Rotor manufacturing apparatus

Abstract

The present application provides a rotor manufacturing apparatus. The rotor manufacturing apparatus has a first mold having a resin pot having an opening at both ends, a plunger located inside the resin pot and capable of moving from one opening of the resin pot toward the other opening, and a second mold located at a position opposite the first mold and on which a rotor body is placed. The first mold has a first mold body having the resin pot, a flat gate plate located between the first mold body and the second mold, capable of separating in a thickness direction with respect to the first mold body, and having a recess on a side in contact with the first mold body, the recess constituting a part of a flow path for flowing of molten resin, and a resin receiving space surrounded by the resin pot, the plunger, and the recess in a state where the first mold body and the gate plate are in contact, and receiving the molten resin. The flow path is connected to the resin receiving space in the state where the first mold body and the gate plate are in contact.

Description

Technical Field

[0001] This invention relates to a rotor manufacturing apparatus. Background Technology

[0002] It is known that rotor manufacturing apparatuses utilize resin to fix magnets housed in storage holes within the rotor body. For example, Patent Document 1 discloses a resin sealing device as a manufacturing apparatus for the rotor body, i.e., the rotor laminated iron core, comprising: an upper mold and a lower mold, which are plate-shaped and clamp the rotor laminated iron core; a plurality of cans containing resin particles; and a plurality of plungers that extrude molten resin from the cans to the outside.

[0003] In the resin sealing device of Patent Document 1, the upper mold is supported by a frame of the resin sealing device. The upper mold has a plurality of cans that are multiple through holes in the vertical direction. A plurality of plungers are located above the upper mold. The plurality of plungers are configured to move vertically within the plurality of cans. The plurality of plungers extrude molten resin from the plurality of cans to the outside by moving downward within the plurality of cans. The lower mold is located below the upper mold. The lower mold is configured to move vertically. The lower mold moves upward, causing the rotor laminated iron core mounted on the lower mold to be clamped by the upper mold and the lower mold.

[0004] The side of the upper mold that contacts the rotor laminated iron core has multiple flow paths for the molten resin in the plurality of cans to flow into. When the rotor laminated iron core is clamped by the upper mold and the lower mold, the plurality of flow paths connect the plurality of cans to the plurality of receiving holes of the rotor laminated iron core.

[0005] When filling the receiving holes of the rotor laminated iron core with resin using the resin sealing device, the molten resin in the plurality of tanks is extruded into the plurality of flow paths using the plurality of plungers. The extruded resin flows into the plurality of receiving holes of the rotor laminated iron core respectively. The resin filling the plurality of receiving holes fixes the magnets in the receiving holes by curing within the plurality of receiving holes.

[0006] Patent Document 1: Japanese Patent Application Publication No. 2006-204068

[0007] In the rotor manufacturing apparatus described in Patent Document 1, the resin in the flow path and the resin in the can are cured as a single block. Therefore, when the upper mold having the can separates from the rotor laminated core, the can and the flow path separate together from the rotor laminated core. Consequently, the sprue in the flow path cannot be removed. In this rotor manufacturing apparatus, the sprue is removed using a cleaning device after the resin filling of the rotor laminated core is complete. Thus, in conventional rotor manufacturing apparatuses, the removal of the sprue is not easy, and therefore, the removal of the sprue is a major obstacle to improving productivity. Summary of the Invention

[0008] The purpose of this invention is to provide a rotor manufacturing apparatus that can easily remove runners and improve productivity during rotor manufacturing.

[0009] An embodiment of the present invention provides a rotor manufacturing apparatus for manufacturing a rotor having a magnet and a cylindrical rotor body having a receiving hole for receiving the magnet, the rotor fixing the magnet within the receiving hole using resin. The rotor manufacturing apparatus includes: a first mold having a resin tank with openings at both ends; a plunger located within the resin tank and movable from one opening to the other; and a second mold located opposite the first mold for holding the rotor body. The first mold includes: a first mold body having the plunger and the resin tank; a flat gating plate located between the first mold body and the second mold, separable in the thickness direction relative to the first mold body, the gating plate having a recess on the side contacting the first mold body, the recess forming part of a flow path for molten resin; and a resin receiving space surrounded by the resin tank, the plunger, and the recess when the first mold body is in contact with the gating plate, the resin receiving space receiving molten resin. The flow path is connected to the resin storage space when the first mold body is in contact with the gating plate.

[0010] According to one embodiment of the present invention, the rotor manufacturing apparatus can easily remove the sprue, thereby improving the productivity of rotor manufacturing. Attached Figure Description

[0011] Figure 1 Partial cross-sectional views of the first and second molds of the rotor manufacturing apparatus according to the embodiment are shown.

[0012] Figure 2 It shows Figure 1 A partially enlarged sectional view.

[0013] Figure 3A partial cross-sectional view is shown illustrating the operation of the gating plate of the rotor manufacturing apparatus according to an embodiment.

[0014] Figure 4 It shows in Figure 1 A plan view of the sprue plate in the rotor manufacturing apparatus of the following embodiment, viewed from direction A.

[0015] Figure 5 A flowchart of the rotor manufacturing process of the rotor manufacturing apparatus according to an embodiment is shown.

[0016] Figure 6 A partial cross-sectional view of the feed process of the rotor manufacturing apparatus according to an embodiment is shown.

[0017] Figure 7 A partial cross-sectional view of the mold-closing process of the rotor manufacturing apparatus according to an embodiment is shown.

[0018] Figure 8 A partial cross-sectional view of the filling process of the rotor manufacturing apparatus according to an embodiment is shown.

[0019] Figure 9 A partial cross-sectional view is shown during the runner removal process of the rotor manufacturing apparatus according to an embodiment.

