Rotor manufacturing apparatus and rotor manufacturing method

Abstract

This invention relates to a rotor manufacturing apparatus and a rotor manufacturing method. The resin injection apparatus (30) for manufacturing a rotor of a rotary electric machine is provided with a resin injection machine (40) having an injection port (40A) for injecting resin, and also with a flow channel (60) having an inlet (60A) that can be connected to the injection port (40A), and a plurality of injection ports (60B) communicating with the inlet (60A) and disposed at positions corresponding to the holes (1B) in the rotor core (1A) where magnets are installed.

Description

Technical Field

[0001] This invention relates to an apparatus for manufacturing rotors for rotating electric machines and a method for manufacturing rotors. Background Technology

[0002] Generally, rotary motors used in vehicles such as hybrid vehicles and electric vehicles employ embedded magnet motors (IPMs). In manufacturing the rotor of such a rotary motor, a rotor core (laminated core) is formed by stacking perforated steel plates. Magnets are inserted into the holes, and thermosetting resin is injected into the holes and heated to fix the magnets to the rotor core, thus obtaining a rotor with magnets embedded in the rotor core. When injecting resin into the holes of the rotor core, the nozzle of the resin injection machine is aligned with the hole where the magnets of the rotor core are positioned, and the resin is injected directly into the hole from the nozzle (see Patent Document 1).

[0003] Patent Document 1: Japanese Patent Application Publication No. 2012-228032

[0004] However, in recent years, rotary motors used in hybrid vehicles, electric vehicles, and the like have become increasingly diversified, with the shape of the rotor and, in particular, the position of the holes for the magnets varying from product to product. However, if a single resin injection device is to be used to accommodate different rotor shapes, significant modifications to the resin injection machine are required to change the nozzle position, which hinders cost reduction. Summary of the Invention

[0005] Therefore, the object of the present invention is to provide a rotor manufacturing apparatus and a rotor manufacturing method that do not require changes to the resin injection machine and can manufacture rotors with different hole positions using the same resin injection machine.

[0006] The manufacturing apparatus for this rotor is used to manufacture rotors for rotating electric machines, and the manufacturing apparatus includes:

[0007] A resin injection machine having a first injection port for injecting resin; and

[0008] The flow channel has an inlet that can be connected to the first ejection outlet; and a plurality of second ejection outlets that communicate with the inlet and are disposed at positions corresponding to the holes in the rotor core where magnet components are installed.

[0009] Furthermore, the method for manufacturing this rotor involves placing a magnet component in a hole in the rotor core, injecting and curing resin, and then fixing the magnet component to the rotor core. This method for manufacturing the rotor of a rotating electric machine includes the following steps:

[0010] The injection device setting process involves setting the aforementioned rotor core in the setting section; and

[0011] In the resin injection process, a flow channel that can be mounted and detached relative to the aforementioned setting part is installed on the aforementioned setting part. The first injection port of the resin injection machine is connected to the inlet of the aforementioned flow channel. Resin from the aforementioned resin injection machine is injected into the holes of the aforementioned rotor core from a plurality of second injection ports arranged in the aforementioned flow channel at positions corresponding to the holes of the aforementioned rotor core.

[0012] Therefore, the flow channel can be changed according to the shape of the rotor core without changing the resin injection machine, and rotors with different hole positions can be manufactured using the same resin injection machine, thus reducing costs. Attached Figure Description

[0013] Figure 1 This is a flowchart illustrating each step of the rotor manufacturing method according to this embodiment.

[0014] Figure 2 This is a perspective view showing the rotor core and the lower plate of the retaining clamp.

[0015] Figure 3 It is a perspective view showing the state in which a rotor core is set on the lower plate of the retaining fixture.

[0016] Figure 4 It is a perspective view showing the state in which the clamp is kept mounted on the rotor core.

[0017] Figure 5 It is a cross-sectional view showing the state in which the injector is separated from the rotor setting part in the injection device.

[0018] Figure 6 This is a cross-sectional view showing the state in which the injection nozzle is installed in the rotor mounting section of the injection device.

[0019] Figure 7 It is a cross-sectional view showing the state in which the rotor core is set in the rotor setting section in the injection device.

[0020] Figure 8 It is a cross-sectional view showing the state of resin being injected into the rotor core in the injection device.

[0021] Figure 9 This is a cross-sectional view showing the state in which the rotor core, which has been filled with resin, is removed from the rotor mounting section in the injection device.

[0022] Figure 10 This is a cross-sectional view of the injection machine, representing the injection device.

[0023] Figure 11A This is a top view showing the injection nozzle.

[0024] Figure 11B This is a cross-sectional view showing the injection nozzle.

[0025] Figure 11C It is a top view showing the positional relationship between the rotor core and the injection nozzle.

[0026] Figure 12A It is an enlarged top view showing the positional relationship between the holes in the rotor core, the nozzle of the injection nozzle, and the gate, as well as the state of the resin after injection.

[0027] Figure 12B It is an enlarged sectional view showing the bore of the rotor core, the nozzle of the injection nozzle, and the gate.

[0028] Figure 12C It is an enlarged cross-sectional view showing the rotor core and the state of the resin after resin injection.

[0029] Figure 13A It is a cross-sectional schematic diagram illustrating the shape and positional relationship of the bore in the rotor core, the nozzle of the injection nozzle, and the gate.

[0030] Figure 13B This is a cross-sectional diagram illustrating the separation of resin from the gate after resin injection.

[0031] Figure 14A This is a top view showing the other injection nozzles that can be replaced.

[0032] Figure 14B This is a cross-sectional view showing the other injection nozzles that can be replaced.

[0033] Figure 15 This is a cross-sectional view showing the state in which a replacement injection nozzle is installed in the rotor mounting section of the injection device. Detailed Implementation

[0034] The following description of this embodiment will be based on the figures.

[0035] [Brief Structure of the Rotor]

[0036] First, let's briefly explain, for example, the structure of the rotor of a hybrid drive system or the drive motor (rotating motor) of an electric vehicle. The drive motor generally consists of a stator and a rotor (rotating component). For example... Figure 2 As shown, the rotor 1 has a rotor core 1A formed by stacking steel plates 1a, which are formed with multiple holes 1b by stamping or other processes. Multiple holes 1B are formed in the rotor core 1A by stacking the steel plates 1a along the stacking direction while ensuring the holes 1b are in phase. Figure 3 As shown, magnets 1M, which serve as magnet components, are inserted into and disposed in each of these holes 1B. In this state, the magnets 1M are fixed to the holes 1B using resin, thereby forming a rotor 1 in which the magnets 1M are embedded in the rotor core 1A.

