Manufacturing methods and apparatus for iron core products

Abstract

This disclosure relates to a method and apparatus for manufacturing iron core products, capable of appropriately supplying molten resin to multiple resin-forming regions of an iron core body. An example of the method for manufacturing the iron core product may include: feeding resin material into multiple first receiving portions formed in a heating section approximately simultaneously; initiating heating of the multiple resin materials disposed in the multiple first receiving portions approximately simultaneously using the heating section; and supplying molten resin from the multiple first receiving portions to the multiple resin-forming regions disposed in the iron core body.

Description

Technical Field

[0001] This disclosure relates to a method for manufacturing iron core products and an apparatus for manufacturing iron core products. Background Technology

[0002] Patent document 1 discloses a resin molding method, which includes: receiving a magnet in a magnet receiving hole of a motor core; clamping the motor core using a molding die; and pressing molding resin into the magnet receiving hole to mold the magnet in the magnet receiving hole.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: International Publication No. 2015 / 053368 Summary of the Invention

[0006] (a) Technical problems to be solved

[0007] This disclosure relates to a method for manufacturing iron core products and an apparatus for manufacturing iron core products, which can appropriately supply molten resin to multiple resin forming regions of the iron core body.

[0008] (II) Technical Solution

[0009] An example of a method for manufacturing an iron core product may include: feeding resin material into a plurality of first receiving portions formed in a heating section approximately simultaneously; starting to heat the plurality of resin materials disposed in the plurality of first receiving portions approximately simultaneously by means of the heating section's temperature rise; and supplying molten resin from the plurality of first receiving portions to a plurality of resin forming regions disposed in the iron core body.

[0010] Another example of a method for manufacturing an iron core product may include: preheating an iron core body having a plurality of magnet insertion holes formed thereon; and feeding resin material into a plurality of magnet insertion holes from a plurality of second receiving portions formed in a conveying section approximately simultaneously, wherein the method utilizes the iron core body to begin heating the plurality of resin materials approximately simultaneously.

[0011] An example of a manufacturing apparatus for iron core products may include: a heating section having a plurality of first receiving sections; an input machine configured to input resin material into the plurality of first receiving sections approximately simultaneously; a heater configured to begin heating the plurality of resin materials disposed in the plurality of first receiving sections by the input machine approximately simultaneously; and an extrusion mechanism configured to extrude molten resin from the plurality of first receiving sections and supply the molten resin to a plurality of resin forming regions disposed on the iron core body. In this case, the same effect as the method of Example 1 can be obtained.

[0012] (III) Beneficial Effects

[0013] According to the manufacturing method and apparatus for the iron core product disclosed herein, molten resin can be appropriately supplied to multiple resin forming regions of the iron core body. Attached Figure Description

[0014] Figure 1 This is a perspective view showing an example of a rotor with a stacked iron core.

[0015] Figure 2 This is a schematic diagram illustrating an example of a manufacturing apparatus for a rotor laminated iron core.

[0016] Figure 3 This is a schematic diagram that partially illustrates an example of a resin-filled system.

[0017] Figure 4 This is a perspective view showing an example of the configuration section.

[0018] Figure 5 This is a schematic diagram that partially illustrates an example of a resin-filled system.

[0019] Figure 6 This is an exploded perspective view showing an example of a conveyor section.

[0020] Figure 7 This is a schematic diagram that partially illustrates an example of a resin-filled system.

[0021] Figure 8 This is a perspective view showing an example of a conveying section and a heating section.

[0022] Figure 9 This is a cross-sectional view that schematically illustrates an example of a resin-filled system.

[0023] Figure 10 This is a cross-sectional view that schematically illustrates another example of a resin-filled system.

[0024] Figure 11 This is a flowchart illustrating the manufacturing method of a rotor laminated iron core.

[0025] Figure 12 This is a cross-sectional view that schematically illustrates another example of a resin-filled system.

[0026] Figure 13 This is a schematic diagram that partially illustrates another example of a resin-filled system.

[0027] Figure 14 This is a cross-sectional view that schematically illustrates another example of a resin-filled system.

[0028] Figure 15 This is a cross-sectional view showing another example of the configuration and conveying sections.

[0029] Figure 16This is a cross-sectional view showing another example of the configuration and conveying sections.

[0030] Figure 17 (a) is a perspective view showing another example of the configuration section. Figure 17 (b) is a perspective view showing another example of a conveyor section. Figure 17 (c) is a perspective view showing another example of a heating element.

[0031] Figure 18 (a) is a perspective view showing another example of a heating element. Figure 18 (b) is Figure 18 (a) BB line profile. Detailed Implementation

[0032] In the following description, the same reference numerals are used for the same elements or elements with the same function, and repeated descriptions are omitted.

[0033] [Rotor laminated iron core]

[0034] First refer to Figure 1 The structure of the rotor laminated iron core 1 (core product) will be described. The rotor laminated iron core 1 is part of the rotor. The rotor is constructed by mounting a main shaft (not shown) to the rotor laminated iron core 1. By combining the rotor with the stator, an electric motor is constructed. The rotor laminated iron core 1 can be part of an embedded magnet type (IPM) motor, or it can be part of other types of motors.

[0035] The rotor laminated iron core 1 includes: a laminate 10 (iron core body), multiple permanent magnets 12 and multiple cured resins 14.

[0036] The laminate 10 is cylindrical. A shaft hole 10a is provided in the center of the laminate 10, extending along the central axis Ax. The shaft hole 10a extends along the height direction (vertical direction) of the laminate 10. Since the laminate 10 rotates around the central axis Ax, the central axis Ax is also the axis of rotation. A main shaft is inserted into the shaft hole 10a.

[0037] A plurality of magnet insertion holes 16 (resin forming regions) are formed in the laminate 10. The magnet insertion holes 16 are arranged at predetermined intervals along the outer periphery of the laminate 10. The number of the plurality of magnet insertion holes 16 formed in the laminate 10 can be three or more. Viewed from above, the three or more magnet insertion holes 16 as a whole can be in a ring shape or a circular ring shape. Each magnet insertion hole 16 extends through the laminate 10 along the central axis Ax. That is, each magnet insertion hole 16 extends along the height direction.

[0038] The laminate 10 is constructed by stacking multiple stamping parts W. The stamping parts W are plate-shaped bodies formed by stamping a metal sheet MS (e.g., an electromagnetic steel sheet) into a predetermined shape, and have a shape corresponding to the laminate 10. Adjacent stamping parts W in the height direction can be fastened to each other by temporary fixing parts 18 (see reference). Figure 1 They can also be joined by adhesives or by welding.

[0039] The laminate 10 can also be constructed using so-called rotary lamination or skew. "Rotary lamination" refers to stacking multiple blanking parts W while offsetting the angles between them. Rotary lamination is primarily used to compensate for thickness deviations in the blanking parts W, thereby improving the flatness, parallelism, and right angle of the laminate 10. "Skewing" refers to stacking multiple blanking parts W with a torsion angle relative to the central axis Ax. Skew is used to reduce tooth groove torque, torque fluctuations, etc. The angle of rotary lamination or skew can be set to any size.

[0040] One permanent magnet 12 can be inserted into each of the magnet insertion holes 16. The shape of the permanent magnet 12 is not particularly limited; for example, it can be a cuboid shape. The type of permanent magnet 12 can be determined according to the application of the motor and the required performance; for example, it can be a sintered magnet or a bonded magnet.

[0041] The curing resin 14 is a cured product of a molten resin material (molten resin) that is filled into the magnet insertion hole 16 where the permanent magnet 12 is disposed. The curing resin 14 can be configured to fix the permanent magnet 12 into the magnet insertion hole 16. The curing resin 14 can be configured to join adjacent punched parts W in the vertical direction to each other. Examples of resin materials constituting the curing resin 14 include thermosetting resins and thermoplastic resins. Specific examples of thermosetting resins include resin compositions comprising epoxy resin, curing initiator, and additives. Examples of additives include fillers, flame retardants, and stress reducers.

