Rotor manufacturing method and rotor manufacturing device

Abstract

The present invention relates to a rotor manufacturing method and a rotor manufacturing device. The rotor manufacturing method comprises: an arrangement step of arranging a rotor core (12) formed by stacking electromagnetic steel sheets in such a way that the stacking direction of the electromagnetic steel sheets faces the up-down direction; a guide inserting step of inserting a rod-shaped guide (52) into a magnet insertion hole (16) extending in the stacking direction of the rotor core (12) after the arrangement step; a sheet inserting step of inserting a plurality of sheets (20) into the magnet insertion hole (16) from the upper side of the rotor core (12) along each side surface (56) of the guide (52) after the guide inserting step; a guide removing step of removing the guide (52) from the magnet insertion hole (16) after the sheet inserting step; and a magnet inserting step of inserting a permanent magnet (18) between the plurality of sheets (20) in the magnet insertion hole (16) after the guide removing step.

Description

[0001] This application claims priority from Japanese Patent Application No. 2021-085038 filed on May 20, 2021, the entire contents of which including the specification, claims, drawings, and abstract are incorporated herein by reference. Technical Field

[0002] The present disclosure relates to a rotor manufacturing method and a rotor manufacturing device, and more particularly to a method and a device for arranging a sheet in a magnet insertion hole of a rotor core. Background Art

[0003] In the past, in rotating electrical machines such as motors and generators, permanent magnet embedded rotors are known. In such rotors, a plurality of magnet insertion holes are formed in a rotor core formed by stacking annular electromagnetic steel sheets so as to extend in the axial direction (the stacking direction of the electromagnetic steel sheets), and permanent magnets are respectively inserted into these magnet insertion holes. In the rotor, there is a rotor in which a sheet is arranged between the permanent magnet and the inner surface of the magnet insertion hole, and the permanent magnet is fixed to the magnet insertion hole by the sheet, or the permanent magnet is insulated from the inner surface of the magnet insertion hole by the sheet.

[0004] Patent document 1 discloses a rotor in which an adhesive sheet coated with an adhesive is mounted on the outer periphery of a permanent magnet, the permanent magnet is inserted into a slit hole (magnet insertion hole) of a rotor core, and then the adhesive of the adhesive sheet is cured to fix the permanent magnet to the inner surface of the slit hole.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Laid-Open No. 9-163649

[0008] In the rotor manufacturing method, there is a method as follows: before inserting the permanent magnet into the magnet insertion hole, multiple sheets corresponding to the multiple side surfaces of the permanent magnet are inserted into the magnet insertion hole, and then the permanent magnet is inserted between the multiple sheets in the magnet insertion hole, thereby arranging each sheet between each side surface of the permanent magnet and the inner surface of the magnet insertion hole.

[0009] The rotor core is formed by stacking electromagnetic steel sheets, so the inner surface of the magnet insertion hole has tiny bumps and depressions. In the above-mentioned rotor manufacturing method, in which the sheet is inserted into the magnet insertion hole independently of the permanent magnet, when the sheet is inserted into the magnet insertion hole, the top of the sheet will tend to the inner surface of the magnet insertion hole and will be caught by the bumps and depressions of the magnet insertion hole, which may cause the sheet to break or be damaged. Therefore, a rotor manufacturing method or rotor manufacturing device is desired that can prevent the sheet from breaking or being damaged when the sheet is inserted into the magnet insertion hole independently of the permanent magnet. Summary of the invention

[0010] The rotor manufacturing method disclosed in the present invention is characterized in that it comprises: a configuration step of configuring a rotor core formed by stacking electromagnetic steel sheets in such a way that the stacking direction of the electromagnetic steel sheets faces the up-down direction; a guide member insertion step of inserting a rod-shaped guide member into a magnet insertion hole of the rotor core extending in the stacking direction after the configuration step; a sheet material insertion step of inserting a plurality of sheets into the magnet insertion hole along the respective side surfaces of the guide member from the upper side of the rotor core after the guide member insertion step; a guide member removal step of removing the guide member from the magnet insertion hole after the sheet material insertion step; and a magnet insertion step of inserting a permanent magnet between the plurality of sheets of the magnet insertion hole after the guide member removal step.