[0037] [Overview of rotor manufacturing method]

[0038] Next, a summary of the rotor manufacturing method of this embodiment will be described. For example... Figure 1 As shown, the manufacturing method of this rotor includes a steel plate stacking process S1, in which stacked steel plates 1a are formed to constitute a rotor core 1A; a magnet setting process S2, in which magnets 1M are inserted into and set in the holes 1B of the rotor core 1A; and a clamping process S3, in which a holding clamp 10 is installed on the rotor core 1A. Furthermore, the manufacturing method of this rotor includes a heating process S4, in which the rotor core 1A is heated; an injection device setting process S5, in which the rotor core 1A is placed in a resin injection device 30 for resin injection; and a resin injection process S6, in which resin is injected into the holes 1B of the rotor core 1A through the resin injection device 30. Moreover, the manufacturing method of this rotor includes a magnet fixing process S7, in which the injected resin is cured to fix the magnets 1M to the rotor core 1A; a clamping removal process S8, in which the holding clamp 10 is removed from the rotor core 1A; and a cooling process S9, in which the rotor core 1A is cooled. The aforementioned processes are carried out sequentially on the factory production line, for example, while the rotor core 1A is moved by a conveyor belt. In addition, although the stacking of the steel plates 1a in the steel plate stacking process S1 described later is adjusted by the operator, in other processes, the conveying of the rotor core 1A, the installation and removal of the holding fixture 10, etc., are carried out by factory equipment such as multi-joint robots.

[0039] [Details of the steel plate lamination process]

[0040] First, use Figure 2 The detailed process of steel plate lamination S1 is explained. For example... Figure 2 As shown, the rotor core 1A is formed, for example, by stamping or other processes, into a hollow circular plate symmetrical about its center point. It is constructed by sequentially overlapping stacked steel plates 1a, each having multiple holes 1b, onto the upper surface 11b of the lower plate 11 of the retaining fixture 10, which will be detailed later. Because each stacked steel plate 1a has slight tolerances, the operator adjusts the phase along the circumference of the hollow circular plate while stacking, so that the uppermost stacked steel plate 1a is stacked with a decreasing tilt relative to a plane orthogonal to the stacking direction (i.e., the horizontal direction). Furthermore, when stacking the steel plates 1a, they can be stacked on the upper surface 11b of the lower plate 11 of the retaining fixture 10 as described above, or they can be stacked at other locations to form the rotor core 1A before being placed on the upper surface 11b of the lower plate 11 of the retaining fixture 10.

[0041] The lower plate 11 of the retaining clamp 10 is a hollow plate-shaped component with a hole 11a formed in the center. A support plate 16 for positioning and supporting the rotor core 1A is fixed in the hole 11a. Furthermore, a first shaft 14 and a second shaft 15 shorter than the first shaft 14 are respectively erected at four positions on the lower plate 11. Thus, when the rotor core 1A is placed on the upper surface 11b of the lower plate 11, the support plate 16 abuts against a portion of the inner circumferential surface of the rotor core 1A, and the second shaft 15 abuts against a portion of the outer circumferential surface, thereby restricting horizontal movement. The relative position of the lower plate 11 and the rotor core 1A is positioned and supported by the lower plate 11. Additionally, multiple air holes 11c are formed on the lower plate 11 at positions overlapping with the hole 1B in the stacking direction when the rotor core 1A is placed. These air holes 11c are formed through the lower plate 11 and serve as venting holes for resin injection, as described later.

[0042] [Details of the magnet setting process]

[0043] Next, use Figure 3 The details of magnet setting process S2 are explained below. For example... Figure 3 As shown, the rotor core 1A, which is disposed on the lower plate 11 of the retaining clamp 10, has multiple holes 1B formed by stacking the holes 1b of the laminated steel plates 1a. Magnets 1M are inserted into and disposed in each hole 1B. Furthermore, in Figure 3 In the rotor core 1A shown, although the configuration is illustrated with the long side of the magnet 1M oriented circumferentially, in this embodiment, as... Figure 11C As shown, assume that the long side of magnet 1M is tilted relative to the circumference, and the two magnets 1M are arranged in a V-shape when viewed from above. Furthermore, magnets are typically demagnetized by heating, so the magnet 1M at this stage is made of the material it was before being magnetized.

[0044] [Details of the fixture installation process]

[0045] Next, use Figure 4 The details of the fixture installation process S3 will be explained. First, the structure of the retaining fixture 10 will be explained.

[0046] like Figure 4As shown, the retaining clamp 10 generally includes a lower plate 11, a pressing plate 12, and an upper plate 13, which are arranged approximately parallel to each other in the vertical direction. As described above, a rotor core 1A is disposed on the upper surface 11b of the lower plate 11, and a pressing plate 12 is disposed above the rotor core 1A in a manner that abuts against the lower surface 12b of the pressing plate 12. The pressing plate 12 is a hollow plate-shaped component with a hole 12a formed in the center, and a plurality of injection holes 12c for injecting resin are formed through it, as will be described in detail later, located above the hole portion 1B of the rotor core 1A. In addition, a plurality of through holes 12d through which the second shaft 15 described above can pass are formed in the pressing plate 12.

[0047] The upper plate 13 is a hollow plate-shaped component with a hole 13a formed in the center, and is fastened to the upper end of the second shaft 15 by bolts 21. Furthermore, a helical spring 23 is compressed between the pressing plate 12 and the upper plate 13. A support shaft (not shown) is arranged inside the helical spring 23, and this support shaft is fixed to the upper plate 13 by bolts 22, thereby positioning and supporting the helical spring 23. The retaining clamp 10 configured in this way is pressed and clamped by the lower plate 11 and the pressing plate 12, which is pressed from the upper plate 13 by the helical spring 23. Thus, the multiple stacked steel plates 1a of the rotor core 1A are held in a state where they are pressed in the stacking direction and in contact with as little gap as possible in the stacking direction. In addition, the upper end of the first shaft 14 is configured to face the lower surface of the pressing plate 12, and abuts against the pressing plate 12 when the pressing plate 12 is pressed downwards by the helical spring 23, without crushing the rotor core 1A in the stacking direction.

[0048] In the fixture installation process S3, when the retaining fixture 10 configured as described above is installed on the rotor core 1A, the rotor core 1A is placed on the upper surface 11b of the lower plate 11, the second shaft 15 passes through the through hole 15d, and the pressing plate 12 is placed above the rotor core 1A. A helical spring 23 is clamped between the pressing plate 12 and the upper plate 13, and the second shaft 15 and the upper plate 13 are fastened by bolts 21. Thus, the retaining fixture 10, which presses and holds the rotor core 1A along the stacking direction, is installed on the rotor core 1A.

[0049] [Details of the heating process]

[0050] Next, the details of the heating process S4 will be explained. In this embodiment, the resin used to fix the magnet 1M to the hole 1B of the rotor core 1A is, for example, a thermosetting resin material that is solid at room temperature, has a melting point of 60 degrees Celsius, a curing point of 120 degrees Celsius, and is used. If the rotor core 1A has a melting point lower than its melting point, there is a concern that the resin may solidify midway during resin injection in the resin injection process S6 described later, resulting in insufficient filling of the hole 1B. Therefore, the rotor core 1A needs to be at or above its melting point during resin injection. Furthermore, in this embodiment, there is a possibility that resin may leak from the tiny gaps between the laminated steel plates 1a when it is injected into the hole 1B. Therefore, by ensuring that the rotor core 1A is at or above its curing point during resin injection, curing begins from the resin in contact with the hole 1B, preventing resin leakage from between the laminated steel plates 1a.