[0042] [Manufacturing apparatus for rotor laminated iron core]

[0043] Next refer to Figure 2 The manufacturing apparatus 100 for the rotor laminated iron core 1 will be described. The manufacturing apparatus 100 is configured to manufacture the rotor laminated iron core 1 starting from a strip of metal sheet MS. The manufacturing apparatus 100 includes an uncoiler 110, a feeding device 120, a punching device 130, a magnet mounting device 140, a resin filling system 200, and a controller Ctr (determination unit).

[0044] The uncoiler 110 is configured to hold the coil 111 in a freely rotatable manner. The coil 111 is formed by winding a metal sheet MS in a coil (vortex) shape. The feeding device 120 includes a pair of rollers 121, 122 that clamp the metal sheet MS from above and below. The pair of rollers 121, 122 are configured to rotate and stop based on an instruction signal from the controller Ctr, intermittently and sequentially feeding the metal sheet MS toward the punching device 130.

[0045] The blanking device 130 operates based on an instruction signal from the controller Ctr. The blanking device 130 is configured to sequentially blank metal sheets MS intermittently fed by the feeding device 120 to form blanked parts W. The blanking device 130 is configured to sequentially stack multiple blanked parts W obtained through the blanking process to form a laminate 10. The laminate 10 formed by the blanking device 130 can be conveyed to the magnet mounting device 140, for example, via a conveyor Cv1, or manually.

[0046] The magnet mounting device 140 operates based on instruction signals from the controller Ctr. The magnet mounting device 140 is configured to place a permanent magnet 12 into each magnet insertion hole 16. The magnet mounting device 140 may be, for example, a robotic arm.

[0047] The resin filling system 200 is configured to fill the magnet insertion hole 16, in which the permanent magnet 12 is disposed, with molten resin M (see reference). Figure 9 Details regarding the resin-filled system 200 will be described later.

[0048] The controller Ctr is configured, for example, to generate signals for activating the delivery device 120, the punching device 130, the magnet mounting device 140, and the resin filling system 200, respectively, based on a program recorded on a recording medium (not shown) or operation input from an operator. The controller Ctr is configured to send the generated signals to the delivery device 120, the punching device 130, the magnet mounting device 140, and the resin filling system 200, respectively.

[0049] [Resin Filling System]

[0050] Next refer to Figures 3-9 The structure of the resin filling system 200 is described. For example... Figures 3-9 As shown, the resin filling system 200 includes: a material supply unit U1, a configuration unit U2, a conveying unit U3, and a heating unit U4.

[0051] like Figure 3As shown, the material supply unit U1 includes: a material feeder 210, a weight sensor SE1 (second measuring device), and a height sensor SE2 (second measuring device). The material feeder 210 includes an arrangement mechanism 211 and a conveying mechanism 212.

[0052] The arranging mechanism 211 is configured to operate based on instructions from the controller Ctr. The arranging mechanism 211 is configured to store multiple resin sheets T (resin material). The arranging mechanism 211 is configured to feed the resin sheets T one by one to the conveying mechanism 212 while adjusting each resin sheet T to a predetermined posture. The arranging mechanism 211 can also be configured to feed two or more resin sheets T as a group to the conveying mechanism 212.

[0053] The conveying mechanism 212 is configured to operate based on instructions from the controller Ctr. The conveying mechanism 212 extends from the arranging mechanism 211 toward the configuration unit U2. The conveying mechanism 212 is configured to sequentially convey resin sheets T, one by one, from the arranging mechanism 211 toward the configuration unit U2. Therefore, in the conveying mechanism 212, multiple resin sheets T are arranged in one column. In the conveying mechanism 212, multiple resin sheets T can also be arranged in two or more columns.

[0054] The weight sensor SE1 is configured to measure the weight of each resin sheet T. The weight data measured by the weight sensor SE1 is sent to the controller Ctr. The weight sensor SE1 can also be configured to be built into the conveyor mechanism 212 to measure the weight of the resin sheet T passing through the conveyor mechanism 212. The weight sensor SE1 can also be configured to be independent of the conveyor mechanism 212 and measure the weight of the resin sheet T transferred by the holding mechanism 230, etc., as described later.

[0055] The height sensor SE2 is configured to measure the height of each resin sheet T. The height sensor SE2 can be a non-contact sensor or a contact sensor. The height data measured by the height sensor SE2 is sent to the controller Ctr. The height sensor SE2 can be configured to be positioned above the conveyor mechanism 212 to measure the height of the resin sheet T passing through the conveyor mechanism 212. The height sensor SE2 can also be configured to measure the height of the resin sheet T at a different position than the conveyor mechanism 212.

[0056] like Figure 3 and Figure 4 As shown, the configuration unit U2 includes: a configuration section 220, a holding mechanism 230, a height sensor SE3 (first measuring device), a drive source D1, and a lifting mechanism D2.

[0057] The configuration unit 220 is configured to hold a predetermined number of resin sheets T at predetermined positions. The configuration unit 220 includes: a plurality of receiving holes 221 (third receiving unit) and a plurality of through holes 222.

[0058] Each of the plurality of receiving holes 221 is configured to receive at least one resin sheet T. When multiple resin sheets T are received in one receiving hole 221, the plurality of resin sheets T can be arranged in a row in the extending direction of the receiving hole 221 (see reference). Figure 3 ).

[0059] Multiple receiving holes 221 are formed on the configuration section 220 in such a way that they extend in the height direction of the configuration section 220. The multiple receiving holes 221 may extend from the upper end surface of the configuration section 220 to the lower part of the configuration section 220, for example. The length of the multiple receiving holes 221 may be set according to the number of resin sheets T to be contained.

[0060] like Figure 4 As shown, the plurality of receiving holes 221 are positioned in a ring shape when viewed from above. The plurality of receiving holes 221 can also be positioned in a circular shape when viewed from above.

[0061] The plurality of through holes 222 includes the same number of through holes 222 as the plurality of receiving holes 221. Each through hole 222 extends along the height direction in a manner communicating with a corresponding receiving hole 221. Each through hole 222 may extend from, for example, from the lower end face of the placement part 220 to the corresponding receiving hole 221. The opening area of ​​each through hole 222 is set to be smaller than the opening area of ​​the corresponding receiving hole 221. Therefore, the resin sheet T disposed in the receiving hole 221 is prevented from falling out of the through hole 222.

[0062] like Figure 3 As shown, the holding mechanism 230 is configured to hold one resin sheet T and transfer it from the material supply unit U1 to the placement unit U2. The holding mechanism 230 may also be configured to hold two or more resin sheets T simultaneously and transfer them from the material supply unit U1 to the placement unit U2. The holding mechanism 230 includes a holding tool 231 and a drive source 232.

[0063] The gripping clamp 231 is configured to grip the resin sheet T. The gripping tool 231 may be composed of, for example, multiple chuck jaws. The resin sheet T can be gripped by the multiple chuck jaws when they are close to each other. When the multiple chuck jaws separate, the multiple chuck jaws can release the resin sheet T.

[0064] The drive source 232 is configured to operate based on instructions from the controller Ctr. The drive source 232 is configured to drive the holding tool 231, causing the holding tool 231 to hold or release the resin sheet T. The drive source 232 is configured to move the holding tool 231 horizontally and / or vertically between the material supply unit U1 and the placement unit U2.

[0065] The height sensor SE3 is configured to measure the height of the resin sheet T housed in each receiving hole 221. The height sensor SE3 can be a non-contact sensor or a contact sensor. The height data measured by the height sensor SE3 is sent to the controller Ctr. The height sensor SE3 can be positioned above the mounting unit 220.

[0066] The drive source D1 is configured to operate based on instructions from the controller Ctr. The drive source D1 is configured to rotate the configuration unit 220 about a central axis extending in the vertical direction. The drive source D1 can be, for example, a rotary motor.

[0067] Multiple lifting mechanisms D2 are configured to operate based on instructions from the controller Ctr. The multiple lifting mechanisms D2 are configured to extend and retract in the vertical direction. The multiple lifting mechanisms D2 may be, for example, lifting cylinders. The front end of each lifting mechanism D2 can be inserted into a corresponding receiving hole 221 and insertion hole 222. Therefore, if the front end D2a of the lifting mechanism D2 rises while a resin sheet T is received in the receiving hole 221, the front end D2a pushes the resin sheet T outward from the receiving hole 221.