[0011] In the rotor manufacturing method disclosed in the present invention, it can also be set as follows: in the guide member insertion process, the guide member is inserted into the magnet insertion hole from the lower side of the rotor core, and a part of the guide member is protruded from the upper end surface of the rotor core to serve as a guide member protrusion; in the sheet insertion process, a plurality of the sheets are supplied to each side surface of the guide member protrusion from obliquely above.

[0012] In the rotor manufacturing method disclosed in the present invention, it can also be set that: in the sheet insertion step, the multiple side surfaces of the guide along which the multiple sheets are arranged and the inner surfaces of the magnet insertion holes respectively opposite to the multiple side surfaces are parallel when the rotor core is viewed from above.

[0013] In the rotor manufacturing method disclosed in the present invention, it can also be set as follows: when the sheet insertion process is completed, the plurality of sheets gradually expand above the magnet insertion hole and extend toward each sheet supply source, and in the magnet insertion process, the permanent magnet is inserted into the magnet insertion hole from between the gradually expanding plurality of sheets.

[0014] In the rotor manufacturing method disclosed in the present invention, it can also be set that: each of the sheets has the property of expanding when heated, and the rotor manufacturing method also includes: a sheet cutting process, cutting each of the sheets at the upper end surface of the rotor core after the magnet insertion process; and a sheet heating process, heating each of the sheets located in the magnet insertion hole after the sheet cutting process.

[0015] The rotor manufacturing device disclosed in the present invention is characterized in that it comprises: a holding member that holds a rotor core formed by stacking electromagnetic steel sheets in a manner that the stacking direction of the electromagnetic steel sheets faces the up-down direction and has a magnet insertion hole extending in the stacking direction; a guide driving unit that inserts a rod-shaped guide into the magnet insertion hole of the rotor core held by the holding member and pulls out the guide from the magnet insertion hole; a sheet supply unit that supplies a plurality of sheets from the upper side of the rotor core along the respective side surfaces of the guide to the magnet insertion hole in a state in which the guide is inserted into the magnet insertion hole; and a magnet supply unit that supplies permanent magnets between the plurality of sheets of the magnet insertion hole in a state in which the plurality of sheets are supplied to the magnet insertion hole and the guide is pulled out from the magnet insertion hole.

[0016] In the rotor manufacturing device disclosed in the present invention, it can also be configured that: the guide driving unit supplies the guide from the lower side of the rotor core to the magnet insertion hole, and makes a part of the guide protrude from the upper end surface of the rotor core as a guide protrusion, and the sheet supply unit supplies a plurality of the sheets to each side surface of the guide protrusion from obliquely above.

[0017] In the rotor manufacturing device disclosed in the present invention, it can also be set that: when the guide member is inserted into the magnet insertion hole, the multiple side surfaces of the guide member along which the multiple sheets are arranged and the inner surfaces of the magnet insertion holes opposite to the multiple side surfaces are parallel when the rotor core is viewed from above.

[0018] In the rotor manufacturing device disclosed in the present invention, it can also be configured that: when the supply of each of the sheets to the magnet insertion hole is completed, the plurality of sheets gradually expand above the magnet insertion hole and extend toward each sheet supply source, and the magnet supply unit supplies the permanent magnet to the magnet insertion hole from between the gradually expanding plurality of sheets.

[0019] In the rotor manufacturing device disclosed in the present invention, it can also be configured that: each of the sheets has the property of expanding when heated, and the rotor manufacturing device also includes: a cutter for cutting each of the sheets on the upper end surface of the rotor core when the permanent magnet is supplied to the magnet insertion hole; and a heater for heating each of the sheets located in the magnet insertion hole when the sheets are cut by the cutter.

[0020] According to the present disclosure, the sheet is inserted into the magnet insertion hole along the guide, so the top of the sheet can be prevented from tending to the inner surface of the magnet insertion hole. Therefore, the top of the sheet can be prevented from being caught by the unevenness of the inner surface of the magnet insertion hole, so the sheet can be prevented from being broken or damaged. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a perspective view showing the rotor core before the permanent magnets are inserted.

[0022] Figure 2 This is a diagram showing a portion of a manufactured rotor as viewed from above.

