing a conventional rotor core (IPM type rotor core) manufacturing apparatus and manufacturing method.

[0022] Figure 7 It is a cross-sectional view showing a conventional rotor core (IPM type rotor core) manufacturing apparatus and manufacturing method.

[0023] Description of Reference Numerals

[0024] 1. IPM type rotor core (rotor core); 2. Laminated iron core; 2a. One end; 2b. The other end; 2c. Magnet insertion hole; 2d. Center hole (axial hole); 3. Permanent magnet (magnet); 4. Resin material; 5. SPM type rotor core (rotor core); 6. Shell member; 7. First mold; 7a. Fitting recess; 8. Second mold; 9. Resin injection portion; 10. Core rod; 11. Through hole; 11a. Guide surface; 12. Guide plate; A. Rotor core manufacturing device; d1. Opening diameter of through hole; d2. Opening diameter of through hole; O1. Axis line. DETAILED DESCRIPTION

[0025] Below, refer to Figures 1 to 3 A rotor core manufacturing apparatus and a rotor core manufacturing method according to one embodiment will be described.

[0026] Here, if Figure 1 、 Figure 2 As shown, the rotor core 1, 5 of this embodiment is coaxially mounted as a whole with the shaft by passing the shaft through the center hole (shaft hole) 2d formed along the axis O1 of the rotor core 1, 5 of this embodiment, thereby forming a rotor of an electric rotating machine such as an electric motor of a machine tool, an industrial robot and other industrial machinery.

[0027] In this embodiment, the rotor core 1 is described as an IPM rotor core (embedded magnet rotor core).

[0028] For example, Figure 1 、 Figure 3 As shown, for the rotor core 1 of this embodiment, its structure includes: a laminated iron core (core) 2 formed by stacking multiple core components (thin plate-shaped components) formed by punching electromagnetic steel plates, permanent magnets (magnets) 3 respectively inserted into multiple magnet insertion holes 2c formed from one end 2a to the other end 2b in the axis O1 direction of the laminated iron core 2, and a resin material 4 injected into the magnet insertion holes 2c to fix the permanent magnets 3 and bury them in the laminated iron core 2.

[0029] like Figure 3 As shown, the device (rotor core manufacturing device) A for manufacturing the rotor core 1 of the present embodiment having the above-mentioned structure includes: a first mold 7 having a fitting recess 7a and a cylindrical core rod 10, wherein the fitting recess 7a fits the laminated core 2 with the permanent magnet 3 inserted in the magnet insertion hole 2c and holds the laminated core 2, and the core rod 10 fits in the center hole 2d formed through the laminated core 2 in the direction of the axis O1; a second mold 8, which is engaged with the first mold 7. , and together with the first mold 7, the laminated iron core 2 is molded and sealed; a resin injection part 9, which is provided in the second mold 8, and uses an injection molding machine to inject resin material 4 into the magnet insertion hole 2c; and a guide plate 12, which has a through hole 11 for the core rod 10 to pass through at the center of the axis O1, and the guide plate 12 is detachably mounted on one end 2a of the laminated iron core 2 in the direction of the axis O1 located on the side of the first mold 7 in a manner that connects the through hole 11 and the center hole 2d.

[0030] The guide plate 12 is formed into a circular ring shape, for example, and the opening diameter d1 of the through hole 11 formed through the center on the side of one surface 12a located on the side of one end 2a of the laminated iron core 2 is approximately the same as the diameter of the center hole 2d, and the opening diameter d2 of the through hole 11 on the side of the other surface 12b located on the side of the first mold 7 is larger than the opening diameter d1 on the side of the one surface 12a.

[0031] Furthermore, the guide plate 12 of this embodiment is formed to have a guide surface 11a on the inner surface of the through hole 11, wherein the diameter of the guide surface 11a gradually increases as it moves from the one surface 12a side toward the other surface 12b side in the direction of the axis O1. The guide surface 11a is formed, for example, by chamfering the peripheral edge portion on the other surface 12b side, performing rounding processing on the peripheral edge portion, or performing tapering processing.