[0020] Figure 10 A partial sectional view is shown in the mold opening process and the runner leveling process of the rotor manufacturing apparatus according to the embodiment.

[0021] Label Explanation

[0022] 1: Rotor manufacturing device; 2: First mold; 3: First mold body; 4: Mounting plate; 5: Resin tank; 5a: Opening; 6: Plunger; 7: Guide shaft; 8: Sprue cleaning plate; 8b: Resin tank insertion hole; 8c: Sprue cover; 9: Heater; 10: Sprue plate retaining plate; 10b: Sprue cover insertion hole; 11: Sprue plate; 11a: Circular part; 11b: Groove part; 12: First sprue plate; 13: Second sprue plate; 14: Flow path; 15: Guide rail; 16: Second mold; 100: Rotor body; 101: Shaft hole; 102: Storage hole; 103: Magnet. Detailed Implementation

[0023] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. Furthermore, the same or equivalent parts in the drawings will be labeled with the same reference numerals without being described repeatedly. Also, the dimensions of the constituent parts in the drawings do not faithfully represent the actual dimensions of the constituent parts or the dimensional ratios of each constituent part.

[0024] Furthermore, in the following description of the rotor manufacturing apparatus 1, which is an exemplary embodiment of the present invention, the direction parallel to the axis of the rotor body 100 is referred to as "axial direction," the direction perpendicular to the axis is referred to as "radial direction," and the direction along an arc centered on the axis is referred to as "circumferential direction." Additionally, the vertical direction in which the rotor manufacturing apparatus 1 is installed is defined as the "up-down direction." However, it is not intended that this definition of direction limit the orientation in which the rotor manufacturing apparatus 1 is used.

[0025] Furthermore, in the following explanation, the terms "fixed," "connected," "joined," and "installed" (hereinafter referred to as "fixed, etc.") include not only cases where parts are directly fixed to each other, but also cases where they are fixed via other parts. That is, in the following explanation, "fixed, etc." means both direct and indirect fixing of parts to each other.

[0026] Furthermore, in the following description of the rotor manufacturing apparatus 1, the rotor body 100 refers to the core of the motor formed by stacking electromagnetic steel sheets along the thickness direction. The rotor body 100 has a shaft hole 101 for housing the shaft and multiple housing holes 102 for housing the magnets 103 (see reference). Figure 1 The shaft hole 101 of the rotor body 100 is a through hole that includes the axis of the rotor body 100. That is, the rotor body 100 is cylindrical in shape extending along the axial direction. A plurality of receiving holes 102 surround the shaft hole 101 and are arranged circumferentially around the rotor body 100. A magnet 103 is received in each receiving hole 102.

[0027] Furthermore, in the following description of the rotor manufacturing apparatus 1, the resin particles P refer to the solid state of the molten resin before it melts and flows into the receiving hole 102 of the rotor body 100. The resin particles P are, for example, cylindrical solids with a diameter of approximately 40 mm. Additionally, the gating system R refers to the flow path 14 through which the molten resin flows from the resin tank 5 into the receiving hole 102 of the rotor body 100 (see reference 14). Figure 1 The cured resin.

[0028] (Structure of rotor manufacturing apparatus 1)

[0029] Figure 1 This is a partial cross-sectional view of the first and second molds of a rotor manufacturing apparatus according to an exemplary embodiment of the present invention. Figure 2 It is Figure 1 A partially enlarged cross-sectional view of a portion of resin tank 5 is shown. Figure 3 This is a partial cross-sectional view showing the operation of the gating plate of the rotor manufacturing apparatus according to an embodiment of the present invention. Figure 4 Is Figure 1 A plan view of the gating plate in the rotor manufacturing apparatus of the following embodiment, viewed from direction A.

[0030] like Figure 1 As shown, the rotor manufacturing apparatus 1 is an apparatus for manufacturing a rotor having a rotor body 100 and a magnet 103. The rotor manufacturing apparatus 1 has a flat first mold 2, a plunger 6, and a flat second mold 16. With the rotor body 100 held in place by the first mold 2 and placed in the second mold 16, the rotor manufacturing apparatus 1 allows molten resin to flow into the rotor body 100.

[0031] like Figure 1 and Figure 3 As shown, the first mold 2 is supported on a frame (not shown) via a first drive mechanism (not shown). The second mold 16 is supported by a frame (not shown). The rotor body 100 is mounted on the second mold 16. The first mold 2 is located at a distance from the second mold 16 in the thickness direction, opposite to the second mold 16. In this embodiment, the first mold 2 is located above the second mold 16. The first mold 2 overlaps with the second mold 16 when the rotor manufacturing apparatus 1 is viewed in the vertical direction. The first mold 2 can be separated from the second mold 16 by the first drive mechanism. That is, the first mold 2 can move in the vertical direction relative to the second mold 16.

[0032] The first mold 2 has a first mold body 3 and a sprue plate 11. The sprue plate 11 is held by a sprue plate retaining plate 10. The first mold body 3 is located above the sprue plate retaining plate 10 and the sprue plate 11. That is, the sprue plate retaining plate 10 and the sprue plate 11 are located between the first mold body 3 and the second mold 16.

[0033] The first mold body 3 has a mounting plate 4 and a sprue cleaning plate 8. The mounting plate 4 has a resin tank 5 and multiple guide shafts 7.

[0034] Mounting plate 4 is a flat plate component on which resin tank 5 is mounted. Mounting plate 4 is connected to the frame via the first drive mechanism in a vertically (thickness direction) manner along its thickness. Mounting plate 4 can move relative to the second mold 16 in the vertical direction (thickness direction) via the first drive mechanism. Furthermore, mounting plate 4 can move vertically while maintaining its position relative to the second mold 16 via the first drive mechanism. Mounting plate 4 has resin tank 5.