[0051] Based on the above background, in the heating step S4, the rotor core 1A (with the holding clamp 10 installed) held by the holding clamp 10 is, for example, placed into a heating device such as a high-frequency heater and heated to above the resin's initial melting temperature, preferably above the initial curing temperature. In this embodiment, in the heating step S4, the rotor core 1A is heated to, for example, approximately 150 degrees Celsius.

[0052] [Detailed instructions for setting up the injection device]

[0053] Next, use Figure 5 , Figure 6 , Figure 7 , Figure 8 , Figure 10 The details of the resin injection device setting process S5, in which the rotor core 1A held by the holding fixture 10 is placed in the resin injection device 30 for resin injection, will be explained. First, the structure of the resin injection device 30, which is a rotor manufacturing device for manufacturing rotors, will be explained.

[0054] like Figure 6 As shown, the resin injection device 30, in a narrow sense, includes a resin injection machine 40 and a worktable section 50 as a mounting section for mounting the rotor core 1A. A flow channel 60 is provided in the worktable section 50, thus, in a broader sense, it constitutes a resin injection device 30 for injecting resin into the rotor core 1A. For example... Figure 10As shown, the resin injection machine 40 comprises: an injection section 47 having a resin injection port 48 formed at its upper end, which serves as a resin material injection port 40B for injecting solid resin; a screw 46 that feeds the resin injected from the resin material injection port 40B into a flow path 49 while melting and stirring; a cylindrical section 41 having a flow path 44 communicating with the flow path 49; a nozzle section 42 fixed to the lower end of the cylindrical section 41 and forming an injection port 40A as a first injection port from which resin is injected from the lower end; a shut-off valve 43 serving as a first valve for opening and closing the flow of resin from the flow path 49 to the flow path 44 via an on / off valve 43a; and a plunger 45 that ejects resin from the flow path 44 from the injection port 40A. Figure 8 As shown, the resin injection machine 40 is equipped with a temperature control device 81, which is a first temperature control device capable of heating or cooling via, for example, a heating wire or a refrigerant supply. To maintain the resin located between the resin inlet 40B and the injection outlet 40A in a molten state, the temperature control device 81 adjusts the resin temperature to approximately 80 degrees Celsius, above the initial melting temperature and below the initial curing temperature. Specifically, the temperature control device 81 melts the room-temperature solid resin injected into the resin inlet 40B by heating the screw 46 and maintains the resin in a molten state.

[0055] On the other hand, such as Figure 6 As shown, the worktable portion 50 includes a lower plate 51 disposed on the lower side; a side wall 53 fixed to the side end of the lower plate 51; and an upper plate 52, which is supported by the side wall 53 and disposed parallel to the lower plate 51 above it, serving as a support portion for the flow channel 60. Furthermore, a hole 51a is formed in the central portion of the lower plate 51, and the worktable portion 50 includes a mounting platform 55 formed to match the shape of the hole 51a, with its upper surface 55a serving as a base for the lower plate 11 holding the clamp 10; and a drive device 59 that controls the drive portion of the mounting platform 55, capable of both lifting and rotating. Furthermore, although the illustration is omitted, a protrusion is provided on the upper surface 55a of the setting platform 55, and a recess is provided on the lower surface of the lower plate 11 of the retaining clamp 10. When the retaining clamp 10 is set on the setting platform 55, these protrusions and recesses are engaged, thereby keeping the clamp 10 positioned relative to the setting platform 55 in the rotational direction. That is, the rotational direction of the retaining clamp 10 and the rotor core 1A is controlled by the rotation of the setting platform 55.

[0056] In addition, such as Figure 5As shown, a mounting hole 52a is formed in the upper plate 52 of the worktable portion 50, allowing the upper shaft portion 62 of the flow channel 60 to fit into the mounting hole 52a, thereby enabling the flow channel 60 to be detachably mounted. The flow channel 60 generally comprises an inlet 60A that fits into the injection port 40A of the resin injection machine 40, and multiple injection ports 60B formed in the branch nozzle 63 that branch out the resin injected from the inlet 60A. Detailed description of the structure of this flow channel 60 will be provided later.

[0057] In the injection device setting step S5, where the rotor core 1A equipped with the retaining clamp 10 is placed in the resin injection device 30 configured as described above, firstly, as... Figure 5 As shown, with the resin injection machine 40 removed from the worktable section 50 and the setting table 55 lowered such that the upper surface 55a is in the same position as the lower plate 51, as... Figure 6 As shown, the flow channel 60 is mounted on the upper plate 52 by fitting the upper shaft portion 62 of the flow channel 60 (details to be described later) into the mounting hole 52a of the upper plate 52. From this state, as... Figure 7 As shown, the rotor core 1A, equipped with the retaining clamp 10, is placed on the mounting table 55. At this time, as described above, the protrusion (not shown) on the upper surface 55a of the mounting table 55 and the recess (not shown) on the lower plate 11 of the retaining clamp 10 are fitted together to fix it in a manner that prevents it from moving in the rotational direction. Then, as... Figure 8 As shown, the setting platform 55 is raised by the drive device 59, so that the branch nozzle 63, which has the injection outlet 60B (described later), is inserted into the through hole 13c formed in the upper plate 13 of the holding clamp 10 and the injection hole 12c formed in the pressing plate 12, and the front end of the branch nozzle 63 is pressed against the injection hole 12c, thereby setting the rotor core 1A relative to the resin injection device 30.

[0058] [Resin Injection Process]

[0059] Next, use Figure 8 , Figure 12A , Figure 12B , Figure 12C The details of the resin injection process S6 will be explained. First, the positional relationship between the injection hole 12c of the pressing plate 12 of the retaining fixture 10 and the hole 1B of the rotor core 1A, as well as the shape of the injection hole 12c, will be explained. Furthermore, Figure 12B It shows Figure 12A AA-direction view section, Figure 12C It shows that in relation to Figure 12B The rotor core 1A was removed from the holding clamp 10 at the same position.

[0060] like Figure 12AAs shown, with the retaining clamp 10 mounted on the rotor core 1A, the injection hole 12c of the pressing plate 12 is positioned to overlap at least partially with the hole 1B of the rotor core 1A. Specifically, the center of the injection hole 12c is configured to be located on the inner diameter side of the rotor core 1A relative to the hole 1B. When resin is injected into the hole 1B, the pressure of the resin pushes the magnet 1M towards the outer periphery. Thus, the magnet 1M is close to the outer diameter side of the rotor core 1A; that is, when assembled as a rotary motor on the stator, the magnet 1M is as close to the stator as possible, strengthening the magnetic force and improving the output and efficiency of the rotary motor.