[0023] Figure 3 It is a diagram schematically showing a rotor manufacturing device.

[0024] Figure 4 This is a diagram showing a state in which the guide is inserted into the magnet insertion hole, as viewed from above the rotor core.

[0025] Figure 5 It is a perspective view showing a part of the sheet feeding arm.

[0026] Figure 6 This is a flowchart showing the flow of the rotor manufacturing method.

[0027] Figure 7 It is a figure for demonstrating the guide inserting process.

[0028] Figure 8 It is a figure for demonstrating the sheet|seat insertion process.

[0029] Fig. 9 It is a figure for demonstrating the sheet|seat insertion process.

[0030] Fig.10 It is a figure for demonstrating the guide member extraction process.

[0031] Fig.11 It is a figure for demonstrating the magnet inserting process and the sheet material cutting process.

[0032] Fig.12 It is a diagram for explaining the sheet heating process.

[0033] Fig.13 This is a diagram for explaining the state of the rotor after the sheet heating step.

[0034] Fig.14 It is a diagram for explaining a rotor manufacturing apparatus according to another embodiment. DETAILED DESCRIPTION

[0035] Hereinafter, each embodiment of the present disclosure will be described according to the accompanying drawings. The configuration described below is an example for explanation and may be appropriately changed according to the specifications of the rotor, etc. In addition, when the following includes multiple embodiments, modified examples, etc., it is assumed from the beginning that their characteristic parts are appropriately combined for use. The same reference numerals are given to the same elements in all the drawings, and repeated descriptions are omitted.

[0036] In the following description, unless otherwise specified, words indicating directions such as up, down, left, and right refer to the directions of the electromagnetic steel sheet 14 (see Figure 1 ) is configured in a direction related to the rotor core 12 in which the stacking direction is toward the up-down direction.

[0037] Figure 1 1 is a perspective view showing the rotor core 12 before the permanent magnet 18 is inserted. The permanent magnet 18 is inserted into each of the plurality of magnet insertion holes 16 of the rotor core 12 to form the rotor 10 for the rotary electric machine. The rotor 10 has a rotary shaft (not shown) that passes through the rotary shaft hole 15 of the rotor core 12 and is fixed to the inner surface of the rotary shaft hole 15. The cylindrical stator (not shown) is arranged around the rotor 10 with a predetermined gap to form the rotary electric machine. When the stator coil provided in the stator is energized, a rotating magnetic field is formed inside the stator, so that the rotor 10 is driven to rotate around the rotary shaft.

[0038] The rotor core 12 is formed by stacking a plurality of electromagnetic steel sheets 14 in the axial direction. The electromagnetic steel sheets 14 are formed by punching silicon steel sheets with a thickness of 1 mm or less into a circular ring shape. Figure 1 In each of the figures, each electromagnetic steel sheet 14 is depicted as being relatively thick. The plurality of electromagnetic steel sheets 14 constituting the rotor core 12 are connected as a whole by riveting, bonding, welding, or the like, in each or all of the plurality of blocks obtained by dividing the rotor core 12 in the axial direction.

[0039] A circular rotating shaft hole 15 is provided at the center of the rotor core 12, and a plurality of magnet insertion holes 16 are provided at intervals in the circumferential direction on the outer periphery of the rotor core 12. The rotating shaft hole 15 and the plurality of magnet insertion holes 16 penetrate the rotor core 12 in the axial direction (the same as the stacking direction of the electromagnetic steel sheets 14) while maintaining the same cross-sectional shape. In this embodiment, the sizes of the magnet insertion holes 16 are the same. It should be noted that the shape, size, etc. of the rotating shaft hole 15 and the number, shape, size, position, etc. of the magnet insertion holes 16 may be appropriately changed according to the specifications of the rotating electrical machine, etc.

[0040] The permanent magnet 18 has a rectangular parallelepiped and is inserted into the magnet insertion hole 16 to form the magnetic pole of the rotor 10. The length of the permanent magnet 18 in the vertical direction is substantially the same as the length of the magnet insertion hole 16 in the vertical direction. In this embodiment, the sizes of the permanent magnets 18 are the same. It should be noted that the shape, size, etc. of the permanent magnet 18 may be appropriately changed according to the specifications of the rotating electrical machine.