[0035] like Figure 1 and Figure 2As shown, the resin tank 5 is a container for holding molten resin. The resin tank 5 is a cylindrical component with openings at both ends along its axial direction. The resin tank 5 is fixed to the mounting plate 4 approximately at its center, with the axial direction pointing vertically. That is, the resin tank 5 has openings at its upper and lower parts. The resin tank 5 moves vertically together with the mounting plate 4. A plunger 6 is inserted into the resin tank 5 through one of the upper openings 5a. Another opening 5b, located at the lower part of the resin tank 5, protrudes downwards from the lower surface 4a of the mounting plate 4. The outer peripheral surface of the other opening 5b has an inverted conical portion 5c, whose outer diameter decreases as it approaches the lower surface 4a of the mounting plate 4. The resin tank 5 constitutes part of a resin holding space X for holding molten resin.

[0036] like Figure 1 and Figure 3 As shown, the plunger 6 is a cylindrical component that extrudes molten resin from the resin storage space X of the resin tank 5. The plunger 6 is supported on the frame via a plunger drive mechanism (not shown). The plunger 6 is inserted into the resin tank 5 through an opening 5a in the axial direction, pointing vertically. That is, the plunger 6 covers the upper opening of the resin tank. The plunger 6 moves relative to the resin tank 5 from one opening 5a to another opening 5b via the plunger drive mechanism. Furthermore, regardless of the vertical position of the mounting plate 4, the plunger 6 remains positioned within the resin tank 5 via the plunger drive mechanism (not shown). The plunger 6 located within the resin tank 5 constitutes part of the resin storage space X for storing molten resin.

[0037] Multiple guide shafts 7 are shaft-shaped components that guide the runner sweep plate 8 and the runner plate retaining plate 10. The multiple guide shafts 7 are connected to the mounting plate 4 in a downward direction along their axial direction. The multiple guide shafts 7 move integrally with the mounting plate 4 in the vertical direction (axial direction). In this embodiment, the multiple guide shafts 7 are arranged opposite each other at predetermined intervals in a direction perpendicular to the axis of the resin tank 5. The multiple guide shafts 7 have engaging portions 7a at their lower ends that support the runner plate retaining plate 10.

[0038] The runner scraper plate 8 is a flat plate component that detaches the runner R from the resin tank 5. The runner scraper plate 8 is located below the mounting plate 4, specifically between the mounting plate 4 and the runner plate 11. The runner scraper plate 8 is connected to the mounting plate 4 via a scraper plate drive mechanism (not shown) with its thickness direction pointing upwards and downwards. The runner scraper plate 8 has multiple guide holes 8a for inserting multiple guide shafts 7 and a resin tank insertion hole 8b for inserting the resin tank 5. The guide holes 8a and the resin tank insertion hole 8b extend along the thickness direction of the runner scraper plate 8. The runner scraper plate 8 has a runner cover 8c that protrudes downwards as a protruding surface, encompassing a rectangular area containing the resin tank insertion hole 8b. Specifically, the resin tank insertion hole 8b is located at the opening of the runner cover 8c. The runner scraper plate 8 has a heater 9 as a heat source. The heater 9 of the runner scraper plate 8 is located near the resin tank insertion hole 8b.

[0039] The runner sweeping plate 8 can be separated from the mounting plate 4 in the thickness direction by the sweeping plate drive mechanism. In this embodiment, the runner sweeping plate 8 moves in the vertical direction relative to the mounting plate 4. That is, the runner sweeping plate 8 can be separated from the mounting plate 4 in the vertical (thickness) direction and can also be separated from the runner plate 11 in the vertical (thickness) direction. In addition, the runner sweeping plate 8 can move in the vertical direction while maintaining its posture relative to the mounting plate 4 by multiple guide shafts 7 inserted into multiple guide holes 8a.

[0040] A portion of the resin tank 5 is inserted into the resin tank insertion hole 8b. When the runner sweeper plate 8 is located at the uppermost position within its movable range and its upper surface 8d is in contact with the lower surface 4a of the mounting plate 4, the runner cover 8c is located above the inverted conical portion 5c of the resin tank 5. When the runner sweeper plate 8 is located at the lowermost position within its movable range and its upper surface 8d is separated from the lower surface 4a of the mounting plate 4, the runner cover 8c is located below the inverted conical portion 5c of the resin tank 5.

[0041] Thus, the first mold body 3 has: a mounting plate 4 having a resin tank 5; and a runner cleaning plate 8 located between the mounting plate 4 and the runner plate 11, which can be separated vertically relative to the mounting plate 4 and the runner plate 11 when the resin tank 5 is inserted into the resin tank insertion hole 8b. The runner cleaning plate 8 is connected to the mounting plate 4 via the cleaning plate drive mechanism. Therefore, the first mold body 3 can be separated vertically relative to the runner plate 11 and the second mold 16 in such a manner that the mounting plate 4, the resin tank 5, the plurality of guide shafts 7, and the runner cleaning plate 8 are integrated. The runner cover 8c moves vertically to a position above and below the inverted conical portion 5c of the resin tank 5.

[0042] The sprue retainer plate 10 is a flat plate component that holds the sprue plate 11. The sprue retainer plate 10 is located below the sprue sweeping plate 8. That is, the sprue retainer plate 10 is located between the sprue sweeping plate 8 and the second mold 16. The sprue retainer plate 10 has multiple guide holes 10a for inserting multiple guide shafts 7 and sprue cover insertion holes 10b for inserting the protruding portion of the sprue cover 8c constituting the sprue sweeping plate 8. The multiple guide holes 10a and the sprue cover insertion holes 10b extend along the thickness direction of the sprue retainer plate 10.