[0068] like Figure 5 and Figure 6 As shown, the conveying unit U3 includes: a conveying section 240 (feeding machine), an opening and closing component 250 (feeding machine), a drive source D3, and a drive source D4.

[0069] The transport section 240 is configured to hold a predetermined number of resin sheets T at predetermined positions. The transport section 240 includes a plurality of receiving holes 241 (second receiving sections).

[0070] Each of the plurality of receiving holes 241 is configured to receive at least one resin sheet T. When multiple resin sheets T are received in one receiving hole 241, the plurality of resin sheets T can be arranged in a row in the extending direction of the receiving hole 241 (see reference). Figure 5 ).

[0071] Multiple receiving holes 241 are formed on the conveying section 240 in such a way that they extend in the height direction of the conveying section 240. The multiple receiving holes 241 may extend from the upper end face to the lower end face of the conveying section 240, for example. The multiple receiving holes 241 may be through holes that penetrate the conveying section 240 in the height direction. The length of the multiple receiving holes 241 may be set, for example, according to the number of resin sheets T to be contained.

[0072] like Figure 6As shown, the plurality of receiving holes 241 are positioned in a ring shape when viewed from above. The plurality of receiving holes 241 can also be positioned in a circular shape when viewed from above. The number of the plurality of receiving holes 241 can be the same as the number of the plurality of receiving holes 221. In this case, the plurality of receiving holes 241 can be located at a position that coincides with the plurality of receiving holes 221 when viewed from above.

[0073] like Figure 5 and Figure 6 As shown, the opening / closing member 250 is disposed at the bottom of the conveying section 240 in a manner that allows it to move horizontally relative to the lower surface of the conveying section 240. For example... Figure 5 As shown, the opening and closing component 250 includes a plurality of through holes 251.

[0074] Multiple through holes 251 are formed in the opening / closing member 250 such that they extend in the height direction. The multiple through holes 251 penetrate the opening / closing member 250 in the height direction. The multiple through holes 251 are positioned to appear annular when viewed from above. The multiple through holes 251 may also be positioned to appear annular when viewed from above.

[0075] The number of through holes 251 can be the same as the number of receiving holes 241. For example... Figure 5 and Figure 6 As shown, each through hole 251 may include a first portion 251a and a second portion 251b. The opening area of ​​the first portion 251a can be set to allow the resin sheet T to pass through. The opening area of ​​the second portion 251b can be set to allow the front end D2a of the lifting mechanism D2 to pass through. The opening area of ​​the second portion 251b is smaller than the area of ​​the bottom surface of the resin sheet T.

[0076] The driver D3 is configured to perform actions based on instructions from the controller Ctr. For example... Figure 5 As shown, the drive source D3 is configured to move the conveying section 240 and the opening / closing member 250 in the horizontal and / or vertical directions between the configuration unit U2 and the heating unit U4. The drive source D3 may be, for example, a linear actuator.

[0077] The drive source D4 is configured to operate based on instructions from the controller Ctr. The drive source D4 is configured to cause the opening / closing member 250 to slide horizontally. For example, the drive source D4 can be configured to move the opening / closing member 250 between a first position in which most of the first part 251a is substantially aligned with the receiving hole 241 when viewed from above, and a second position in which the second part 251b is primarily aligned with the receiving hole 241 when viewed from above.

[0078] like Figure 5As shown, when the opening / closing member 250 is in the first position, the resin sheet T can move from the receiving hole 221 to the receiving hole 241 through the first part 251a. When the opening / closing member 250 is in the second position, although the resin sheet T disposed in the receiving hole 241 is blocked from falling from the through hole 251, the front end D2a of the lifting mechanism D2 can pass through the second part 251b.

[0079] The heating unit U4 is configured to fill the magnet insertion hole 16, through which the permanent magnet 12 is inserted, with molten resin M. For example... Figures 7-9 As shown, the heating unit U4 includes: a clamp 260, a heating mold 270 (heating part), and multiple extrusion mechanisms 280.

[0080] like Figure 9 As shown, the fixture 260 includes a base component 261 and a through post 262 disposed on the base component 261. The base component 261 is configured to support the laminate 10. The through post 262 is located approximately at the center of the base component 261 and protrudes upward from the upper surface of the base component 261. The through post 262 is cylindrical and has an outline corresponding to the shaft hole 10a of the laminate 10.

[0081] The heating mold 270 is configured to clamp the laminate 10 and the fixture 260 together with the lower mold 291 in the height direction. The heating mold 270 also functions as an upper mold. When the heating mold 270 and the lower mold 291 clamp the laminate 10 and the fixture 260, a predetermined load is applied to the laminate 10 in the height direction.

[0082] The heating mold 270 includes a plurality of receiving holes 271 (first receiving portions). Each of the plurality of receiving holes 271 is configured to receive at least one resin sheet T. When multiple resin sheets T are received in one receiving hole 271, the plurality of resin sheets T can be arranged in a row in the extending direction of the receiving hole 271 (see reference). Figure 7 and Figure 8 ).

[0083] Multiple receiving holes 271 are formed in the heating mold 270 such that they extend in the height direction of the heating mold 270. For example, the multiple receiving holes 271 may extend from the upper end face to the lower end face of the heating mold 270. The multiple receiving holes 271 may be through holes that penetrate the heating mold 270 in the height direction. The length of the multiple receiving holes 271 may be set, for example, according to the number of resin sheets T to be received.

[0084] like Figure 8As shown, the plurality of receiving holes 271 are positioned in a ring shape when viewed from above. The plurality of receiving holes 271 can also be positioned in a circular ring shape when viewed from above. The number of the plurality of receiving holes 271 can be the same as the number of the plurality of receiving holes 241. In this case, the plurality of receiving holes 271 can be located at a position that coincides with the plurality of receiving holes 241 when viewed from above. When the heated mold 270 and the lower mold 291 clamp the laminate 10 and the fixture 260, each receiving hole 271 can be located at a position corresponding to the magnet insertion hole 16 of the laminate 10.

[0085] like Figure 7 and Figure 9 As shown, the heating mold 270 includes a heater 273. The heater 273 is configured to operate based on instructions from the controller Ctr. The heater 273 is configured to heat the resin sheet T housed in each receiving hole 271 by heating the heating mold 270. If the resin sheet T is heated using the heater 273, the resin sheet T melts, as... Figure 9 As shown, the change is to molten resin M. The heater 273 can be disposed inside the heating mold 270 or outside the heating mold 270.

[0086] Multiple extrusion mechanisms 280 are configured to extrude molten resin M into magnet insertion holes 16. Each extrusion mechanism 280 includes a plunger 281 and a drive source 282. Each plunger 281 is configured to be inserted into a corresponding receiving hole 271 from above. Each drive source 282 is configured to operate based on instructions from a controller Ctr. Each drive source 282 is configured to move the corresponding plunger 281 up and down. Therefore, each plunger 281 can be independently inserted and removed relative to its corresponding receiving hole 271 via its corresponding drive source 282. Alternatively, one drive source 282 can cause multiple plungers 281 to move up and down simultaneously.

[0087] This example illustrates the heating mold 270 functioning as an upper mold, but an additional upper mold 292 can also be provided. This upper mold 292, together with the lower mold 291, can hold the heating mold 270, the laminate 10, and the fixture 260 (see reference). Figure 10 In this case, it is sufficient to simply provide a through hole 293 communicating with the receiving hole 271 on the upper die 292, and it is sufficient to provide an extrusion mechanism 280 (plunger 281 and drive source 282) in each through hole 293.

[0088] [Manufacturing method of rotor laminated iron core]

[0089] Next refer to Figures 3 to 11 The manufacturing method of the rotor laminated iron core 1 will be described. The process of forming the laminated body 10 using the punching device 130 is omitted here; subsequent processes will be described.