[0041] Two sheets 20 are arranged on both sides of the permanent magnet 18. The sheet 20 is formed of a material containing glass fiber and is an expansion sheet that expands when heated. The sheet 20 is pressed and heated under a strong force to become a thin form, and after being inserted into the magnet insertion hole 16, it is heated again to expand and change into a thick form.

[0042] Figure 2 1 is a diagram showing a portion of the manufactured rotor 10 viewed from above, and in this diagram are shown two permanent magnets 18 inserted into two magnet insertion holes 16. As shown in this figure, the cross section of the permanent magnet 18 is slightly smaller than the cross section of the magnet insertion hole 16. Each of the two sheets 20 is arranged between the side surface 19 on the long side of the permanent magnet 18 (hereinafter referred to as the long side surface 19) and the inner surface of the magnet insertion hole 16 when viewed from above the rotor core 12. As described in detail below, before the permanent magnet 18 is inserted into the magnet insertion hole 16, the two sheets 20 are inserted into the magnet insertion hole 16, and then the permanent magnet 18 is inserted between the two sheets 20 in the magnet insertion hole 16, and the two sheets 20 are heated. As a result, each sheet 20 expands and fills the gap between the long side surface 19 of the permanent magnet 18 and the inner surface of the magnet insertion hole 16, so that the permanent magnet 18 is fixed in the magnet insertion hole 16.

[0043] The sheet 20 also has the function of insulating the long side surface 19 of the permanent magnet 18 from the inner surface of the rotor core 12. In addition, the sheet 20 can also be in the form of a sponge-like cross-section when it expands in the magnet insertion hole 16. In this case, the sheet 20 can have air permeability and liquid permeability. Therefore, when the rotating electric machine assembled with the manufactured rotor 10 is driven, air flows in the sheet 20, thereby obtaining the effect of cooling the permanent magnet 18. In addition, in the mode in which cooling oil is supplied to the rotor 10 when driving the rotating electric machine, the cooling oil flows in the sheet 20, thereby obtaining the effect of cooling the permanent magnet 18. It should be noted that, when viewed from above from the rotor core 12, the sheet can also be arranged on the side surface 19A (hereinafter referred to as the short side surface 19A) of the short side of the permanent magnet 18, and this embodiment will be described later.

[0044] Next, a method for manufacturing the rotor 10 will be described in detail. Figure 3 3 is a diagram schematically showing a rotor manufacturing device 30 for manufacturing a rotor. Figure 1 The rotor manufacturing device 30 is a device for placing two sheets 20 and the permanent magnet 18 in the magnet insertion hole 16 .

[0045] The rotor manufacturing device 30 includes: a worktable 46 that supports the rotor core 12; a rod-shaped guide 52 that is inserted into the magnet insertion hole 16 of the rotor core 12; a guide driving unit 50 that drives the guide 52 up and down; a magnet supply unit 32 that is arranged on the upper side of the rotor core 12; and two sheet supply units 40 that are located on both sides of the magnet supply unit 32. It should be noted that there is a guide 52 for each magnet insertion hole 16 of the rotor core 12. In addition, in this embodiment, there is only one upper group consisting of the magnet supply unit 32 and the two sheet supply units 40, but a plurality of upper groups may be provided as described later.

[0046] The workbench 46 is a support member that has an annular shape when viewed from above and supports the lower end of the outer peripheral side of the rotor core 12 from below. The rotor core 12 is placed on the workbench 46 in a manner such that the stacking direction of the electromagnetic steel sheets faces the up-down direction. In the workbench 46, holes 49 for the guides 52 to pass through are formed at positions corresponding to the magnet insertion holes 16 of the rotor core 12, and the periphery of each hole 49 forms a protrusion 48 that protrudes upward along the inner surface of the magnet insertion hole 16. The protrusions 48 of the workbench 46 enter the magnet insertion holes 16 of the rotor core 12, thereby positioning the rotor core 12 on the workbench 46. The workbench 46 also functions as a holding member for the rotor core 12.