[0061] like Figure 12B As shown, the injection hole 12c of the pressing plate 12 of the retaining clamp 10 is formed with: a first inclined surface 12ca whose inner diameter gradually decreases so as to be pressed and fitted by the conical inclined surface 63a at the front end of the branch nozzle 63 of the flow channel 60, and which becomes a sealed state when fitted; and a second inclined surface 12ca disposed below the first inclined surface 12ca (on the rotor core 1A side), inclined at an acute angle θ relative to the center of the injection hole 12c, so that the inner diameter of the injection hole 12c is oriented toward the rotor core 1A in the through direction of the injection hole 12c. A. A smaller, tapered second inclined surface 12cb; a step portion 12cc formed between the first inclined surface 12ca and the second inclined surface 12cb to prevent the branch nozzle 63 from entering the step portion 12cc of the second inclined surface 12cb; a small diameter portion 12ce formed at the front end below the second inclined surface 12cb, with the smallest aperture, functioning as a throttling portion; and an enlarged opening portion 12cd that extends horizontally (in a direction orthogonal to the through direction) below the small diameter portion 12ce and becomes the opening of the injection hole 12c.

[0062] Furthermore, in this embodiment, the angle θ of the second inclined surface 12cb is, for example, 30 degrees, but any acute angle is acceptable, that is, any angle greater than 0 degrees and less than 45 degrees is acceptable. Additionally, the opening 12cd is enlarged in this embodiment, for example... Figure 12A As shown, when viewed from above, the portion including the small diameter 12ce is formed as a rectangle extending horizontally, but it is not limited to this. In the cross-sectional view, it can be any shape, such as a circle, an ellipse, or an elongated hole, as long as the cross-sectional area in the horizontal direction is wider than the small diameter 12ce. The enlarged opening 12cd is formed such that, when the pressing plate 12 abuts against the upper surface 1Aa of the rotor core 1A, it spans the upper surface 1Aa of the rotor core 1A and the hole 1B. In addition, the small diameter 12ce is formed, for example, with a diameter of about 1 mm to 5 mm, and the thickness of the enlarged opening 12cd in the vertical direction is, for example, about 0.5 mm.

[0063] In the resin injection process S6, where resin is injected into the hole 1B of the rotor core 1A through the injection hole 12c of the pressing plate 12 of the holding clamp 10 configured in this way, as... Figure 8 As shown, in the resin injector 40 of the resin injection device 30, the resin in the flow path 44 is pressed by opening the shut-off valve 43 and using the plunger 45 (see reference). Figure 10 Resin is ejected from the injection port 40A into the inlet 60A of the flow channel 60, and resin is ejected from each injection port 60B of the flow channel 60 into each hole 1B. The resin presses the magnet 1M toward the outer diameter side of the rotor core 1A and fills the area around the magnet 1M with resin.

[0064] At this time, the air inside the hole 1B is discharged through the air hole 11c of the lower plate 11 of the retaining clamp 10, and the resin is filled into the hole 1B without gaps. Furthermore, the rotor core 1A is heated to a temperature higher than the initial curing temperature of the resin, as described above, so curing begins from the portion of the resin filled into the hole 1B that contacts the side of the hole 1B. This prevents resin from leaking out through the gaps between the laminated steel plates 1a. Figure 12C As shown, the resin 99 is filled into the opening portion of the hole 1B, and the enlarged opening 12cd is also filled while slightly expelling air. A rectangular, plate-shaped resin plate 99a is formed, spanning the upper surface 1Aa of the hole 1B and the rotor core 1A. Furthermore, the function of this plate 99a will be explained in detail in the fixture removal process S8 described later.

[0065] [Details of the magnet fixing process]

[0066] Next, the details of the magnet fixing process S7 will be explained. For example... Figure 9As shown, once the resin injection process S6 is completed, the rotor core 1A, with the retaining clamp 10 mounted on it, is removed from the settable 55 from the resin injection device 30. In this state, the rotor core 1A, with the retaining clamp 10 mounted on it, is heated by a heating device (not shown) to maintain the temperature at approximately 150 degrees Celsius above the initial curing temperature of the resin. That is, the resin filling the hole 1B of the rotor core 1A begins to cure from the portion in contact with the rotor core 1A during injection, as described above. However, there are still uncured portions inside the hole 1B. Therefore, in the magnet fixing process S7, the heated state is maintained until the resin in the hole 1B is maintained above the initial curing temperature and completely cured. Maintaining the temperature above the initial curing temperature for a specified time period allows the magnet 1M to be completely fixed to the hole 1B of the rotor core 1A using the resin. Furthermore, although this embodiment describes heating the rotor core 1A to a temperature of approximately 150 degrees Celsius using a heating device in the magnet fixing process S7, it is possible to heat it to a temperature higher than this (e.g., approximately 170 degrees Celsius) in order to accelerate resin curing.

[0067] As described above, once the resin curing is completed in the magnet fixing process S7, the rotor core 1A is completed as rotor 1. Furthermore, the rotor shaft and the like are then mounted on rotor 1 to form a rotor with a shaft, constituting a rotor in a broader sense as a component of a rotary electric machine.

[0068] Furthermore, although the heating process S4 and the magnet fixing process S7 are described separately in this embodiment, as mentioned above, the heating of the rotor core 1A begins in the heating process S4 and continues until the magnet fixing process S7 maintains the temperature of the rotor core 1A above the resin's initial curing temperature. Therefore, the heating process in a broad sense continues until the heating process S4, the injection device setting process S5, the resin injection process S6, and the magnet fixing process S7. In other words, although the heating process S4 occurs before the resin injection, it is performed to allow the resin to cure, so it can also be considered a process of fixing the magnet 1M to the rotor core 1A.

[0069] [Details of the fixture removal process]

[0070] Next, the details of the clamp removal process S8 will be explained. If the magnet 1M is completely fixed to the hole 1B of the rotor core 1A through resin curing in the aforementioned magnet fixing process S7, then the retaining clamp 10 will be removed from the rotor core 1A (rotor 1). That is, the retaining clamp 10 will be removed from the rotor core 1A in the reverse order of the installation sequence of the retaining clamp 10 relative to the rotor core 1A in the clamp installation process S3. Specifically, the clamp is released... Figure 4The bolt 21 is tightened and the upper plate 13 and coil spring 23 are removed. Then, the lower plate 11 is removed by pulling out the pressing plate 12 from the second shaft 15, becoming... Figure 3 As shown in the diagram, finally, the rotor core 1A is removed from the lower plate 11 facing upwards, thus ending the fixture removal process S8.

[0071] Here, using Figure 13A as well as Figure 13B The separation of resin by the injection hole 12c of the pressing plate 12 of the retaining clamp 10 will be described. Furthermore, Figure 13A as well as Figure 13B The diagram shown is schematic for ease of explanation. For the detailed shape of the injection hole 12c, Figure 12B The shape shown is correct.

[0072] Typically, after resin is filled from the nozzle, if the nozzle is removed, uncured resin extends in a linear fashion, sometimes creating what is known as burrs. To prevent these burrs from contacting surrounding components inside the rotating motor or from falling into the motor itself, a deburring process is required to cleanly remove them. However, such a deburring process requires specialized equipment, and automating it is difficult, necessitating the allocation of operators and raising concerns about increased costs. Therefore, in this embodiment, the injection hole 12c is characterized in shape to eliminate the need for deburring.