[0090] First, the laminate 10, placed in the fixture 260, is transported to the magnet mounting device 140. That is, as... Figure 9 or Figure 10 As shown, the laminate 10 is placed in the fixture 260 with the through post 262 inserted into the shaft hole 10a. Next, permanent magnets 12 are inserted into each magnet insertion hole 16 (see reference). Figure 11 Step S11). The insertion of the permanent magnet 12 into each magnet insertion hole 16 can be done manually or, based on the instruction of the controller Ctr, by a robotic arm (not shown) or the like provided by the magnet mounting device 140. Afterwards, the laminate 10 is transported to the heating unit U4 together with the clamp 260 in a manner located below the heating mold 270 (for example, in a manner where the upper end face of the laminate 10 abuts against the lower end face of the heating mold 270).

[0091] On the other hand, in the resin filling system 200, firstly, the controller Ctr controls the material feeder 210 to adjust the resin sheets T to a predetermined posture and arrange them one by one, while feeding them downstream using the conveying mechanism 212. When the resin sheets T reach the weight sensor SE1 and the height sensor SE2, the weight sensor SE1 and the height sensor SE2 can measure the weight and height of each resin sheet T and send the measurement data to the controller Ctr (see reference). Figure 11 Step S12).

[0092] The controller Ctr can determine whether the height and weight of the resin sheet T are within the specified range based on measured data. When the height and weight of the resin sheet T are not within the specified range, the controller Ctr can control a discharge mechanism (not shown) to remove the resin sheet T from the conveying mechanism 212 and can issue an alarm to the operator. Whether the height of the resin sheet T is within the specified range can be determined by whether it is within the range of -1.5mm to +1.5mm relative to a preset reference height, or by whether it is within the range of -1.3mm to +1.3mm relative to a preset reference height. Similarly, whether the weight of the resin sheet T is within the specified range can be determined by whether it is within the range of -1.0g to +1.0g relative to a preset reference weight, or by whether it is within the range of -0.7g to +0.7g relative to a preset reference weight.

[0093] When the resin sheet T reaches the downstream end of the conveying mechanism 212, the controller Ctr controls the drive source 232 to hold the resin sheet T using the gripping clamp 231. Next, the controller Ctr controls the drive source 232 to move the gripping tool 231 so that it is positioned above the designated receiving hole 221 of the placement section 220. Then, the controller Ctr controls the drive source 232 to release the resin sheet T from the gripping tool 231. Thus, as... Figure 3 and Figure 4 As shown, the resin sheet T is housed in the designated receiving hole 221.

[0094] When the number of resin sheets T to be received in one receiving hole 221 is set to one, the controller Ctr can control the drive source D1 to rotate the placement unit 220 circumferentially by a predetermined angle, so that the receiving hole 221 where the next resin sheet T should be inserted corresponds to the release position where the holding mechanism 230 releases the resin sheet T. On the other hand, when the number of resin sheets T to be received in one receiving hole 221 is multiple, after a predetermined number of resin sheets T are received in that receiving hole 221, the controller Ctr can control the drive source D1 to rotate the placement unit 220 circumferentially by a predetermined angle, so that the receiving hole 221 where the next resin sheet T should be inserted corresponds to the aforementioned release position. By repeating this operation multiple times, a predetermined number of resin sheets T are inserted into all the receiving holes 221 (see reference). Figure 11 Step S13).

[0095] like Figure 3 As shown, for each rotation of the aforementioned configuration unit 220, the height sensor SE3 measures the height within the receiving hole 221 after a predetermined number of resin sheets T have been inserted, and sends the measurement data to the controller Ctr (see reference). Figure 11 (Step S14). The controller Ctr can determine whether a specified number of resin sheets T are present in the receiving hole 221 based on the measured data.

[0096] When the height within the receiving hole 221 is outside the specified range, the controller Ctr can issue an alarm to the operator. Alternatively, when there is insufficient resin sheet T within the receiving hole 221 (when the height within the receiving hole 221 is less than the lower limit of the specified range), the controller Ctr can control the drive source 232 to add the insufficient amount of resin sheet T into the receiving hole 221. When there is an excess of resin sheet T within the receiving hole 221 (when the height within the receiving hole 221 exceeds the upper limit of the specified range), the controller Ctr can control the drive source 232 to remove the excess resin sheet T from the receiving hole 221.

[0097] Next, as Figure 5As shown, controller Ctr controls drive sources D3 and D4, positioning the conveying unit 240 above the placement unit 220 and the opening / closing member 250 in a first position. In this state, controller Ctr controls each lifting mechanism D2, raising each front end D2a, thereby inserting the resin sheet T from each receiving hole 221 into the corresponding receiving hole 241. Next, controller Ctr controls drive source D4, positioning the opening / closing member 250 in a second position. Then, controller Ctr controls each lifting mechanism D2, lowering each front end D2a. Thus, the resin sheet T in each receiving hole 241 is held by the conveying unit 240 and the opening / closing member 250 (see reference). Figure 11 Step S15).

[0098] Next, as Figure 7 and Figure 8 As shown, controller Ctr controls drive source D3 to position the conveying section 240 and opening / closing member 250 above the heating mold 270. At this time, controller Ctr can control heater 273 to preheat the heating mold 270 to a predetermined temperature. Next, controller Ctr controls drive source D4 to position the opening / closing member 250 in the first position. Thus, resin sheets T (see reference 270) are inserted approximately simultaneously from the corresponding receiving holes 241 into each heated receiving hole 271. Figure 11 (Step S16). Therefore, heating of the resin sheet T begins approximately simultaneously in each receiving hole 271. In addition, to prevent the resin sheet T from falling out of the receiving hole 271, the laminate 10 can be positioned below the heating mold 270 before the resin sheet T is inserted into the receiving hole 271 (before the opening / closing member 250 moves to the first position).

[0099] When the resin sheet T melts in each receiving hole 271 to become molten resin M, the controller Ctr controls each drive source 282 to use the corresponding plunger 281 to extrude the molten resin M in each receiving hole 271 into each magnet insertion hole 16 (see reference). Figure 11 (Step S17). Molten resin M is then filled into each magnet insertion hole 16. At this time, the laminate 10 can be pressurized using a heated mold 270 and lower mold 291, or an upper mold 292 and lower mold 291. When the molten resin M filled into each magnet insertion hole 16 solidifies, the heated mold 270 is removed from the laminate 10. Thus, cured resin 14 is formed in each magnet insertion hole 16, and the rotor laminated core 1 is completed.

[0100] [effect]

[0101] Based on the above example, heating of the resin sheets T disposed in each receiving hole 271 begins approximately simultaneously. That is, the timing of the start of heating of each resin sheet T is unlikely to have a time difference. Therefore, the viscosity of the molten resin M in each receiving hole 271 is unlikely to deviate. Thus, it is easy to uniformly supply the molten resin M to the multiple magnet insertion holes 16, thereby suppressing situations such as unfilled areas of molten resin M in the magnet insertion holes 16 and leakage of molten resin M from the magnet insertion holes 16. As a result, molten resin M can be appropriately supplied to the multiple magnet insertion holes 16. Therefore, the defect rate of the rotor laminated core 1 can be reduced.

[0102] Based on the above example, resin sheets T are fed into the heated receiving holes 271 approximately simultaneously from the corresponding receiving holes 241. Therefore, the feeding of resin sheets T from the conveying section 240 into the heating mold 270 does not require waiting for the heating mold 270 to finish heating. Therefore, the productivity of the rotor laminated core 1 can be improved.

[0103] Based on the above example, by positioning the opening / closing member 250 in the first position, resin sheets T are inserted from each receiving hole 241 into the corresponding receiving hole 271 approximately simultaneously. Therefore, the insertion of resin sheets T into each receiving hole 271 can be achieved approximately simultaneously by the extremely simple method of sliding the opening / closing member 250.

[0104] Based on the above example, the receiving holes 271 are arranged in a circular pattern. Therefore, molten resin M can be supplied more appropriately to the plurality of magnet insertion holes 16 formed in a circular pattern on the laminate 10.

[0105] Based on the above examples, one or more resin sheets T can be disposed in the receiving holes 221, 241, and 271. In this case, by increasing or decreasing the number of resin sheets T according to the capacity of the magnet insertion hole 16, the molten resin M can be supplied more appropriately.