[0043] In the runner plate retaining plate 10, guide shafts 7 are inserted into each of the plurality of guide holes 10a. Thus, the runner plate retaining plate 10 is positioned below the runner sweeping plate 8 with its thickness direction pointing vertically upwards. Furthermore, the runner plate retaining plate 10 engages with the engaging portions 7a of the plurality of guide shafts 7. That is, the runner plate retaining plate 10 is connected to the mounting plate 4 via the plurality of guide shafts 7. The runner plate retaining plate 10 can move vertically (in the thickness direction) while maintaining its posture relative to the mounting plate 4 via the plurality of guide shafts 7.

[0044] The sprue plate 11 is a flat plate component having a flow path 14 that allows molten resin from the resin tank 5 to flow into the rotor body 100 through a receiving hole 102. The sprue plate 11 is located below the sprue plate retainer plate 10, that is, between the sprue plate retainer plate 10 and the second mold 16. The sprue plate 11 is held to the sprue plate retainer plate 10 in a vertically oriented manner in the thickness direction. The sprue plate 11 covers the sprue cover insertion hole 10b of the sprue plate retainer plate 10. The sprue plate 11 includes a flat first sprue plate 12 and a second sprue plate 13.

[0045] The first sprue plate 12 and the second sprue plate 13 are located below the runner plate 11. That is, the first sprue plate 12 is located between the runner plate 11 and the second mold 16. The first sprue plate 12 is held on the runner plate retaining plate 10 while in contact with the runner plate 11 in a vertically oriented manner in the thickness direction. The second sprue plate 13 is held on the runner plate retaining plate 10 while in contact with the first sprue plate 12 in a vertically oriented manner in the thickness direction. That is, the first sprue plate 12 and the second sprue plate 13 are held on the runner plate retaining plate 10 with their thickness directions overlapping.

[0046] like Figure 4 As shown, the runner plate 11 has through holes for the flow of molten resin. Specifically, the through holes have a circular portion 11a that is circular in shape when viewed from above and a plurality of grooves 11b extending radially from the circular portion 11a.

[0047] The first sprue plate 12 has a plurality of through holes 12a. When the sprue plate 11 and the first sprue plate 12 overlap, the plurality of through holes 12a are connected to a plurality of grooves 11b of the sprue plate 11. The second sprue plate 13 has a plurality of through holes 13a. When the first sprue plate 12 and the second sprue plate 13 overlap, the plurality of through holes 12a and the plurality of through holes 13a are connected to each other. The sprue plate 11, the first sprue plate 12, and the second sprue plate 13 constitute a flow path 14 for allowing molten resin to flow within the receiving hole 102 of the rotor body 100.

[0048] The flow path 14 includes a flow path body and resin outlets. The circular portion 11a and multiple groove portions 11b of the runner plate 11 constitute the flow path body. The circular portion 11a is the upstream portion of the flow path body. When viewed axially, the circular portion 11a overlaps with another opening 5b of the resin tank 5. That is, the flow path body is connected to another opening 5b of the resin tank 5. Each groove portion 11b is the downstream portion of the flow path body. Multiple through holes 12a and multiple through holes 13a constitute multiple resin outlets. The multiple resin outlets are connected to the downstream portion of the flow path body. Furthermore, when viewed axially, the multiple resin outlets overlap with multiple receiving holes 102 of the rotor body 100 placed in the second mold 16. That is, the multiple resin outlets are connected to the multiple receiving holes 102. In this embodiment, upstream refers to the upstream direction of resin flow when molten resin in the resin tank 5 flows from the resin tank 5 into the multiple receiving holes 102. The upstream side of the flow path body refers to the side of the flow path body that is relatively close to the resin tank 5. The downstream side of the flow path body refers to the side of the flow path body that is relatively close to the plurality of receiving holes 102.

[0049] The openings below the circular portion 11a and the plurality of grooves 11b, which form the through hole of the sprue plate 11, are covered by the first sprue plate 12. Thus, the circular portion 11a and the plurality of grooves 11b are configured as recesses with the first sprue plate 12 as their bottom surface. That is, the sprue plate 11 has a recess that forms part of the flow path 14. The recess of the sprue plate 11, formed by the circular portion 11a and the first sprue plate 12, covers the opening at the bottom of the resin tank 5 when the first mold body 3 is in contact with the sprue plate 11. Therefore, the first mold 2 has a resin receiving space X formed by a plunger 6 covering one opening 5a of the resin tank 5 inside the cylinder of the resin tank 5 and the recess of the sprue plate 11 covering the other opening 5b of the resin tank 5. The flow path 14 of the sprue plate 11 is connected to the resin receiving space X when the first mold body 3 is in contact with the sprue plate 11 (see reference). Figure 7 ).

[0050] The portion of the circular portion 11a covering the main body of the flow path in the first sprue plate 12 has a resin particle recess 12b, which is a circular recess for holding resin particles P. That is, the resin particle recess 12b is further recessed along the thickness direction of the sprue plate 11 relative to the bottom surface of the circular portion 11a. When viewed along the thickness direction of the sprue plate, the resin particle recess 12b is located within the area overlapping with the resin storage space X of the resin tank 5. The resin particles P placed in the resin particle recess 12b are stored in the resin storage space X of the resin tank 5 while the sprue plate 11 is in contact with the first mold body 3 (see reference). Figure 7 ).

[0051] Alternatively, the first mold 2 may also have multiple sprue plates 11. In this case, the multiple sprue plates 11 overlap in the thickness direction.