[0047] The guide member 52 is a rod-shaped member extending in the vertical direction with a uniform cross section. Figure 7 In this way, the driving portion 50 is inserted into the magnet insertion hole 16 from the bottom to the top of the rotor core 12 through the guide. Figure 4 The guide 52 is inserted into the magnet insertion hole 16 as viewed from above the rotor core 12 ( Figure 7 When the rotor core 12 is viewed from above, the guide 52 has an outer contour that is the shape of the magnet insertion hole 16 reduced by a predetermined ratio. When the rotor core 12 is viewed from above, the two sheets 20 are inserted into the magnet insertion hole 16 along the side surfaces 56 of the two long sides of the guide 52 (hereinafter referred to as the long side surfaces 56).

[0048] exist Figure 3 In the embodiment, the guide driving unit 50 is disposed below the table 46. The guide driving unit 50 is an actuator that moves each guide 52 from below to above to insert into each magnet insertion hole 16, and moves each guide 52 from above to below to remove from each magnet insertion hole 16.

[0049] The magnet supply unit 32 includes a main body 34 that holds the upper portion of the permanent magnet 18 inside, and a top end 36 that orients the lower portion of the permanent magnet 18 toward the magnet insertion hole 16. The main body 34 of the magnet supply unit 32 releases the holding of the permanent magnet 18, so that the permanent magnet 18 is lowered by gravity, thereby supplying the permanent magnet 18 to the magnet insertion hole 16.

[0050] The two sheet supply units 40 are arranged to face each other with the magnet supply unit 32 interposed therebetween. The two sheet supply units 40 are respectively provided with: a sheet supply source 41 having a sheet 20 rolled into a roll; and a sheet supply arm 42 coupled to a side surface of the main body 34 of the magnet supply unit 32 and receiving the supply of the sheet 20 from the sheet supply source 41. It should be noted that the two sheet supply units 40 have a left-right symmetrical structure with the magnet supply unit 32 interposed therebetween. Figure 5 Yes means Figure 3 The sheet feeding arm 42 is a perspective view of a portion of the sheet feeding arm 42 on the left side. The sheet feeding arm 42 includes a sheet feeding plate 43 on which the sheet 20 from the sheet feeding source is placed. The sheet feeding plate 43 is inclined obliquely downward so that the sheet 20 moves from the sheet feeding source toward the magnet insertion hole.

[0051] Next, a rotor manufacturing method using the rotor manufacturing apparatus 30 will be described. Figure 6 is a flow chart showing the process of the rotor manufacturing method 90. Figure 6 In the process, the first S100 (rotor core configuration process) and the last S112 (sheet heating process) are processes performed only once on the rotor core 12, and S102 to S110 are processes performed on each magnet insertion hole of the rotor core 12.

[0052] First, in S100, the rotor core 12 formed by stacking electromagnetic steel sheets is arranged so that the stacking direction of the electromagnetic steel sheets is oriented in the vertical direction (arrangement step). Figure 3 The process of placing the rotor core 12 on the workbench 46 is shown.

[0053] Next, in S102, if Figure 7 As shown in FIG. 1 , the guide 52 is moved upward from the bottom by the guide driving unit 50, so that the guide 52 is inserted into the magnet insertion hole 16 (guide inserting process). At this time, the guide driving unit 50 causes the top end of the guide 52 to protrude beyond the upper end surface 72 of the rotor core 12. Hereinafter, the portion of the guide 52 protruding from the upper end surface 72 of the rotor core 12 is referred to as the guide protruding portion 53.

[0054] like Figure 4 (Viewed from above the rotor core 12 Figure 7As shown in the figure of the state of the guide 52, the two long side surfaces 56 of the guide 52 along which the two sheets are inserted are parallel to the inner surface 60 of the magnet insertion hole 16 opposite to the two long side surfaces 56. That is, an equal gap is formed between the long side surfaces 56 of the guide 52 and the inner surface 60 of the magnet insertion hole 16, and there is no locally narrowed portion between them. As a result, when the sheet is inserted into the magnet insertion hole 16, the top of the sheet can be prevented from being partially caught by the inner surface 60 of the magnet insertion hole 16.