[0106] Based on the above examples, multiple resin sheets T can be arranged in a row along their length within the receiving holes 221, 241, and 271. In this case, even if the capacity of the magnet insertion hole 16 is large, the molten resin M can be supplied more appropriately. Furthermore, when multiple resin sheets T are arranged in a row along their length within the receiving hole 271, the multiple resin sheets T can be heated approximately evenly.

[0107] Based on the above example, the height and / or weight of each resin sheet T can be measured using height sensor SE2 and / or weight sensor SE1. In this case, the controller Ctr determines in advance whether the height and / or weight of each resin sheet T is within the specified range before the resin sheet T melts. Therefore, an appropriate amount of molten resin M can be supplied to the magnet insertion hole 16.

[0108] Based on the above example, the height within the receiving hole 221 after a predetermined number of resin sheets T have been inserted can be measured. That is, the height of the resin sheets T contained within the receiving hole 221 can be measured. In this case, the controller Ctr determines in advance whether a predetermined number of resin sheets T are disposed in each receiving hole 221 before the resin sheets T melt. Therefore, an appropriate amount of molten resin M can be supplied to the magnet insertion hole 16.

[0109] Based on the above example, after resin sheets T are inserted into each receiving hole 221 of the placement section 220, these resin sheets T are inserted into each receiving hole 241 of the conveying section 240. That is, the placement section 220 and the conveying section 240 respectively perform: placement processing of multiple resin sheets T and conveying processing of multiple resin sheets T to the heating mold 270. Therefore, during the conveying of multiple resin sheets T to the heating mold 270 using the conveying section 240, the placement processing, which tends to take longer, can be performed. Therefore, the waiting time required for placement processing of multiple resin sheets T can be reduced, thereby improving the productivity of the rotor laminated core 1.

[0110] Based on the above example, the resin sheets T are inserted one by one into the receiving hole 221 using the holding clamp 231. Even if dust is generated from the resin sheets T during the process of holding the resin sheets T using the holding clamp 231, since the holding clamp 231 does not adsorb the resin sheets T but physically clamps them, it is less affected by the dust. Therefore, the time and frequency of maintenance operations can be reduced, thereby improving the productivity of the rotor laminated core 1.

[0111] [Variation Example]

[0112] The disclosure in this specification is illustrative in all respects and not limiting. Various omissions, substitutions, and modifications may be made to the above examples within the scope of the claims and without departing from their spirit.

[0113] (1) The heating mold 270 may also include two or more receiving holes 271. When the heating mold 270 includes three or more receiving holes 271, these receiving holes 271 may be arranged in a ring. "Ring" may include: three receiving holes 271 arranged in a triangular shape, four receiving holes 271 arranged in a quadrilateral shape, five receiving holes 271 arranged in a pentagonal shape, etc. The conveying unit 240 may also include two or more receiving holes 241, similar to the heating mold 270. The placement unit 220 may also include two or more receiving holes 221, similar to the heating mold 270.

[0114] (2) The filling of the molten resin M into the magnet insertion hole 16 can be performed in two or more stages. In this case, the size and / or material of the resin sheet T used in each filling can be the same or different. For example, depending on the type of filler contained in the resin sheet T, the fluidity of the molten resin M filled first can be set to be lower than that of the molten resin M filled later.

[0115] (3) When multiple resin sheets T are contained in a receiving hole 221, 241, 271, the size and / or material of these resin sheets T may be the same or different.

[0116] (4) In the above example, resin sheet T, i.e. solid resin material, is contained in the receiving holes 221, 241, and 271. However, liquid or powder resin material can also be contained in the receiving holes 221, 241, and 271.

[0117] (5) The opening and closing member 250 may be disposed at the bottom of the configuration section 220 in a manner that allows it to move horizontally relative to the lower surface of the configuration section 220. In this case, with the conveying section 240 located below the configuration section 220, the opening and closing member 250 on the bottom surface of the configuration section 220 may be slid horizontally to insert the resin sheet T in the receiving hole 221 into the receiving hole 241.

[0118] (6) In the above example, molten resin M is filled from the top of the laminate 10, but molten resin M can also be filled from the bottom of the laminate. Alternatively, molten resin M can be filled from both the top and bottom of the laminate 10.

[0119] Reference Figure 12 Here is an example of the structure of the heating unit U4 when molten resin M is filled from below the laminate 10. Figure 12 The heating unit U4 shown is... Figure 9 The difference in the illustrated heating unit U4 is that it also has an upper mold 295, an extrusion mechanism 280, and a fixture 260.

[0120] The upper die 295 is configured to clamp the laminate 10 and the fixture 260 together with the heated die 270 in the height direction. The plungers 281 of the plurality of extrusion mechanisms 280 are configured to be inserted into the corresponding receiving holes 271 from below.

[0121] The base component 261 of the clamp 260 may include multiple through holes 263.

[0122] Multiple through holes 263 are formed on the base member 261 in such a way that they extend in the height direction of the base member 261. For example, the multiple through holes 263 may extend from the upper end face to the lower end face of the base member 261.

[0123] Multiple through holes 263 can be positioned in a ring shape when viewed from above. Alternatively, multiple through holes 263 can be positioned in a circular ring shape when viewed from above. The number of through holes 263 can be the same as the number of receiving holes 271. In this case, the multiple through holes 263 can be located at positions that coincide with the multiple receiving holes 271 when viewed from above. When the laminate 10 is clamped using the jig 260, the heating mold 270, and the upper mold 295, each through hole 263 can be located at a position corresponding to the magnet insertion hole 16 of the laminate 10. Furthermore, multiple resin flow paths (e.g., grooves, through holes) can be included on either the surface of the base component 261 of the jig 260 that contacts the laminate 10, or the surface of the lower mold 270 that contacts the jig 260. The resin flow paths can fluidly connect the receiving holes 271, the through holes 263, and the magnet insertion hole 16. In this case, each receiving hole 271 may not coincide with the corresponding magnet insertion hole 16 when viewed from above. In this case, there may be more through holes 263 than multiple receiving holes 271.

[0124] Next, refer to Figure 12 and Figure 13 To illustrate: In Figure 12 In the exemplified heating unit U4, the process of inserting the resin sheet T into the heating mold 270 ( Figure 11 Step S16), and the process of filling the magnet insertion hole 16 with molten resin M. Figure 11 Step S17).

[0125] In the process of placing the resin sheet T into the heated mold 270, such as Figure 13 As shown, controller Ctr controls drive source D3 to position the conveyor section 240 and opening / closing member 250 above the heating mold 270. At this time, controller Ctr can control heater 273 to preheat the heating mold 270 to a predetermined temperature. Next, controller Ctr controls drive source D4 to position the opening / closing member 250 in the first position. Thus, resin sheets T (see reference 270) are inserted approximately simultaneously from their respective receiving holes 241 into the heated receiving holes 271. Figure 11 (Step S16). Therefore, heating of the resin sheet T begins approximately simultaneously in each receiving hole 271. In addition, since the plunger 281 is inserted into each receiving hole 271 from below, the plunger 281 prevents the resin sheet T from falling.

[0126] Next, in the process of filling the magnet insertion hole 16 with molten resin M, as follows: Figure 12As shown, a clamp 260 on which the laminate 10 is placed is placed on a heated mold 270. Then, an upper mold 295 is placed on the laminate 10. Thus, the laminate 10 and the clamp 260 are held by the upper mold 295 and the heated mold 270 with a predetermined load applied from the height direction. That is, in Figure 12 In the exemplified heating unit U4, the heating mold 270 also functions as the lower mold.

[0127] With the laminate 10 and fixture 260 clamped by the upper mold 295 and the heated mold 270, when the resin sheet T melts in each receiving hole 271 to become molten resin M, the controller Ctr controls each drive source 282 to use the corresponding plunger 281 to extrude the molten resin M in each receiving hole 271 into each magnet insertion hole 16 (see reference). Figure 11 (Step S17). At this time, the laminate 10 can be pressurized by the upper mold 295 and the heated mold 270. As a result, molten resin M flows into each magnet insertion hole 16 through each through hole 263, thereby filling each magnet insertion hole 16 with molten resin M. When the molten resin M filling each magnet insertion hole 16 solidifies, the upper mold 295 is removed from the laminate 10. In this way, solidified resin 14 is formed in each magnet insertion hole 16, and the rotor laminated iron core 1 is completed.