[0052] like Figure 1 and Figure 4 As shown, the first mold body 3 has a guide rail 15 that holds the sprue plate 11, the first gate plate 12, and the second gate plate 13. The guide rail 15 is located on the lower surface 10d of the sprue plate holding plate 10 at a radially opposite position along the rotor body 100. The guide rail 15 holds the two ends of the overlapping sprue plate 11, the first gate plate 12, and the second gate plate 13. Thus, the sprue plate 11, the first gate plate 12, and the second gate plate 13 can move in a direction perpendicular to the thickness direction and the direction of the two ends held by the guide rail 15, while being overlapped in the thickness direction. Therefore, the sprue plate 11, the first gate plate 12, and the second gate plate 13 can be mounted and detached relative to the first mold body 3. In addition, the guide rail 15 is preferably mountable and detachable relative to the first mold body 3. In this case, for example, the guide rail 15 is mounted to the lower surface 10d of the sprue plate holding plate 10 by screws.

[0053] like Figure 3 As shown, when the first mold body 3 is located at the lowermost position within its movable range and the upper surface 10c of the sprue plate holder 10 is in contact with the lower surface 8e of the sprue sweeping plate 8, a protruding portion of the sprue cover 8c having the sprue sweeping plate 8 is inserted into the sprue cover insertion hole 10b of the sprue plate holder 10. At this time, the sprue cover 8c is in contact with the upper surface 11c of the sprue plate 11. As a result, the recess of the sprue plate 11, which is part of the flow path 14, is covered by the sprue cover 8c and the lower end of the resin tank 5. The inverted conical portion 5c of the resin tank 5, located below the sprue cover 8c, is located within the recess, which is part of the flow path 14.

[0054] When the first mold body 3 moves upward and the upper surface 10c of the sprue retaining plate 10 separates from the lower surface 8e of the sprue sweeping plate 8, the sprue plate 11 and the sprue retaining plate 10 do not move until the engaging portion 7a of the guide shaft 7 engages with the sprue retaining plate 10. When the sprue retaining plate 10 and the sprue plate 11 are clamping the rotor body 100 mounted on the second mold 16, even if the mounting plate 4 and the guide shaft 7 move upward, the sprue retaining plate 10 and the sprue plate 11 will still clamp the rotor body 100 mounted on the second mold 16 until the engaging portion 7a of the guide shaft 7 engages with the sprue retaining plate 10.

[0055] When the first mold body 3 is located at the uppermost position within its movable range and the engaging portion 7a of the guide shaft 7 is engaged with the sprue plate retaining plate 10, the sprue plate retaining plate 10 and the sprue plate 11 separate from the second mold 16 in a state of separation from the sprue sweeping plate 8. That is, the sprue plate 11 and the sprue plate retaining plate 10 can separate relative to the first mold body 3 in the vertical direction (thickness direction).

[0056] The rotor body 100 is clamped between the second mold 16 and the first mold 2. The second mold 16 is supported by a frame (not shown). The rotor body 100 is mounted on the upper surface 16a of the second mold 16. The second mold 16 is configured to position the rotor body 100 in a predetermined position. The second mold 16 has a heater 9 as a heat source. The heater 9 of the second mold 16 is located at the upper end inside the second mold 16.

[0057] Thus, the rotor manufacturing apparatus 1 comprises: a first mold 2 having a resin tank 5 with an opening 5a at one end and an opening 5b at the other end; a plunger 6 located within a resin receiving space X, movable from one opening 5a of the resin tank 5 toward the other opening 5b; and a second mold 16 for mounting the rotor body 100, the second mold 16 being positioned opposite the first mold 2. The first mold 2 comprises: a first mold body 3 having the resin tank 5; a runner plate 11, which is flat and located between the first mold body 3 and the second mold 16, separable in the thickness direction relative to the first mold body 3, and having a recess on the side in contact with the first mold body 3, the recess forming part of a flow path 14 for the flow of molten resin; and a resin receiving space X, which is surrounded by the resin tank 5, the plunger 6, and the recess of the runner plate 11 when the first mold body 3 is in contact with the runner plate 11, the resin receiving space X receiving molten resin. The flow path 14 is connected to the resin storage space X when the first mold body 3 is in contact with the sprue plate 11.

[0058] The first mold body 3 includes: a mounting plate 4 having a resin tank 5; and a runner cleaning plate 8 located between the mounting plate 4 and the runner plate 11, having a resin tank insertion hole 8b for inserting the resin tank 5, and being separable in the thickness direction relative to both the mounting plate 4 and the runner plate 11 when the resin tank 5 is inserted into the resin tank insertion hole 8b. When the mounting plate 4 is in contact with the runner cleaning plate 8 and the runner cleaning plate 8 is in contact with the runner plate 11, the first mold 2 uses the end of the resin tank 5 on the runner plate 11 side and the runner cleaning plate 8 to cover the recess of the runner plate 11.

[0059] Thus, in the rotor manufacturing apparatus 1, the flow path 14 for molten resin to flow into the rotor body 100 is provided on the side of the sprue plate 11 that contacts the first mold body 3. Therefore, in the rotor manufacturing apparatus 1 of this application, by separating the first mold body 3, on which the resin tank 5 is located, from the sprue plate 11, the flow path 14 is released from the first mold body 3 side, and the sprue R, which is solidified as a block with the resin in the resin tank 5, is pulled out from the flow path 14 toward the first mold body 3 side as the first mold 2 moves. Therefore, the sprue in the flow path 14 is easily removed. Furthermore, by separating the sprue sweeping plate 8 from the mounting plate 4, the sprue R, which is integrally solidified with the resin in the resin tank 5, is extruded along the direction of separation from the resin tank 5 using the sprue sweeping plate 8. Thus, the sprue R is easily removed from the flow path 14 and the resin tank 5 using the sprue sweeping plate 8.