[0055] Then, in Figure 6 In S104, two sheets 20 are simultaneously inserted into the magnet insertion hole 16 from the upper side of the rotor core 12 along the two long side surfaces 56 of the guide member 52 (sheet insertion process). Figure 7 As shown, the two sheet feeding units 40 respectively deliver the sheet 20 from the sheet feeding source 41, and feed the sheet 20 to the side of the guide protrusion 53 from obliquely above through the sheet feeding plate 43. Figure 8 As shown, the two sheets 20 enter the magnet insertion hole 16 along the two long side surfaces 56 of the guide member 52 .

[0056] Then, if Fig. 9 As shown, each of the two sheet feeding units 40 stops feeding the sheet 20 when the sheet 20 reaches the lower end of the magnet insertion hole 16. When the sheet insertion process is completed, as shown in FIG. Fig. 9 As shown, the two sheets 20 are in a state of extending toward each sheet supply source 41 while gradually spreading from the magnet insertion hole 16 on the upper side of the magnet insertion hole 16 .

[0057] Then, in Figure 6 In S106, Fig.10 As shown in FIG. 1 , the guide 52 is moved downward by the guide driving unit 50 and is pulled out from the magnet insertion hole 16 (guide pulling out step).

[0058] Then, in Figure 6 In S108, Fig.11 As shown, the main body 34 of the magnet supply part 32 loosens or releases the holding of the permanent magnet 18, thereby inserting the permanent magnet 18 into the magnet insertion hole 16 from between the two gradually expanding sheets 20 (magnet insertion process). At this time, the permanent magnet 18 is guided toward the magnet insertion hole 16 by the top end 36 of the magnet supply part 32. In addition, the permanent magnet 18 is guided into the magnet insertion hole 16 by the two gradually expanding sheets 20. The permanent magnet 18 descends in the magnet insertion hole 16 by gravity, and is supported by the protrusion 48 when it reaches the protrusion 48 of the workbench 46.

[0059] Then, in Figure 6 In the S110, Fig.11As shown, the two sheets 20 are cut along the upper end surface 72 of the rotor core 12 by the cutter 80 (sheet cutting step). The two sheets in the magnet insertion holes 16 are supported by the protrusions 48 of the table 46 .

[0060] Afterwards, in S112, the two sheets 20 in the magnet insertion holes 16 are heated, but this is done for all the sheets 20 in the magnet insertion holes 16 at once after the processing of S102 to S110 for all the magnet insertion holes 16 is completed. When the arrangement of the two sheets 20 and the permanent magnet 18 for one magnet insertion hole 16 is completed, the upper group (magnet supply unit 32 and two sheet supply units 40) located on the upper side of the rotor core 12 moves to the top of the next magnet insertion hole 16, and arranges the two sheets 20 and the permanent magnet 18 for the magnet insertion hole 16. In this way, two sheets 20 and the permanent magnet 18 are arranged for each magnet insertion hole 16. It should be noted that more than two upper groups can also be provided to process more than two magnet insertion holes 16 at the same time.

[0061] It should be noted that in order to insert the permanent magnet 18 to the lower end of the magnet insertion hole 16, it can be set as follows: after the permanent magnet 18 is inserted into all the magnet insertion holes 16, the lower surface of the inner circumferential side of the rotor core 12 is slightly lifted by another workbench, so that the protrusions 48 of the workbench 46 are moved out of the magnet insertion holes 16, thereby inserting each permanent magnet 18 to the lower end of each magnet insertion hole 16.

[0062] Then, in Figure 6 In S112, Fig.12 As shown in FIG. 1 , the heater 82 is arranged so as to approach each magnet insertion hole 16 from the outer periphery of the rotor core 12, and each sheet 20 located in each magnet insertion hole 16 is heated by the heater 82 (sheet heating step). Fig.13 As shown, the sheet 20 located in the magnet insertion hole 16 expands to fill the gap between the side surface of the permanent magnet 18 and the inner surface of the magnet insertion hole 16, so that the permanent magnet 18 is fixed in the magnet insertion hole 16. It should be noted that in this embodiment, the sheet heating process is performed after the arrangement of the two sheets 20 and the permanent magnet 18 for all the magnet insertion holes 16 is completed, but the sheet heating process may be performed each time the two sheets 20 and the permanent magnet 18 are arranged in one magnet insertion hole 16. Through the above process, the manufacture of the rotor 10 using the rotor manufacturing device 30 is completed.