[0128] Additionally, this example illustrates the heating mold 270 functioning as a lower mold, but a separate lower mold 296 can also be provided. This lower mold 296, together with the upper mold 295, can hold the laminate 10, the fixture 260, and the heating mold 270 (see reference). Figure 14 In this case, it is sufficient to simply provide a through hole 297 communicating with the receiving hole 271 in the lower die 296, and it is sufficient to provide an extrusion mechanism 280 (plunger 281 and drive source 282) in each through hole 297. In addition, the lower die 296 can be integrated with the heating die 270.

[0129] (7) In the above example, the case of manufacturing the iron core product using the heating mold 270 is illustrated, but the heating mold 270 may not be used. That is, the method of manufacturing the iron core product may include: preheating the laminate 10 having a plurality of magnet insertion holes 16 formed thereon; and feeding resin material into the plurality of magnet insertion holes 16 approximately simultaneously from the plurality of receiving holes 241 formed in the conveying section 240, the method utilizing the heat from the laminate 10 to start heating the plurality of resin materials approximately simultaneously. It may be that the resin sheet T is heated while the permanent magnet 12 and the resin sheet T are disposed in the magnet insertion hole 16, thereby filling the magnet insertion hole 16 with molten resin M. In this case, the resin sheet T may be heated by heating the laminate 10, or the resin sheet T may be heated by inserting the heated permanent magnet 12 into the magnet insertion hole 16. In this example, the resin sheet T received in each receiving hole 241 of the conveying section 240 is not fed into the heating mold 270, but is directly fed into the corresponding magnet insertion hole 16. If the heat from the laminate 10 is insufficient, a heating device such as a heater can be arranged around the laminate for additional heating. Alternatively, the resin sheet T can be heated using the heat from the heated laminate 10 and the permanent magnet 12 pre-positioned in the magnet insertion hole 16, or by inserting the heated permanent magnet 12 into the magnet insertion hole 16 of the heated laminate 10 approximately simultaneously after the resin sheet is inserted. Using the heated permanent magnet 12 allows for faster curing of the resin material compared to using only the heat from the laminate 10. Furthermore, heating the resin material from both the outside and inside further accelerates curing and shortens manufacturing time. Since the resin material is introduced into the multiple magnet insertion holes 16 approximately simultaneously, time differences in the start times of heating the multiple resin materials are less likely to occur. Therefore, situations such as unfilled areas of molten resin in the magnet insertion holes 16 and leakage of molten resin from the magnet insertion holes 16 can be suppressed. Furthermore, the heating mold 270, which does not require heating of the resin material, simplifies the apparatus, reduces its cost, and offers excellent maintainability. Since no resin flow path is required, the generation of unwanted resin can be suppressed.

[0130] (8) can be as follows Figure 15As illustrated, with the configuration unit 220 in an upright position (with the receiving holes 221 extending laterally), the holding mechanism 230 moves to a position corresponding to each receiving hole 221, thereby inserting resin sheets T into each receiving hole 221. Alternatively, the configuration unit 220 can be rotated circumferentially by a predetermined angle to correspond to the release position where the holding mechanism 230 releases the resin sheets T. On the other hand, when the number of resin sheets T to be received in one receiving hole 221 is set to multiple, after a predetermined number of resin sheets T are received in that receiving hole 221, the controller Ctr controls the drive source D1 to rotate the configuration unit 220 circumferentially by a predetermined angle so that the next receiving hole 221 to be inserted corresponds to the aforementioned release position. By repeating this operation multiple times, a predetermined number of resin sheets T are inserted into all the receiving holes 221. Then, by rotating the configuration unit 220 approximately 90° toward the conveying unit 240, resin sheets T can be inserted from each receiving hole 221 into the corresponding receiving hole 241. When resin sheet T is fed from conveyor 240 into heating mold 270, it can also be applied. Figure 15 Example way.

[0131] (9) can be as follows Figure 16 As illustrated, the resin sheet T is inserted with the placement section 220 upright (with the receiving hole 221 extending laterally) and the conveying section 240 upright (with the receiving hole 241 extending laterally). For example, a rod-shaped extrusion member 300 can be used to extrude the resin sheet T placed in the receiving hole 221 into the receiving hole 241 in a generally horizontal direction. Afterward, the conveying section 240 can be rotated approximately 90° so that the opening / closing member 250 is located on the bottom surface. The conveying section 240 can be transferred to the next process simply by rotating it approximately 90°, thus having the advantage of preventing the device structure from becoming complicated. When the resin sheet T is inserted from the placement section 220 into the conveying section 240, it is not necessary to operate the opening / closing member 250. Therefore, not only can the resin sheets T be inserted simultaneously, but they can also be inserted sequentially. In addition, the waiting time until the resin sheet T is inserted into the receiving hole 221 of the placement section 220 can be shortened.

[0132] (10) A heater may be provided in the configuration section 220 to preheat the resin sheet T housed in each receiving hole 221. A heater may also be provided in the transport section 240 to preheat the resin sheet T housed in each receiving hole 241.

[0133] (11) When filling the magnet insertion hole 16 with molten resin M, an intermediate plate (not shown) may be disposed between the heating mold 270 and the laminate 10. The intermediate plate may contain multiple resin flow paths (e.g., grooves, through holes). The resin flow paths can fluidly connect the receiving hole 271 to the magnet insertion hole 16. In this case, each receiving hole 271 may not coincide with the corresponding magnet insertion hole 16 when viewed from above.

[0134] (12) After the laminate 10 and the fixture 260 are clamped by the heating mold 270 and the lower mold 291, the resin sheet T can be inserted into each receiving hole 271.

[0135] (13) When the laminate 10 and the fixture 260 are clamped using the lower mold 291 and the upper mold 292, power from a drive source or the like can be provided to at least one of the lower mold 291 and the upper mold 292. Power from a drive source or the like can also be provided to the heated mold 270.

[0136] (14) The holding mechanism 230 can be a robotic arm, etc.

[0137] (15) The resin sheet T can be directly inserted into each receiving hole 241 of the conveying section 240 using the holding mechanism 230. That is, the conveying section 240 can also serve as the placement section 220.

[0138] (16) The resin sheet T can be directly inserted into each receiving hole 271 of the heating mold 270 using the holding mechanism 230. That is, the heating mold 270 can also serve as the placement unit 220 and the conveying unit 240. In this case, the heater 273 can start heating the heating mold 270 after the resin sheet T has been inserted into all the receiving holes 271. The heating mold 270 can move in a manner that circulates between the placement unit U2 and the heating unit U4.

[0139] (17) such as Figure 17 As illustrated in (a), the configuration unit 220 can be constructed from a combination of multiple components 220A. Each component 220A may include at least one receiving hole 221. When the configuration unit 220 is constructed from a combination of multiple components 220A, the multiple receiving holes 221 may be arranged in a ring. The resin sheet T can be fed into the delivery unit 240 from the multiple components 240A individually or approximately simultaneously.

[0140] like Figure 17 As illustrated in (b), the conveying section 240 can also be constructed from a combination of multiple components 240A. Figure 17 As illustrated in (c), the heating mold 270 can also be constructed from a combination of multiple parts 270A.

[0141] (18) such as Figure 18As shown, the heating mold 270 can be composed of multiple components 270A and a main body component 270B. Components 270A can each be a cylindrical component having at least one receiving hole 271. The main body component 270B can include a holding space 272 for holding the multiple components 270A. The holding space 272 can also be a through hole, recess, etc., with a shape corresponding to the outer shape of the multiple components 270A.

[0142] (19) The placement section 220 may replace the receiving hole 221 by including a receiving section capable of receiving the resin sheet T, or it may include a receiving section capable of receiving the resin sheet T in addition to the receiving hole 221. The conveying section 240 may replace the receiving hole 241 by including a receiving section capable of receiving the resin sheet T, or it may include a receiving section capable of receiving the resin sheet T in addition to the receiving hole 241. The heating mold 270 may replace the receiving hole 271 by including a receiving section capable of receiving the resin sheet T, or it may include a receiving section capable of receiving the resin sheet T in addition to the receiving hole 271. These receiving sections may be through holes, non-through holes (recesses), or other shapes.