[0073] In the above resin injection process S6, such as Figure 13A As shown, with the branch nozzle 63 of the flow channel 60 inserted into the injection hole 12c of the pressing plate 12 and pressed against it, resin is injected into the hole 1B of the rotor core 1A. At this time, the position of the injection outlet 60B is such that the branch nozzle 63 does not enter the second inclined surface 12cb due to the step portion 12cc, so it is located on the side of the second inclined surface 12cb in the through direction, closer to the small diameter portion 12ce of the injection hole 12c. It is located lower than the injection outlet 60B of the branch nozzle 63, and is filled with resin 99, especially in the portion surrounded by the second inclined surface 12cb and the portion surrounded by the enlarged opening portion 12cd. Figure 13B As shown, the plate portion 99a is formed by the enlarged opening 12cd (refer to...). Figure 12C Furthermore, a conical portion 99b is formed from the second inclined surface 12cb in a conical shape, connected to the plate portion 99a. At this time, a narrow-diameter portion 12ce forms a horizontally tapering intermediate portion between the resin plate portion 99a and the conical portion 99b. In this embodiment, the injection port 60B is located at the end of the first inclined surface 12ca, but it can also enter the middle of the second inclined surface 12cb.

[0074] Furthermore, in the fixture removal process S8, when the pressing plate 12 is removed from the upper surface 1Aa of the rotor core 1A, if the pressing plate 12 is separated from the rotor core 1A, the second inclined surface 12cb will pull upwards in a manner that grips the conical portion 99b, causing the shear stress to concentrate on the weaker, tapered middle portion, leading to its breakage. Additionally, when the pressing plate 12 is pulled upwards, the conical portion 99b pulls the plate portion 99a, but... Figure 12A As shown, the plate portion 99a spans the hole portion 1B and the upper surface 1Aa of the rotor core 1A, and the plate portion 99a is formed to be bonded to the rotor core 1A with an area greater than or equal to the cross-sectional area of ​​the small diameter portion 12ce. Therefore, most of the tensile stress is borne by the upper surface 1Aa of the rotor core 1A, which can prevent the resin 99 through the hole portion 1B from stretching the magnet 1M and affecting the positional accuracy of the magnet 1M. Furthermore, in Figure 13B Although the fracture portion 99bx of the conical portion 99b and the fracture portion 99ax of the plate portion 99a are shown to be concave and convex respectively, due to changes in temperature and tensile strength, they may sometimes be roughly smooth or have opposite concavity and convexity. Furthermore, when the branch nozzle 63 leaves the injection hole 12c, resin may sometimes extend linearly from the injection outlet 60B, generating burrs. However, the portion generating these burrs is in the upper part of the conical portion 99b, and the conical portion 99b is ultimately discarded. Therefore, even if burrs are generated in this part, they will not remain in the rotor core 1A.

[0075] As described above, in the fixture removal process S8, when the pressing plate 12 of the holding fixture 10 is removed from the rotor core 1A, the conical portion 99b can be cleanly broken from the resin plate portion 99a, eliminating the need for a deburring process, for example. Furthermore, since the holding fixture 10 is removed before cooling in the cooling process S9 (described later), the separation between the lower plate 11 and the resin in the hole portion 1B of the rotor core 1A, and between the pressing plate 12 and the aforementioned resin plate portion 99a and hole portion 1B, can be performed while the resin is still hot and not cooled. This separation can be performed before the resin cools and strengthens the fixation, making the removal of the holding fixture 10 easier. Additionally, the conical portion 99b remaining in the injection hole 12c of the pressing plate 12 is removed and discarded, for example, by being pushed out with a pin. Then, the holding fixture 10, which also includes the air hole 11c of the lower plate 11, is cleaned with a brush or the like and reused in the manufacture of the next rotor core 1A.

[0076] [Details of the cooling process]

[0077] Finally, the details of the cooling process S9 will be explained. As described above, in the clamp removal process S8, after the retaining clamp 10 is removed from the rotor core 1A (rotor 1), the rotor core 1A with the retaining clamp 10 removed and the retaining clamp 10 removed from the rotor core 1A are placed together into the cooling device, so that the rotor core 1A and the retaining clamp 10 are cooled separately inside the cooling device. That is, if the retaining clamp 10 is installed in the rotor core 1A, especially in the state where the lower plate 11 and the pressing plate 12 are in contact with and cover the two sides of the rotor core 1A in the vertical direction, removing the retaining clamp 10 results in a larger surface area exposed in the rotor core 1A than the area before removal, thus improving the cooling efficiency. In addition, since the retaining clamp 10 also has a large heat capacity, it is difficult to cool when the retaining clamp 10 is installed in the rotor core 1A due to its large heat capacity. However, by separating them, their respective heat capacities are reduced, thus improving the cooling efficiency. This shortens the cooling time of the rotor core 1A, and also shortens the cooling time of the holding clamp 10.

[0078] [Detailed structure of the flow channel]

[0079] Next, use Figure 11A , Figure 11B as well as Figure 11C The detailed structure of the flow channel 60 will be explained. Furthermore, in this embodiment, the flow channel 60 is configured to match the shape of the rotor core 1A, where the hole 1B is formed at 32. This is a specially designed component used in the manufacture of the rotor 1, so when manufacturing rotors of other shapes, it is replaced with a shape consistent with that of the rotor core. A shape consistent with other rotor core shapes means that the position of the injection port 60B, the shape of the inlet 60A, and the shape of the upper shaft portion 62 (described later) are changed according to the number and arrangement of the holes in the rotor core so that it can correspond to the resin injection machine 40 and the worktable portion 50 even when changed. Regardless of the type, the flow channel is formed to have a substantially similar shape.

[0080] like Figure 11A as well as Figure 11BAs shown, the flow channel 60 of this embodiment comprises a circular plate-shaped main body 61, an axial upper shaft portion 62 extending upward from the center of the main body 61, and a plurality of branch nozzles 63 extending downward from the outer periphery below the main body 61. The upper shaft portion 62 is configured to be detachable from the mounting hole 52a of the upper plate 52 of the worktable portion 50. In addition, in this embodiment, the number of branch nozzles 63 is set to be half the number of holes 1B of the rotor core 1A, that is, when the number of holes 1B (i.e., magnets 1M) of the rotor core 1A is 32, the number of branch nozzles 63 is configured to be 16. This is because the number of holes 1B of the rotor core 1A is as high as 32, and the holes 1B are close to each other. On the other hand, in order for the wall thickness of the branch nozzles 63 with injection outlets 60B to be sufficient to withstand the pressure of the resin, it is not possible to prepare injection outlets 60B corresponding to the number of holes 1B without making the injection outlets 60B close to each other.

[0081] Inside the flow channel 60, such as Figure 11B As shown, the injection flow path 67, which serves as the resin inlet 60A at its upper end, is formed in the vertical direction along the central axis of the circular plate-shaped upper shaft portion 62 and the main body 61. Furthermore, as... Figure 11C As shown, a branch flow path 68 is formed inside the main body 61, branching from the input flow path 67 toward the branch nozzle 63. The branch flow path 68 is formed as follows: a radial flow path 68A, branching into eight horizontally in a direction orthogonal to the central axis from the input flow path 67; and circumferential flow paths 68B, branching out on both sides in a circumferential direction on the outer periphery of the radial flow path 68A. Furthermore, as... Figure 11B As shown, inside the main body 61 and each branch nozzle 63, an injection flow path 69 is formed downwards from the circumferential end of the circumferential flow path 68B of the branch flow path 68, and an injection outlet 60B, serving as a second injection outlet, is formed at the lower end of the injection flow path 69. Furthermore, a shut-off valve 64, serving as a second valve for opening and closing the injection outlet 60B, is provided inside each injection flow path 69.