[0063] The rotor core 12 is formed by stacking electromagnetic steel sheets, so the inner surface of the magnet insertion hole 16 has minute irregularities. According to the rotor manufacturing method 90 described above, in each magnet insertion hole 16, two sheets 20 are inserted into the magnet insertion hole 16 along the two long side surfaces 56 of the guide 52, so that the top end of the sheet 20 can be suppressed from approaching the inner surface 60 of the magnet insertion hole 16. Therefore, the top end of the sheet 20 will not be caught by the irregularities of the inner surface of the magnet insertion hole 16 or will not be easily caught by the irregularities of the inner surface of the magnet insertion hole 16, so that the top end of the sheet 20 can be suppressed from being broken or damaged.

[0064] In the absence of the guide 52, when two sheets 20 are simultaneously fed into the magnet insertion hole 16, one sheet 20 may be pushed by the other sheet 20 so that the tip of the sheet approaches the inner surface of the magnet insertion hole 16. In particular, since the sheet 20 of this embodiment is made of a brittle material including glass fiber, when the tip of the sheet approaches the inner surface of the magnet insertion hole 16 and is caught by the tiny unevenness of the surface, the tip of the sheet may be damaged. However, according to the rotor manufacturing method 90 described above, such a situation can be suppressed.

[0065] Next, a rotor manufacturing method according to another embodiment will be described. In the above-described embodiment, the two long side surfaces 19 (see Figure 2 ) is configured with the sheet 20, but the sheet 20 may also be configured on the two short side surfaces 19A of the permanent magnet 18. In addition, the sheet 20 may also be configured on all side surfaces 19, 19A of the permanent magnet 18.

[0066] Fig.14 : is a diagram schematically showing a rotor manufacturing device 30A in which sheets 20, 20A are arranged on all sides of a permanent magnet. In this figure, the sheet supply section 40, 40A of the rotor manufacturing device 30A is shown as viewed from above, and the magnet supply section of the rotor manufacturing device 30A is omitted. In this figure, a guide 52 is inserted into a magnet insertion hole 16 of the rotor core 12, but the state before the sheet 20, 20A is inserted into the magnet insertion hole 16 is shown. The rotor manufacturing device 30A is the same as the rotor manufacturing device 30 described above in terms of structure except for the sheet supply section. In addition, except for the sheet insertion process, the manufacture of the rotor by the rotor manufacturing device 30A is the same as the manufacture of the rotor by the rotor manufacturing device 30 described above.

[0067] The rotor manufacturing device 30A includes two sheet supply units 40 for supplying the sheet 20 to the two long side surfaces 56 of the guide 52, and two sheet supply units 40A for supplying the sheet 20A to the two short side surfaces 56A of the guide 52 (the side surfaces on the short side of the guide 52 when viewed from above the rotor core 12). The two sheet supply units 40 and the two sheet supply units 40A are arranged on the side surfaces of the main body (not shown) of the magnet supply unit, and are located on the upper side of the rotor core 12.

[0068] In the manufacture of the rotor by the rotor manufacturing device 30A, in the sheet inserting step, two sheets 20 are inserted into the magnet insertion hole 16 from the two sheet supply parts 40 along the two long side surfaces 56 of the guide 52, and two sheets 20A are inserted into the magnet insertion hole 16 from the two sheet supply parts 40A along the two short side surfaces 56A of the guide 52. The insertion of these sheets 20 and 20A is performed simultaneously. Then, after the insertion of the sheets 20 and 20A is completed, the guide extraction step, the magnet insertion step, the sheet cutting step, and the sheet heating step are performed in the same manner as the rotor manufacturing method described above.

[0069] In this rotor manufacturing method, four sheets 20, 20A are also inserted into the magnet insertion hole 16 along the side faces 56, 56A of the guide 52, thereby preventing the top end of each sheet 20, 20A from approaching the inner surface of the magnet insertion hole 16, and preventing the top end of each sheet 20, 20A from breaking or being damaged.