[0143] (20) In the above example, the number of resin sheets T disposed in the receiving hole 221 is determined by measuring the height of the receiving hole 221 after a predetermined number of resin sheets T have been inserted. However, the number of resin sheets T disposed in the receiving hole 241 can also be determined by measuring the height of the resin sheets T disposed in the receiving hole 241. Alternatively, the number of resin sheets T disposed in the receiving part of a can that is different from the dispensing part 220 and the conveying part 240 can also be determined by measuring the height of the resin sheets T disposed in the receiving part of that can.

[0144] (21) This technology can also be applied to other core products besides the rotor laminated core 1. Other core products may include stator laminated cores, non-laminated stator cores, and non-laminated rotor cores. The stator core may be a segmented stator core composed of multiple iron chips, or a non-segmented stator core. A non-segmented stator laminated core may be a core formed by stacking multiple annular stamping parts W. Alternatively, a non-segmented stator laminated core may be a core in which multiple teeth are provided on a yoke, and multiple bent stamping parts are stacked to form annular shapes by bending between the teeth. A non-laminated rotor core or stator core may be a core formed by compressing strong magnetic material powder, or a core formed by injection molding a resin material containing strong magnetic material powder.

[0145] (22) This technology can also be applied to a method for manufacturing a core product that includes a step of filling molten resin M into a resin injection portion (e.g., a through hole, slot, etc.) extending in the height direction. For example, this technology can be applied when a resin film for insulating the stator core from the winding is provided on the inner circumferential surface of the slot of the stator core. Alternatively, this technology can be applied when joining multiple stamped parts W.

[0146] (23) Multiple permanent magnets 12 can be inserted into a magnet insertion hole 16. In this case, the multiple permanent magnets 12 can be arranged adjacent to each other in the stacking direction in a magnet insertion hole 16, or they can be arranged in the length direction of the magnet insertion hole 16.

[0147] [Other examples]

[0148] Example 1. One example of a method for manufacturing a core product (1) may include: feeding resin material (T) into a plurality of first receiving portions (271) formed in a heating mold (270) approximately simultaneously; starting heating the plurality of resin materials (T) disposed in the plurality of first receiving portions (271) using the heating mold (270) approximately simultaneously; and supplying molten resin (M) from the plurality of first receiving portions (271) to a plurality of resin forming regions (16) disposed in the core body (10). Generally, the viscosity of molten resin tends to increase with heating time. However, in the case of Example 1, since the resin material is fed into the plurality of first receiving portions 271 approximately simultaneously, the timing of the start of heating of the plurality of resin materials is less likely to cause a time difference. Therefore, the viscosity of the molten resin in each of the plurality of first receiving portions is less likely to deviate. Therefore, it is easy to uniformly supply molten resin from the plurality of first receiving portions to the plurality of resin forming regions of the core body, thereby suppressing situations such as: unfilled molten resin areas in the resin forming regions; leakage of molten resin from the resin forming regions. As a result, molten resin can be appropriately supplied to multiple resin-forming regions of the iron core body.

[0149] Example 2. In the method of Example 1, the plurality of first receiving portions (271) may include three or more first receiving portions formed in a circular arrangement on the heating portion (270). In this case, molten resin can be supplied more appropriately to the plurality of resin forming regions formed in a circular arrangement on the iron core body.

[0150] Example 3. In the method of Example 1 or Example 2, each of the plurality of resin materials (T) may be composed of at least one resin sheet (T). In this case, by increasing or decreasing the number of resin sheets according to the capacity of each resin forming region, the molten resin can be supplied more appropriately.

[0151] Example 4. Regarding the method of Example 3, it may further include: measuring the height of each resin material (T) among the multiple resin materials (T) before starting heating the multiple resin materials (T) approximately simultaneously, and determining the number of resin sheets (T) constituting each resin material (T). In this case, it can be determined in advance whether a predetermined number of resin sheets are arranged in each first receiving portion before the resin sheets melt. Therefore, it is possible to supply an appropriate amount of molten resin to the multiple resin forming regions.

[0152] Example 5. Regarding the method of Example 3 or Example 4, it may further include: measuring the height and / or weight of each resin sheet (T) constituting each resin material (T) before starting heating the multiple resin materials (T) approximately simultaneously. In this case, it can be determined in advance whether the height and / or weight of each resin sheet is within a specified range before the resin sheets melt. Therefore, it is possible to supply appropriate amounts of molten resin to multiple resin forming regions.

[0153] Example 6. In any of the methods in Examples 3 to 5, each of the plurality of resin materials (T) may comprise a plurality of resin sheets arranged in a row along the length of a corresponding first receiving portion (271) within a plurality of first receiving portions (271). In this case, even if the capacity of each resin forming region is large, molten resin can be supplied more appropriately. Furthermore, since the plurality of resin sheets are arranged in a row within each first receiving portion, the plurality of resin sheets (T) can be heated approximately evenly.

[0154] Example 7. Regarding any of Examples 1 to 6, the method may further include: distributing resin material (T) to each of the plurality of second receiving portions (241) formed in the conveying section (240). The method of feeding resin material (T) into the plurality of first receiving portions (271) approximately simultaneously may include: feeding the plurality of resin materials (T) disposed in the plurality of second receiving portions (241) into the plurality of first receiving portions (271) of the heated mold (270) approximately simultaneously. In this case, since the plurality of resin materials are fed into the plurality of first receiving portions of the preheated heated mold approximately simultaneously, no waiting time required for the heated mold to heat up is generated. Therefore, the productivity of the iron core product can be improved.

[0155] Example 8. In the method of Example 7, the feeding of resin material (T) into multiple first receiving sections (271) approximately simultaneously may involve actuating an opening / closing member (250) disposed at the bottom of the conveying section (240) to cause the outlets of multiple second receiving sections (241) to open approximately simultaneously from a closed state. In this case, the feeding of multiple resin materials into multiple first receiving sections can be achieved by the extremely simple method of actuating the opening / closing member.

[0156] Example 9. Regarding the method of Example 7 or Example 8, it may further include: dispensing resin material (T) into the plurality of third receiving portions (221) formed in the dispensing section (220) respectively. Dispensing resin material (T) into the plurality of second receiving portions (241) respectively may include: feeding the plurality of resin materials (T) disposed in the plurality of third receiving portions (221) into the plurality of second receiving portions (241) respectively. In this case, the dispensing process of the plurality of resin materials and the conveying process of the plurality of resin materials to the heating mold are performed separately in the dispensing section and the conveying section. Therefore, during the conveying of the plurality of resin materials to the heating mold using the conveying section, the dispensing process, which tends to take longer, can be performed. Therefore, the waiting time required for the dispensing process of the plurality of resin materials can be reduced, thereby improving the productivity of the iron core product.

[0157] Example 10. In the method of Example 9, the process of placing resin material (T) into multiple third receiving parts (221) may include repeatedly using a holding clamp (231) to hold the resin material (T) and placing it into any of the multiple third receiving parts (221). In this case, even if dust is generated from the resin material during the process of holding the resin material with the holding clamp, the holding clamp is less susceptible to the effects of the dust. Therefore, the time and frequency of maintenance operations can be reduced, thereby improving the productivity of the core product.

[0158] Example 11. Regarding the method of Example 9 or Example 10, it may further include: measuring the height of each resin material (T) among the multiple resin materials (T) disposed in the multiple third receiving sections (221), and determining the number of resin sheets (T) constituting each resin material (T). In this case, the same effect as the method of Example 4 can be obtained.

[0159] Example 12. One example of a manufacturing apparatus (100) for a core product (1) may include: a heating unit (270) having a plurality of first receiving portions (271); feeding machines (240, 250) configured to feed resin material (T) into the plurality of first receiving portions (271) approximately simultaneously; a heater (273) configured to begin heating the plurality of resin materials (T) disposed in the plurality of first receiving portions (271) by the feeding machines (240, 250) approximately simultaneously; and an extrusion mechanism (280) configured to extrude molten resin (M) from the plurality of first receiving portions (271) and supply the molten resin (M) to a plurality of resin forming regions (16) disposed on the core body (10). In this case, the same effect as the method in Example 1 can be obtained.