[0060] Another opening 5b at the end of the sprue plate 11 in the resin tank 5 has an inverted conical portion 5c, in which the outer diameter of the resin tank 5 decreases as it moves toward the mounting plate 4.

[0061] The inverted conical portion 5c at the end of the sprue plate 11 in the resin tank 5 is located within the recess forming the flow path 14, so the molten resin in the flow path 14 is solidified in a manner that wraps around the inverted conical portion 5c. A sprue R is fixed on the inverted conical portion 5c. By separating the first mold body 3, which has the resin tank 5, from the sprue plate 11, the sprue R fixed on the resin tank 5 is stretched away from the flow path 14. The sprue R in the flow path 14 is easily removed from the flow path 14 by the movement of the first mold body 3.

[0062] The sprue 11 has a recess 12b for resin particles that is recessed relative to the recess when viewed along the thickness direction of the sprue 11 within the recess that forms the flow path 14. When the first mold body 3 is in contact with the sprue 11, the resin tank 5 collects the resin particles P supplied to the resin particle recess 12b on the sprue 11.

[0063] The first mold body 3, which has a resin tank 5, moves toward the sprue plate 11 to house the resin particles P placed on the sprue plate 11 within the resin housing space X of the first mold body 3. At this time, the resin particles P are positioned appropriately on the sprue plate 11 with reference to the resin particle recess 12b. Therefore, the supply error of the resin particles P into the resin housing space X caused by positional deviation during supply is reduced. In addition, since the resin particles P are positioned by the resin particle recess 12b, their position after being placed on the sprue plate 11 is less likely to shift. Therefore, the supply error of the resin particles P into the resin housing space X caused by positional deviation after being placed on the sprue plate 11 can be reduced.

[0064] The flow path 14 includes: a flow path body, the upstream side of which is connected to the resin receiving space X of the resin tank 5; and a resin outlet, located downstream of the flow path body. The sprue plate 11 includes a first sprue plate 12 having a through hole 12a extending in the thickness direction and a second sprue plate 13 having a through hole 13a. Furthermore, the sprue plate 11, the first sprue plate 12, and the second sprue plate 13 are detachable relative to the first mold body 3. The first sprue plate 12 and the second sprue plate 13 are located on opposite sides of the thickness direction of the side of the sprue plate 11 that contacts the first mold body 3, with the first sprue plate 12 and the second sprue plate 13 overlapping in the thickness direction. The flow path body includes a recess in the sprue plate 11. The resin outlet includes through holes 12a and 13a connected to the first sprue plate 12 and the second sprue plate 13 in the overlapping thickness direction.

[0065] The rotor manufacturing apparatus 1 includes a gating plate 11, a first gate plate 12, and a second gate plate 13. The gating plate 11 has a recess included in the flow path body, and the first gate plate 12 and the second gate plate 13 have resin outlet portions. The resin outlet portions are formed by through holes 12a and 13b that are connected and overlap in the thickness direction of the first gate plate 12 and the second gate plate 13. Therefore, in the event of a problem with the flow path body or the resin outlet portion, the problematic gating plate 11 or the first gate plate 12 can be replaced.

[0066] The runner plate 11 has a through hole consisting of a circular portion 11a that extends through the thickness direction and is circular in shape when viewed from above, and a plurality of grooves 11b extending radially from the circular portion 11a. The flow path body includes the through hole. In this way, the flow path 14 can be easily constructed from the runner plate 11 with the through hole.

[0067] Next, use Figures 5 to 10 The rotor manufacturing process S100 of rotor manufacturing apparatus 1 will be described. Figure 5 This is a flowchart of the rotor manufacturing process of the rotor manufacturing apparatus according to an embodiment of the present invention. Figure 6This is a partial cross-sectional view of the supply process of the rotor manufacturing apparatus according to an embodiment of the present invention. Figure 7 This is a partial cross-sectional view of the mold-closing process of the rotor manufacturing apparatus according to an embodiment of the present invention. Figure 8 This is a partial cross-sectional view of the filling process of the rotor manufacturing apparatus according to an embodiment of the present invention. Figure 9 This is a partial cross-sectional view of the runner removal process of the rotor manufacturing apparatus according to an embodiment of the present invention. Figure 10 This is a partial sectional view of the mold opening process and the runner leveling process of the rotor manufacturing apparatus according to an embodiment of the present invention.

[0068] like Figure 5 As shown, the rotor manufacturing process S100 includes a supply process S110, a mold closing process S120, a resin filling process S130, a sprue removal process S140, a mold opening process S150, and a sprue leveling process S160.

[0069] like Figure 6 As shown, in the initial state of the rotor manufacturing apparatus 1, the first mold body 3 is located at the uppermost position within its movable range. The sprue cleaning plate 8 in the first mold body 3 is located at the lowermost position within its movable range. The sprue plate 11 and the sprue plate retaining plate 10 are separated from the sprue cleaning plate 8 and from the second mold 16.

[0070] In the supply process S110, a rotor body 100 and resin particles P are supplied to the rotor manufacturing apparatus 1. In the supply process S110, the rotor body 100 is placed on the second mold 16. Additionally, resin particles P are supplied to the resin particle recess 12b of the sprue plate 11. After the supply process S110 is completed, the rotor manufacturing process S100 is transferred to the mold closing process S120.