[0032] The guide plate 12 has a pin (not shown) protruding outward from the one surface 12a in the direction of the axis O1 at a predetermined position on the one surface 12a thereof. The guide plate 12 is positioned at a predetermined position on the one end 2a of the laminated core 2 and is detachably attached thereto by engaging the pin with a hole (not shown) pre-determined along the axis O1 at a predetermined position on the one end 2a of the laminated core 2.

[0033] The resin injection portion 9 provided in the second mold 8 is constructed to include a resin flow path for conveying the resin material 4 from the injection molding machine and supplying and injecting the resin material 4 into the magnet insertion hole 2c of the laminated iron core 2 formed by clamping the first mold 7 and the second mold 8.

[0034] Next, a method for manufacturing the rotor core 1 (a method of injecting the resin material 4 to embed the permanent magnets 3 in the laminated core 2 and integrally fix them to the laminated core 2 ) using the rotor core 1 manufacturing apparatus A of the present embodiment having the above-described structure will be described.

[0035] First, the guide plate 12 is detachably attached to the one end portion 2a of the laminated core 2 having the permanent magnet 3 inserted into the magnet insertion hole 2c, with the pin fitted into the hole and the through hole 11 communicating with the center hole 2d (guide plate attaching step).

[0036] Next, the core rod 10 of the first mold 7 is passed through the through hole 11 of the guide plate 12 to the center hole 2d of the laminated core 2 and the laminated core 2 (and the guide plate 12) are fitted into the fitting recess 7a of the first mold 7 (first mold installation step).

[0037] Next, the second mold 8 is joined to the first mold 7 , and the laminated iron core 2 is molded together with the first mold 7 and sealed (second mold mounting step).

[0038] Then, resin material 4 is injected into magnet insertion holes 2c using an injection molding machine via resin injection section 9 provided in second mold 8 (resin injection process). Molds 7 and 8 are opened at an appropriate time to release rotor core 1. Guide plate 12 is then removed from rotor core 1. Thus, rotor core 1 is manufactured, with permanent magnets 3 inserted into magnet insertion holes 2c embedded and fixed in place by resin material 4. The guide plate 12 is then reused to manufacture another rotor core 1.

[0039] On the other hand, in the manufacturing device A of the rotor core 1 and the manufacturing method of the rotor core 1 of the present embodiment, a guide plate 12 is provided in which the opening diameter d1 of the through hole 11 on the one surface 12a side is approximately the same as the diameter of the center hole 2d and the opening diameter d2 of the through hole 11 on the other surface 12b side is larger than the opening diameter d1 on the one surface 12a side, or a guide plate 12 having a guide surface 11a on the inner surface of the through hole 11 is pre-installed on the one end portion 2a side of the laminated iron core 2.

[0040] Thus, the core rod 10 of the first die 7 can be inserted from the side of the through-hole 11, which has a larger opening diameter d2 and is located on one surface 12a of the guide plate 12. The core rod 10 is then guided by the guide surface 11a of the guide plate 12, located on the inner surface of the through-hole 11, while being fitted into the center hole 2d of the laminated core 2. Specifically, when the laminated core 2 is fitted into the fitting recess 7a of the first die 7, the through-hole 11 of the guide plate 12, and more specifically, the guide surface 11a in this embodiment, automatically guides the core rod 10 so that the axis O1 of the center hole 2d of the laminated core 2 and the core rod 10 are coaxially aligned, allowing the core rod 10 to be properly fitted into the center hole 2d of the laminated core 2.

[0041] Therefore, according to the manufacturing device A of the rotor core 1 and the manufacturing method of the rotor core 1 of this embodiment, when the laminated iron core 2 is embedded in the first mold 7, the core rod 10 can be passed through and embedded in the center hole 2d of the laminated iron core 2 more easily, reliably, and accurately than before, thereby seeking to improve the manufacturing efficiency of the rotor core 1 and improve the quality of the rotor core 1.

[0042] As mentioned above, one embodiment of the rotor core manufacturing apparatus and the rotor core manufacturing method has been described. However, the present invention is not limited to the above-described one embodiment, and can be modified appropriately without departing from the scope of the present invention.

[0043] For example, in the present embodiment, the resin injection portion 9 is provided in the second mold 8 , but the resin injection portion 9 may be provided in the first mold 7 .

[0044] In the present embodiment, the rotor core is described as an IPM rotor core (embedded magnet rotor core), but an SPM rotor core (surface magnet rotor core) may also be used.