[0160] Example 13. In the device (100) of Example 12, the plurality of first receiving parts (271) may include three or more first receiving parts formed in a circular arrangement on the heating part (270). In this case, the same effect as the method of Example 2 can be obtained.

[0161] Example 14. In the apparatus (100) of Example 12 or Example 13, each of the plurality of resin materials (T) may be composed of at least one resin sheet (T).

[0162] In this case, the same effect as the method in Example 3 can be achieved.

[0163] Example 15. Regarding the apparatus (100) of Example 14, it may further include: a first measuring device (SE3) configured to measure the height of each of the plurality of resin materials (T); and a determination unit (Ctr) configured to determine the number of resin sheets (T) constituting each resin material (T) based on the height measured by the first measuring device (SE3). In this case, the same effect as the method of Example 4 can be obtained.

[0164] Example 16. Regarding the apparatus (100) of Example 14 or Example 15, it may further include a second measuring instrument (SE2) configured to measure the height and / or weight of each resin sheet (T) constituting each resin material (T). In this case, the same effect as the method of Example 5 can be obtained.

[0165] Example 17. In any of the apparatus (100) in Examples 14 to 16, each of the plurality of resin materials (T) may comprise a plurality of resin sheets (T) arranged in a row along the length direction of a corresponding first receiving portion (271) in a plurality of first receiving portions (271). In this case, the same effect as the method in Example 6 can be obtained.

[0166] Example 18. In any of the apparatus (100) in Examples 12 to 17, the feeding machine (240, 250) may include a conveying section (240) having a plurality of second receiving portions (241). The conveying section (240) may be configured to feed a plurality of resin materials (T) disposed in the plurality of second receiving portions (241) substantially simultaneously into a plurality of first receiving portions (271) of a heated mold (270) being heated by a heater (273). In this case, the same effect as the method in Example 7 can be obtained.

[0167] Example 19. In the apparatus (100) of Example 18, the feeding machine (240, 250) may further include an opening and closing member (250) disposed at the bottom of the conveying section (240) and configured to open and close the outlets of the plurality of second receiving sections (241) approximately simultaneously. Alternatively, the conveying section (240) may be configured such that the opening and closing member (250) causes the outlets of the plurality of second receiving sections (241) to open approximately simultaneously from a closed state, thereby feeding the plurality of resin materials (T) disposed in the plurality of second receiving sections (241) into the plurality of first receiving sections (271) of the heating mold (270) which is being heated by the heater (273) at approximately the same time. In this case, the same effect as the method of Example 8 can be obtained.

[0168] Example 20. Regarding the apparatus (100) of Example 18 or Example 19, it may further include a configuration section (220) having formed a plurality of third receiving sections (221). The configuration section (220) may be configured to feed a plurality of resin materials (T) disposed in the plurality of third receiving sections (221) into a plurality of second receiving sections (241). In this case, the same effect as the method of Example 9 can be obtained.

[0169] Example 21. Regarding the apparatus (100) of Example 20, it may also include a gripping clamp (231) configured to repeatedly grip the resin material (T) and place it into any of the plurality of third receiving portions (221). In this case, the same effect as the method of Example 10 can be obtained.

[0170] Example 22. Regarding the apparatus (100) of Example 20 or Example 21, it may further include: a first measuring device (SE3) configured to measure the height of each resin material (T) among a plurality of resin materials (T) disposed in a plurality of third receiving portions (221); and a determination unit (Ctr) configured to determine the number of resin sheets (T) constituting each resin material (T) based on the height measured by the first measuring device (SE3). In this case, the same effect as the method of Example 4 can be obtained.

[0171] Explanation of reference numerals in the attached figures

[0172] 1-Rotor laminated iron core (iron core product), 10-Layer body (iron core body), 16-Magnet insertion hole (resin forming area), 100-Manufacturing apparatus, 200-Resin filling system, 220-Configuration section, 221-Receiving hole (third receiving section), 230-Holding mechanism, 231-Holding fixture, 240-Conveying section (feeding machine), 241-Receiving hole (second receiving section), 250-Opening and closing component (feeding machine), 270-Heating mold (heating section), 271-Receiving hole (first receiving section), 273-Heater, 280-Extrusion mechanism, Ctr-Controller (judgment unit), M-Melted resin, SE1-

[0173] Weight sensor (second measuring device), SE2-height sensor (second measuring device), SE3-height sensor (first measuring device), T-resin sheet (resin material), U1-material supply unit, U2-configuration unit, U3-conveying unit, U4-heating unit.

Claims

1. A method of manufacturing a core product, which is a method of manufacturing a laminated core in a resin filling system including a conveying section and a heating section, comprising: The heating section including a plurality of first accommodation sections is preheated to a prescribed processing temperature, wherein the plurality of first housing sections are located outside the core body; a plurality of resin materials are arranged in a plurality of second housing sections formed in the conveying section, wherein the plurality of second housing sections respectively house the plurality of resin materials; after the heating section is preheated to the processing temperature, the plurality of resin materials are roughly simultaneously fed from the plurality of second housing sections to each of the plurality of first housing sections formed in the heating section; heating of the plurality of resin materials arranged in the plurality of first housing sections is roughly simultaneously started by the heating section; molten resin is supplied from the plurality of first housing sections to a plurality of resin formation regions provided in the core body and respectively housing magnets; and the molten resin is solidified around the magnets in the plurality of resin formation regions of the core body.

2. The method according to claim 1, wherein: the plurality of first housing sections include three or more first housing sections formed in the heating section in a manner arranged in a circular ring shape.

3. The method according to claim 1 or 2, wherein: each of the plurality of resin materials respectively includes at least one resin sheet.

4. The method according to claim 3, further comprising: before the heating of the plurality of resin materials is roughly simultaneously started, measuring a height of each of the plurality of resin materials to determine a number of resin sheets that constitute each of the plurality of resin materials.

5. The method according to claim 3, further comprising: before the heating of the plurality of resin materials is roughly simultaneously started, measuring a height and / or a weight of each of the resin sheets that constitute each of the plurality of resin materials.

6. The method according to claim 3, wherein: each of the plurality of resin materials respectively includes a plurality of resin sheets arranged in a line along a length direction of a corresponding one of the plurality of first housing sections within the corresponding one of the plurality of first housing sections.

7. The method according to claim 1, wherein: the roughly simultaneous feeding of the resin materials to the plurality of first housing sections includes operating an opening and closing member arranged at a bottom of the conveying section to roughly simultaneously change outlets of the plurality of second housing sections from a closed state to an open state.

8. The method according to claim 1 or 7, further comprising: arranging the plurality of resin materials in a plurality of third housing sections formed in an arrangement section, the arranging of the resin materials in the plurality of second housing sections includes feeding the plurality of resin materials arranged in the plurality of third housing sections to the plurality of second housing sections, respectively.

9. The method according to claim 8, wherein: the arranging of the resin materials in the plurality of third housing sections includes repeatedly grasping the resin materials by a grasping jig and arranging the resin materials in any one of the plurality of third housing sections a plurality of times.

10. The method according to claim 8, wherein: Further comprising: measuring a height of each of the plurality of resin materials disposed in the plurality of third housing portions, and determining a number of resin sheets that constitute each of the plurality of resin materials.

11. An iron core product manufacturing apparatus comprising: a heating portion formed with a plurality of first housing portions, wherein the plurality of first housing portions are located outside the iron core body; a conveying portion formed with a plurality of second housing portions; an input machine configured to input resin materials from the plurality of second housing portions to the plurality of first housing portions at substantially the same time; a heater configured to start heating the plurality of resin materials disposed in the plurality of first housing portions by the input machine at substantially the same time; and an extruding mechanism configured to extrude molten resin in each of the plurality of first housing portions and supply the molten resin to a plurality of resin formation regions provided in the iron core body and housing magnets, respectively, the molten resin being solidified around the magnets.

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