[0071] like Figure 7As shown, in the mold closing process S120, the rotor body 100 is clamped by the first mold 2 and the second mold 16. In the mold closing process S120, the first mold body 3 moves downward from its uppermost position within its movable range. Simultaneously, the sprue cleaning plate 8 moves from its lowermost position within its movable range to the uppermost position where its upper surface 8d contacts the lower surface 4a of the mounting plate 4. Through the downward movement of the first mold body 3, the sprue plate 11, held in the sprue plate retaining plate 10, contacts the upper end of the rotor body 100. The sprue plate 11 and the sprue plate retaining plate 10 stop in the state where the sprue plate 11 contacts the upper end of the rotor body 100. The first mold body 3 moves within its movable range to the lowermost position where its upper surface 10c contacts the lower surface 8e of the sprue cleaning plate 8. At this time, the first mold 2 takes the resin particles P on the sprue plate 11 into the resin storage space X. The second mold 16 and the first mold 2, which has the first mold body 3 and the sprue plate 11, clamp the rotor body 100 placed on the second mold 16 with a specified force. In the rotor manufacturing process S100, after the mold closing process S120 is completed, the process is transferred to the resin filling process S130.

[0072] like Figure 8 As shown, in the resin filling process S130, molten resin flows into the receiving hole 102 of the rotor body 100. In the resin filling process S130, the heater 9 of the first mold body 3 heats the resin tank 5 of the first mold body 3. The resin particles P in the resin receiving space X, which is part of the resin tank 5, melt within the resin receiving space X due to the heat from the heated resin tank 5. Simultaneously, the heater 9 of the second mold 16 heats the rotor body 100. After a predetermined heating time, the plunger 6 moves downwards within the resin tank 5. The plunger 6 extrudes the molten resin in the resin receiving space X into the flow path 14 of the gating plate 11 connected to the resin receiving space X. Resin within the resin storage space X is filled into the storage hole 102 of the rotor body 100 through a resin outlet portion formed by multiple through holes 12a of the first gating plate 12 and multiple through holes 13a of the second gating plate 13 via a flow path body consisting of the circular portion 11a and multiple groove portions 11b of the gating plate 11. The resin supplied to the storage hole 102 cures, and the magnet 103 is fixed within the storage hole 102 using the resin. Thus, the rotor is manufactured by the rotor manufacturing apparatus 1. In the rotor manufacturing process S100, after the resin filling process S130 is completed, the process is transferred to the gating removal process S140.

[0073] like Figure 9As shown, in the runner removal process S140, the runner R is removed from the flow path 14. In the runner removal process S140, the resin in the resin receiving space X and the resin in the recess of the flow path 14 solidify as a block when cooled, and the inverted conical portion 5c of the resin tank 5 located in the recess is rolled in and solidified. The first mold body 3 moves upward to separate the runner cover 8c from the upper surface 11c of the runner plate 11. The first mold body 3 is lifted away from the runner plate 11 in the state where the runner R in the recess is engaged at the inverted conical portion 5c of the resin tank 5 by moving upward. The runner R is pulled upward from the flow path body of the runner plate 11 and the resin outlet portion of the first gate plate 12 and the second gate plate 13. At this time, the runner plate holding plate 10 is kept in contact with the upper end of the rotor body 100 due to its own weight. In this way, the first mold body 3 removes the sprue R from the flow path body of the sprue plate 11 and the resin outlet of the first gate plate 12 and the second gate plate 13.

[0074] like Figure 10 As shown, in the mold opening process S150, the clamping of the first mold 2 and the second mold 16 on the rotor body 100 is released. In the mold opening process S150, the first mold 2 moves to its uppermost position within its movable range. The sprue plate 11 and the sprue plate retaining plate 10 are separated from the sprue cleaning plate 8 by the engaging part 7a of the guide shaft 7. The clamping of the first mold 2 and the second mold 16 on the rotor body 100 is released. In the rotor manufacturing process S100, after the mold opening process S150 is completed, the process moves to the sprue cleaning process S160.

[0075] In the runner leveling process S160, the runner R is removed from the rotor manufacturing apparatus 1, and the rotor body 100 is taken out. In the runner leveling process S160, the runner cleaning plate 8 moves to its lowest position within its movable range, separating the upper surface 8d of the runner cleaning plate 8 from the lower surface 4a of the mounting plate 4. At this time, the runner cover 8c moves from a position above the inverted conical portion 5c of the resin tank 5 to a position below the inverted conical portion 5c of the resin tank 5. As a result, the runner cover 8c extrudes the runner R, which is engaged with the inverted conical portion 5c of the resin tank 5, in a direction away from the resin tank 5, thus separating it from the inverted conical portion 5c of the resin tank 5. Then, the rotor body 100 filled with resin placed in the second mold 16 is taken out. Furthermore, the runner plate 11, the first gate plate 12, and the second gate plate 13 can be replaced in the runner leveling process S160. In the rotor manufacturing process S100, after the runner leveling process S160 is completed, the process is transferred to the supply process S110.

[0076] Thus, in the mold closing process S120, the sprue plate 11, while in contact with the first mold body 3, clamps the rotor body 100 placed in the second mold 16. In the resin filling process S130, the plunger 6, with the rotor body 100 clamped by the sprue plate 11 and the second mold 16, extrudes the molten resin in the resin tank 5 into the flow path 14. In the sprue removal process S140, the first mold body 3, with the molten resin flowing into the rotor body 100 through the plunger 6, separates from the sprue plate 11.

[0077] Furthermore, in the runner removal process S140, the runner cleaning plate 8 separates from the runner plate 11 while the rotor body 100 is held by the first mold body 3. The runner cleaning plate 8 separates from the mounting plate 4 while separated from the runner plate 11.