[0082] Additionally, the flow channel 60 is provided with heating wires 65 arranged in a circumferential manner, and refrigerant flow paths 66 also arranged in a circumferential manner. These heating wires 65 and refrigerant flow paths 66 are connected with... Figure 8The temperature control device 82 shown is connected as a second temperature control device. Since the flow channel 60 is separated from the pressing plate 12 of the holding clamp 10, the flow channel 60 is affected by thermal interference from the holding clamp 10 and the rotor core 1A. Therefore, the temperature control device 82 adjusts the temperature to maintain the resin temperature between the inlet 60A and the outlet 60B at approximately 80 degrees Celsius above the initial melting temperature and below the initial curing temperature, for example, below the initial curing temperature, by supplying current to the heating wire 65 for heating or supplying refrigerant to the refrigerant flow path 66 for cooling. As described above, the temperature control device 81 performs temperature management in the resin injection machine 40 for melting the resin, and the temperature control device 82 performs temperature management corresponding to temperature changes caused by interference in the flow channel 60; that is, they can perform temperature management independently.

[0083] [Details of the resin injection process]

[0084] Next, the usage state of the flow channel 60 and the operation of the worktable 50 in the resin injection process S6 will be explained. If resin is injected from the injection port 40A of the resin injector 40 into the inlet 60A of the flow channel 60, the resin flows from the inlet flow path 67 of the flow channel 60 into eight radial flow paths 68A and then flows from each radial flow path 68A through the circumferential flow path 68B to the injection port 60B of the 16 branch nozzles 63. By opening each shut-off valve 64, the resin is injected from the injection port 60B at position 16 into each injection hole 12c, and resin is injected from these injection holes 12c into the hole 1B at position 16 of the rotor core 1A.

[0085] Thus, once the resin filling of the eight holes 1B in the rotor core 1A is complete, then as... Figure 7 As shown, the setting platform 55 is lowered by the drive device 59, causing the rotor core 1A, on which the holding clamp 10 is mounted, to leave the branch nozzle 63. Then, the setting platform 55 is rotated by the drive device 59 to perform phase matching so that the branch nozzle 63 is positioned above the unfilled resin hole 1B, and then the setting platform 55 is raised to insert and position the branch nozzle 63 into the injection hole 12c where no resin has been injected. Then, resin injection is performed in the same manner as described above, and the remaining 16 holes 1B in the 32 holes 1B are also filled with resin, thus ending the resin injection process S6. Furthermore, when resin is injected from the injection port 60B into the holes 1B of the rotor core 1A, the shut-off valve 64 is opened to inject resin, and when injection is complete, the injection port 64B is closed by the shut-off valve 64 to stop the injection of resin from the injection port 60B.

[0086] At this time, the injection path 67, branch path 68, and multiple injection paths 69 from the inlet 60A to the outlet 60B of the flow channel 60 are filled with resin for the next resin injection. The capacity of the injection path 67, branch path 68, and multiple injection paths 69 is designed such that the amount of resin filling the flow channel 60 is greater than the amount of resin injected at once from the multiple injection paths 69 toward each hole 1B. As a result, until the next injection, the temperature of the resin inside the flow channel 60 can be maintained at approximately 80 degrees Celsius, above the initial melting temperature and below the initial curing temperature, by the temperature regulating device 82, so that the resin at the appropriate temperature can be injected into the hole 1B of the rotor core 1A.

[0087] Furthermore, this resin injection process S6 occurs when resin is injected into the next rotor core 1A; in other words, before the flow channel 60 is changed to manufacture rotor cores of different shapes. Figure 9 The diagram shows the situation where the injection port 40A of the resin injection machine 40 is engaged with the inlet port 60A of the flow channel 60. That is, when changing the flow channel 60, as... Figure 6 The resin injector 40 is raised so that the injection port 40A leaves the inlet 60A. In this state, the flow channel 60 is removed from the worktable section 50, and the next flow channel 60 is placed on the worktable section 50. In this way, when changing the flow channel 60, the resin injection can be stopped from the injection port 40A by the shut-off valve 43 of the resin injector 40, thus preventing resin leakage.

[0088] In this embodiment, since the rotor core 1A mounted on the mounting platform 55 moves relative to the flow channel 60, at least during the resin injection process S6, it is not necessary to move the flow channel 60 and the resin injection machine 40. Compared to the case where the resin injection machine 40 is moved every time resin is injected, the drive mechanism can be simplified, and the structure of the resin injection machine 40 can be simplified. In addition, since it is not necessary to move the flow channel 60 and the resin injection machine 40, it is also not necessary to move the temperature control device 81 and the temperature control device 82. For example, the wiring that supplies current to the heating wire 65 and the piping that delivers refrigerant to the refrigerant flow path 66 do not need to be moved, and their structure can also be simplified.

[0089] [Structure of other flow channels]

[0090] Next, the structure of flow channel 160, which differs from the flow channel 60 described above, will be explained. For example... Figure 14A as well as Figure 14B As shown, the flow channel 160 is formed with a smaller outer diameter than the flow channel 60 mentioned above. That is, it is a flow channel for injecting resin into a rotor core whose position (i.e., outer diameter) is smaller than the diameter of the rotor core 1A mentioned above.

[0091] That is, the flow channel 160 is the same as the flow channel 60 described above, comprising a circular plate-shaped main body 161, an axial upper shaft portion 162 extending upward from the center of the main body 161, a plurality of branch nozzles 163 extending downward from the outer periphery below the main body 161, and a plurality of shut-off valves 164 disposed on each of these branch nozzles 163. Similarly, inside the flow channel 160, an inlet flow path 167, whose upper end becomes a resin inlet 160A, is formed in the vertical direction along the central axis of the upper shaft portion 162 and the circular plate-shaped main body 161. Furthermore, inside the main body 161, a branch flow path 168 is formed that branches from the inlet flow path 167 toward the branch nozzles 163, and an injection flow path 169 is formed downward from each circumferential end of the branch flow path 168, with an injection outlet 160B forming a second injection outlet at the lower end of the injection flow path 169. Similarly, a heating wire 165 arranged in a circumferential manner and a refrigerant flow path 166 arranged in a circumferential manner are provided in the flow channel 160. Moreover, the flow channel 160 is configured such that, with the center of the axial direction of the inlet flow path 167 as the central axis, the radius from the inlet 160A to the outlet 160B is different from the radius from the inlet 60A to the outlet 60B of the aforementioned flow channel 60, that is, its radius is smaller.