[0045] Specifically, for example, Figure 2 As shown, the SPM type rotor core 5 is constructed to include: a laminated iron core 2, permanent magnets 3 arranged at equal intervals along the circumferential direction on the outer peripheral surface side of the laminated iron core 2, a cylindrical shell member 6 that surrounds and covers the laminated iron core 2 together with the permanent magnets 3, and a resin material 4 that is injected between the shell member 6 and the laminated iron core 2 to bury and fix the permanent magnets 3.

[0046] When manufacturing this SPM rotor core 5, the guide plate 12 is mounted on the laminated core 2 to which the magnets 3 and the outer shell member 6 are attached. In this state, the guide plate 12 is fitted into the fitting recess 7a of the first mold 7. The second mold 8 is then joined and the molds are closed. Then, a molding machine is used to inject resin material from the resin injection portion 9 between the outer shell member 6 and the laminated core 2, thereby embedding and securing the permanent magnets 3.

[0047] Even in this case, by using the same guide plate 12 as that of the present embodiment, the same operational effects as those of the present embodiment can be obtained.

Claims

1. A rotor core manufacturing device, wherein: The manufacturing device of the rotor core includes: The first mold has: a fitting recess for fitting a laminated core having a magnet inserted into a magnet insertion hole or a laminated core having a magnet and a housing member attached to its outer circumference and for holding the laminated core; and a cylindrical core rod for fitting into a center hole formed through the laminated core in an axial direction; a second mold that is engaged with the first mold and, together with the first mold, closes the mold of the laminated core and seals the laminated core; a resin injection portion provided in the first mold or the second mold, for injecting a resin material into the magnet insertion hole or between the housing member and the laminated core using a molding machine; and a guide plate having a through hole at the center of the axis through which the core rod passes, the guide plate being detachably mounted on one end of the laminated core in the axial direction on the first mold side by being positioned so that the through hole and the center hole are communicated with each other. In the guide plate, the opening diameter of the through hole on one surface side at one end side of the laminated core is substantially the same as the diameter of the center hole, and the opening diameter of the through hole on the other surface side at the first mold side is larger than the opening diameter on the one surface side. The through hole of the guide plate is formed to have a guide surface on the inner surface, and the diameter of the guide surface gradually increases from the one surface side toward the other surface side in the axial direction. When the core rod is inserted into the through hole, the core rod is guided by the guide surface to the center hole of the laminated iron core.

2. The rotor core manufacturing device according to claim 1, wherein: The guide plate is positioned at the one end portion of the laminated core by fitting a pin protruding from one surface side of the guide plate into a hole recessed in the laminated core.

3. The rotor core manufacturing device according to claim 1 or 2, wherein: The through hole of the guide plate is formed by chamfering the peripheral edge portion on the other surface side.

4. A method for manufacturing a rotor core, wherein: The manufacturing method of the rotor core includes: A guide plate mounting step, wherein the guide plate having a through hole at the center of the axis is positioned on one axial end portion of the laminated core having a magnet inserted into the magnet insertion hole or having a magnet and a housing member mounted on the outer circumference thereof so that the through hole communicates with a center hole formed by penetrating the laminated core in the axial direction, thereby detachably mounting the guide plate on the one end portion of the laminated core; a first die installation step of inserting a cylindrical rod-shaped core rod provided in the first die through the through hole of the guide plate into the center hole of the laminated core and fitting the laminated core into the fitting recess of the first die; a second mold mounting step of joining the second mold to the first mold, and clamping the laminated core together with the first mold to seal the laminated core; and a resin injection step of injecting a resin material into the magnet insertion hole or between the housing member and the laminated core via a resin injection portion provided in the first mold or the second mold; In the guide plate, the opening diameter of the through hole on one surface side at one end side of the laminated core is substantially the same as the diameter of the center hole, and the opening diameter of the through hole on the other surface side at the first mold side is larger than the opening diameter on the one surface side. The through hole of the guide plate is formed to have a guide surface on the inner surface, the guide surface gradually increasing in diameter from the one surface side toward the other surface side in the axial direction. In the first die mounting step, the core rod is inserted into the through-hole while being guided to the center hole of the laminated core by a guide surface located on an inner surface of the through-hole.

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