[0078] Separated from the first mold body 3 containing the resin tank 5 by the sprue plate 11, the runner 14 is released from the first mold body 3 side. The sprue R, which has solidified as a block with the resin in the resin tank 5, is pulled out from the runner 14 toward the first mold body 3 side as the first mold 2 separates. At the same time, the sprue R is cut off from the rotor body 100. Furthermore, separated from the mounting plate 4 by the sprue sweeping plate 8, the sprue R, which engages with the inverted conical portion 5c of the resin tank 5, is removed from the resin tank 5. As a result, the productivity when manufacturing rotors using the rotor manufacturing apparatus 1 can be improved.

[0079] (Other implementation methods)

[0080] The embodiments of the present invention have been described above, but these embodiments are merely illustrative examples for implementing the present invention. Therefore, the invention is not limited to the above embodiments, and appropriate modifications can be made to the above embodiments without departing from their spirit.

[0081] In the above embodiment, the resin tank 5 has an inverted conical portion 5c at its end on the side of the runner plate 11 for engaging the runner R. However, the resin tank only needs to have a portion with a shape that allows molten resin to flow around and solidify. For example, the resin tank may also have a groove in the circumferential direction.

[0082] In the above embodiment, the runner plate 11 has a flow path body, and the first gate plate 12 and the second gate plate 13 have resin outlet portions. However, the runner plate may also have a flow path body and a resin outlet portion. The runner plate has a circular recess constituting the flow path body and a plurality of through holes made of resin forming the outlet portion.

[0083] In the above embodiment, the first mold body 3 has a first sprue plate 12 and a second sprue plate 13. However, the first mold body 3 may also have three or more sprue plates. In this case, the first mold body has a first sprue plate located at the position closest to the first mold body and a second sprue plate located at the position closest to the rotor body, with one or more sprue plates between the first sprue plate and the second sprue plate.

[0084] In the above embodiment, the gating slab 11 is made of a single flat plate material. However, the gating slab may also be made of a plurality of flat plate materials.

[0085] Industrial availability

[0086] This invention can be applied to rotor manufacturing apparatuses that use resin to fix magnets in rotors.

Claims

1. A rotor manufacturing apparatus for manufacturing a rotor having a magnet and a cylindrical rotor body, the rotor body having a receiving hole for receiving the magnet, the rotor fixing the magnet within the receiving hole using resin, wherein... The rotor manufacturing apparatus has the following features: The first mold has a resin tank with openings at both ends; A plunger, located within the resin tank, movable from one opening of the resin tank toward another opening; and The second module, located opposite the first module, is used to mount the rotor body. The first mold has: The first mold body has the resin tank; A flat sprue plate, located between the first mold body and the second mold, separable in the thickness direction relative to the first mold body, and having a recess on the side in contact with the first mold body, the recess forming part of a flow path for the molten resin to flow; and The resin storage space, which is surrounded by the resin tank, the plunger, and the recess when the first mold body is in contact with the sprue plate, contains molten resin. The flow path is connected to the resin receiving space when the first mold body is in contact with the gating plate. The flow path includes: The main body of the flow path, the upstream side of which is connected to the resin storage space of the resin tank; and The resin outlet is located downstream of the main flow path. The gating system comprises a plurality of flat gating plates, each having a through hole extending along its thickness. The gating plate can be attached to and detached relative to the first mold body. The plurality of sprue plates are located on the opposite side of the thickness direction of the side of the sprue plate that contacts the first mold body, in a state of overlap in the thickness direction. The flow path body includes the recess of the gating plate. The resin outlet section includes a through hole in the plurality of gating plates connected in a state where the plurality of gating plates overlap in the thickness direction.

2. The rotor manufacturing apparatus according to claim 1, wherein, The first module body has: Mounting plate having the resin tank; and A runner plate, located between the mounting plate and the runner plate, has a resin tank insertion hole for inserting the resin tank. When the resin tank is inserted into the resin tank insertion hole, it can be separated in the thickness direction relative to both the mounting plate and the runner plate. When the first mold is in contact with the mounting plate and the runner sweeping plate and the runner sweeping plate and the runner plate, the end of the runner plate on the side of the resin tank and the runner sweeping plate are used to cover the recess of the runner plate.

3. The rotor manufacturing apparatus according to claim 2, wherein, The end of the resin tank on the side of the runner plate has an inverted conical portion, in which the outer diameter of the resin tank decreases as it moves toward the mounting plate.

4. The rotor manufacturing apparatus according to any one of claims 1 to 3, wherein, When the sprue plate is in contact with the first mold body, it clamps the rotor body placed in the second mold between itself and the second mold. With the rotor body held between the sprue plate and the second mold, the plunger extrudes the molten resin in the resin tank into the flow path. While molten resin is flowing into the rotor body through the plunger, the first mold body separates from the runner plate.

5. The rotor manufacturing apparatus according to claim 2 or 3, wherein, When the sprue plate is in contact with the first mold body, it clamps the rotor body placed in the second mold between itself and the second mold. With the rotor body held between the sprue plate and the second mold, the plunger extrudes the molten resin in the resin tank into the flow path. With the rotor body held between the sprue plate and the second mold, the sprue sweeping plate separates from the sprue plate. The gating plate is separated from the mounting plate in a state of separation from the gating plate.

6. The rotor manufacturing apparatus according to any one of claims 1 to 3, wherein, The sprue plate has a recess that is further recessed relative to the recess within the area overlapping the resin storage space when viewed along the thickness direction of the sprue plate in the recessed portion.

7. The rotor manufacturing apparatus according to any one of claims 1 to 3, wherein, The gating slab has a through hole extending along its thickness direction. The flow path body includes the through hole.

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