[0092] Furthermore, the upper shaft portion 162 is formed in the same shape as the upper shaft portion 62 of the flow channel 60, so that it can be mounted and detached relative to the mounting hole 52a of the upper plate 52 of the worktable portion 50. Thus, as Figure 15 As shown, by fitting the upper shaft portion 162 into the mounting hole 52a of the upper plate 52, the flow channel 160 can be freely mounted on the upper plate 52.

[0093] Furthermore, although it is stated that the injection outlet 160B of the flow channel 160 is in a smaller diameter position relative to the flow channel 60, conversely, the radius from the inlet to the injection outlet can also be increased, that is, it can also be a flow channel for injecting resin into a rotor core with a large radius of bore.

[0094] <Summary of this implementation method>

[0095] The manufacturing apparatus (30) for this rotor described above

[0096] The rotor manufacturing apparatus (30) for manufacturing the rotor (1) of a rotating electric machine includes:

[0097] A resin injection machine (40) having a first injection port (40A) for injecting resin; and

[0098] The flow channel (60) has an inlet (60A) that can be connected to the first ejection outlet (40A) and a plurality of second ejection outlets (60B) that communicate with the inlet (60A) and are arranged at positions corresponding to the holes (1B) of the magnet assembly (1M) in the rotor core (1A).

[0099] Therefore, by changing the flow channel 60 according to the shape of the rotor core 1A (rotor 1), it is possible to manufacture rotors 1 with different hole positions without changing the resin injection machine, and to reduce costs by using the same resin injection machine 40.

[0100] Furthermore, the manufacturing apparatus (30) for this rotor includes a mounting section (50) on which the aforementioned rotor core (1A) is mounted.

[0101] The aforementioned flow channels (60, 160) can be detachably installed on the aforementioned mounting section (50).

[0102] Therefore, flow channel 60 (160) can be easily replaced.

[0103] Furthermore, in the manufacturing apparatus (30) of this rotor,

[0104] The aforementioned mounting section (50) has:

[0105] The support (52) allows the flow channels (60, 160) to be installed and removed, and provides positioning support when the flow channels (60, 160) are installed.

[0106] A mounting platform (55) is disposed below the support portion (52) and is capable of housing the rotor core (1A) and of being raised and lowered relative to the support portion (52); and

[0107] The drive unit (59) is capable of moving and driving the aforementioned mounting platform (55).

[0108] By raising the mounting platform (55) on which the rotor core (1A) is mounted, the hole (1B) of the rotor core (1A) is positioned opposite the second injection port (60B, 160B) of the flow channel (60, 160), and resin can be injected from the resin injection machine (40).

[0109] Therefore, when injecting resin into the hole 1B of the rotor core 1A, it is not necessary to move the flow channel 60 (160) or the resin injection machine 40, thus simplifying the structure of the resin injection machine 40.

[0110] Furthermore, in the manufacturing apparatus (30) of this rotor,

[0111] The aforementioned rotor core (1A) is formed such that the aforementioned hole (1B) is the first in the circumferential direction.

[0112] The aforementioned flow channels (60, 160) have the aforementioned second injection outlets (60B, 160B) in a second number less than the first number.

[0113] The aforementioned drive unit (59) is configured to rotate and drive the aforementioned mounting platform (55).

[0114] Therefore, even if the first number of holes 1B in the rotor core 1A is large and the holes 1B are close to each other, even if the branch nozzle 63 (163) with the injection outlet 60B (160B) cannot get close enough to prepare the first number of injection outlets 60B (160B) in the holes 1B, resin can still be injected into all holes 1B in the rotor core 1A.

[0115] In addition, the manufacturing apparatus (30) for this rotor includes:

[0116] The first temperature regulating device (81) regulates the temperature of the resin in the resin injection machine (40); and

[0117] The second temperature regulating device (82) regulates the temperature of the resin in the flow channel (60).

[0118] Therefore, temperature management for the resin in the molten resin injection machine 40 and temperature management for temperature changes caused by disturbances in the flow channel 60 (160) can be performed independently. In addition, since the rotor core 1A provided on the mounting table 55 moves relative to the flow channel 60 (160), it is not necessary to move the flow channel 60 (160) and the resin injection machine 40, or the temperature regulating device 81 and the temperature regulating device 82, at least during the resin injection process S6.

[0119] Furthermore, in the manufacturing apparatus (30) of this rotor,

[0120] The aforementioned flow channel includes a first flow channel (60) and a second flow channel (160) configured such that the radius from the inlet (160A) to the second outlet (160B) is different from the radius from the inlet (60A) to the second outlet (60B) of the first flow channel (60).

[0121] Therefore, even when manufacturing components with different radii for the bore 1B of the rotor core 1A, the resin injection can be addressed simply by changing the flow channel.

[0122] Furthermore, in the manufacturing apparatus (30) of this rotor,

[0123] The resin injection machine (40) described above has a first valve (43) capable of opening and closing the first injection port (40A).

[0124] The aforementioned flow channels (60, 160) have second valves (64, 164) capable of opening and closing the aforementioned second injection outlets (60B, 160B).

[0125] Therefore, the injection and stopping of resin from the flow channel 60 (160) into the hole 1B of the rotor core 1A can be freely controlled by the shut-off valve 43. In addition, the injection and stopping of resin from the resin injector 40 into the flow channel 60 (160) can be freely controlled by the shut-off valve 64 (164), and in particular, the resin can be stopped when the flow channel 60 (160) is replaced.

[0126] Furthermore, in the manufacturing apparatus (30) of this rotor,

[0127] The flow channels (60, 160) are configured such that the amount of resin filling from the inlet (60A, 160A) into the plurality of second injection outlets (60B, 160B) is greater than the amount of resin ejected from the plurality of second injection outlets (60B, 160B) toward the orifice (1B) at one time.

[0128] Therefore, the temperature of the resin injected into the hole 1B of the rotor core 1A can be maintained at an appropriate temperature inside the flow channel 60 (160).

[0129] Furthermore, in the manufacturing method of this rotor,

[0130] The method for manufacturing the rotor (1) of a rotary electric motor by placing a magnet component (1M) in a hole (1B) of a rotor core (1A), injecting resin to cure it, and fixing the magnet component (1M) to the rotor core (1A) includes the following steps:

[0131] In the injection device setting process (S5), the rotor core (1A) is set in the setting section (50); and

[0132] In the resin injection process (S6), a flow channel (60) that can be installed and removed relative to the setting part (50) is installed on the setting part (50), and the first injection port (40A) of the resin injection machine (40) is connected to the inlet (60A) of the flow channel (60). Resin from the resin injection machine (40) is injected into the hole (1B) of the rotor core (1A) from a plurality of second injection ports (60B) in the flow channel (60) that are arranged at positions corresponding to the holes (1B) of the rotor core (1A).

[0133] Therefore, by changing the flow channel 60 according to the shape of the rotor core 1A (rotor 1), it is possible to manufacture rotors 1 with different hole positions without changing the resin injection machine, and to achieve cost reduction using the same resin injection machine 40.

[0134] Furthermore, in the manufacturing method of this rotor,

[0135] The aforementioned mounting section (50) has:

[0136] The support (52) allows the flow channel (60) to be installed and removed, and provides positioning support when the flow channel (60) is installed.