Claims

1. A rotor manufacturing method, characterized in that: have: an arrangement step of arranging a rotor core formed by stacking the electromagnetic steel sheets so that the stacking direction of the electromagnetic steel sheets faces the up-down direction; a guide inserting step of inserting a rod-shaped guide into the magnet insertion hole of the rotor core extending in the stacking direction after the arranging step; a sheet inserting step of inserting a plurality of sheets into the magnet insertion hole from the upper side of the rotor core along the respective side surfaces of the guide after the guide inserting step; a guide member extraction step of extracting the guide member from the magnet insertion hole after the sheet insertion step; as well as The magnet inserting step is to insert a permanent magnet between the plurality of sheets in the magnet insertion hole after the guide extracting step.

2. The rotor manufacturing method according to claim 1, characterized in that: In the guide inserting step, the guide is inserted into the magnet insertion hole from the lower side of the rotor core, and a portion of the guide is protruded from the upper end surface of the rotor core to form a guide protruding portion. In the sheet inserting step, the plurality of sheets are supplied from obliquely above to the respective side surfaces of the guide protruding portion.

3. The rotor manufacturing method according to claim 1 or 2, characterized in that: In the sheet inserting step, the plurality of side surfaces of the guide along which the plurality of sheets are arranged and inner surfaces of the magnet insertion holes facing the plurality of side surfaces are parallel in a plan view of the rotor core.

4. The rotor manufacturing method according to any one of claims 1 to 3, characterized in that: When the sheet inserting process is completed, the plurality of sheets gradually extend above the magnet insertion hole toward each sheet supply source. In the magnet inserting step, the permanent magnet is inserted into the magnet insertion hole from between the plurality of sheets that are gradually expanded.

5. The rotor manufacturing method according to claim 4, characterized in that: Each of the sheets has the property of expanding when heated, The rotor manufacturing method further comprises: a sheet cutting step of cutting each of the sheets at an upper end surface of the rotor core after the magnet inserting step; and The sheet heating step is to heat each of the sheets located in the magnet insertion hole after the sheet cutting step.

6. A rotor manufacturing device, characterized in that: have: a holding member that holds a rotor core formed by stacking electromagnetic steel sheets in such a manner that the stacking direction of the electromagnetic steel sheets is oriented in an up-down direction and has a magnet insertion hole extending in the stacking direction; a guide driving unit that inserts a rod-shaped guide into the magnet insertion hole of the rotor core held by the holding member, and pulls the guide out of the magnet insertion hole; a sheet supply unit that supplies a plurality of sheets from an upper side of the rotor core to the magnet insertion hole along respective side surfaces of the guide in a state in which the guide is inserted into the magnet insertion hole; as well as The magnet supply unit supplies a permanent magnet between the plurality of sheets in the magnet insertion hole in a state where the plurality of sheets are supplied to the magnet insertion hole and the guide is pulled out from the magnet insertion hole.

7. The rotor manufacturing device according to claim 6, characterized in that: The guide driving unit supplies the guide from the lower side of the rotor core to the magnet insertion hole, and causes a portion of the guide to protrude from the upper end surface of the rotor core as a guide protruding portion. The sheet supply unit supplies the plurality of sheets from obliquely above to each side surface of the guide protruding portion.

8. The rotor manufacturing device according to claim 6 or 7, characterized in that: When the guide is inserted into the magnet insertion hole, the side surfaces of the guide along which the sheets are arranged and the inner surfaces of the magnet insertion hole facing the side surfaces are parallel in a plan view of the rotor core.

9. The rotor manufacturing device according to any one of claims 6 to 8, characterized in that: When the supply of each sheet to the magnet insertion hole is completed, the plurality of sheets gradually extend above the magnet insertion hole toward each sheet supply source. The magnet supply unit supplies the permanent magnet to the magnet insertion hole from between the plurality of sheets that gradually expand.

10. The rotor manufacturing device according to claim 9, characterized in that: Each of the sheets has the property of expanding when heated, The rotor manufacturing device further comprises: a cutter for cutting each of the sheets at an upper end surface of the rotor core in a state where the permanent magnets are supplied to the magnet insertion holes; as well as The heater heats each of the sheets located in the magnet insertion hole in a state where each of the sheets is cut by the cutter.

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