[0137] A mounting platform (55) is disposed below the support portion (52) and is capable of housing the rotor core (1A) and of being raised and lowered relative to the support portion (52); and

[0138] The drive unit (59) is capable of moving and driving the aforementioned mounting platform (55).

[0139] In the above-mentioned injection device setting process (S5), by raising the setting platform (55) on which the rotor core (1A) is provided, the hole (1B) of the rotor core (1A) is positioned opposite the second injection outlet (60B) of the flow channel (60).

[0140] In the above-mentioned resin injection process (S6), resin from the above-mentioned resin injection machine (40) is injected into the hole (1B) of the above-mentioned rotor core (1A) from a plurality of second injection outlets (60B) of the above-mentioned flow channel (60).

[0141] Therefore, when injecting resin into the hole 1B of the rotor core 1A, it is not necessary to move the flow channel 60 or the resin injection machine 40, thus simplifying the structure of the resin injection machine 40.

[0142] Furthermore, in the manufacturing method of this rotor,

[0143] The aforementioned rotor core (1A) is formed such that the aforementioned hole (1B) is the first in the circumferential direction.

[0144] The aforementioned flow channel (60) has the aforementioned second injection outlet (60B) by a second number less than the first number.

[0145] The aforementioned drive unit (59) is configured to rotatably drive the aforementioned mounting platform (55).

[0146] In the above resin injection process (S6),

[0147] Resin is injected into the second number of holes (1B) of the rotor core (1A) from the plurality of second injection ports (60B) of the aforementioned flow channel (60).

[0148] The drive unit (59) lowers the mounting platform (55), causing the rotor core (1A) to descend; rotates the mounting platform (55), causing the rotor core (1A) to rotate; and raises the mounting platform (55), causing the rotor core (1A) to rise.

[0149] Resin is injected into the unreinjected holes (1B) of the rotor core (1A) from the multiple second injection ports (60B) of the flow channel (60).

[0150] Therefore, even if the first number of holes 1B in the rotor core 1A is large and the holes 1B are close to each other, resin can still be injected into all holes 1B in the rotor core 1A even if the branch nozzle 63 with the injection outlet 60B cannot be brought close enough to prepare the first number of injection outlets 60B in the holes 1B.

[0151] Furthermore, in the manufacturing apparatus (30) of this rotor,

[0152] The aforementioned flow channel includes a first flow channel (60) and a second flow channel (160) configured such that the radius from the inlet (160A) to the second outlet (160B) is different from the radius from the inlet (60A) to the second outlet (60B) of the first flow channel (60).

[0153] The first flow channel (60) and the second flow channel (160) can be selectively installed on the above-mentioned setting part (50).

[0154] Therefore, even when manufacturing components with different radii for the bore 1B of the rotor core 1A, the resin injection can be addressed simply by changing the flow channel.

[0155] <Possibility of other implementation methods>

[0156] Furthermore, in the embodiment described above, although it is shown that the retaining clamp 10 is generally composed of a lower plate 11, a pressing plate 12, an upper plate 13 and a helical spring 23, it is not limited to this. As long as it can clamp and retain the rotor core 1A in the stacking direction, it can be any structure.

[0157] Furthermore, although this embodiment describes that the resin is injected after heating to above the resin's initial curing temperature in the heating step S4, it is not limited to this. It is also possible to preheat to around the initial melting temperature in the heating step S4, and then formally heat to above the processing temperature in the magnet fixing step S7 after resin injection.

[0158] Furthermore, although this embodiment describes the case where the holding clamp 10 is also cooled by a cooling device in the cooling process S9, it is not limited to this. The holding clamp 10 can also be cooled naturally. In particular, it is sufficient to prepare multiple holding clamps 10 in such a way that natural cooling is sufficient even if the holding clamp 10 is reused.

[0159] Furthermore, although this embodiment describes the case where the rotor core 1A (rotor 1) is cooled by a cooling device in the cooling process S9, it is not limited to this. Of course, even if the rotor core 1A is cooled naturally, removing the holding clamp 10 can shorten the cooling time.

[0160] Furthermore, although this embodiment describes the case where the injection holes 12c of the resin-forming plate portion 99a and the conical portion 99b are formed on the pressing plate 12 of the holding clamp 10, which serves as an abutment member, it is not limited to this. For example, if the rotor core 1A is not held by the holding clamp 10, but is held by other methods for resin injection, it is also possible to consider not using the holding clamp 10. In this case, it is possible to form the injection holes of the resin-forming plate portion 99a and the conical portion 99b on other plates that abut against the rotor core 1A.

[0161] Furthermore, although the case where the resin is formed through the injection hole 12c in this embodiment is described as a plate portion 99a and a conical portion 99b, their shapes can be arbitrary. That is, the shape of the enlarged opening protruding from the upper surface of the rotor core 1A does not have to be plate-shaped; for example, it can be triangular pyramid, square pyramid, cone, hemispherical, etc. In addition, the shape formed in the pointed portion does not have to be conical; for example, it can be triangular pyramid, square pyramid, cone, hemispherical, etc.

[0162] In addition, although this embodiment describes the case where the flow channel 60 can be detachably supported on the worktable 50, the flow channel 60 can also be directly fixed and supported on the nozzle 42 of the resin injection machine 40, or it can be supported on other parts other than the worktable 50.

[0163] Furthermore, although this embodiment describes the case where the rotor core 1A is placed on the mounting platform 55 and the rotor core 1A is raised towards the flow channel 60 so that the injection port 60B is opposite to the hole portion 1B of the rotor core 1A via the injection hole 12c, it is not limited to this. The direction in which the rotor core 1A is moved can be determined according to the orientation of the resin injection machine 40 and the flow channel 60. In other words, as long as it is configured so that the resin injection machine 40 and the flow channel 60 do not move at least in the resin injection process S6, any structure is acceptable.

[0164] Furthermore, although this embodiment describes the case where the temperature control device 81 manages the temperature of the resin injection machine 40 and the temperature control device 82 manages the temperature of the flow channel 60, it is not limited to this. For example, temperature management can be performed by a single temperature control device. Conversely, multiple temperature control devices can be used to refine the temperature management of the resin injection machine 40 and the flow channel 60.

[0165] Furthermore, although this embodiment describes a so-called compression molding resin injection machine that compresses and injects molten resin, similar to the resin injection machine 40, it is not limited to this. For example, a so-called transfer molding resin injection machine that injects preheated resin material after placing it into a transfer chamber may also be used.

[0166] Industrial applications

[0167] The manufacturing apparatus and method for this rotor can be used to manufacture rotors for rotating electric machines, and are particularly suitable for situations where it is desired to manufacture rotors with different hole positions using the same resin injection machine.

[0168] Explanation of reference numerals in the attached figures

[0169] 1…rotor

[0170] 1A…rotor core

[0171] 1B…hole section

[0172] 1M…Magnetic component (magnet)

[0173] 30…Rotor manufacturing apparatus (resin injection apparatus)

[0174] 40… Resin Injection Machine

[0175] 40A…First injection exit (injection exit)

[0176] 43…First valve (stop valve)

[0177] 50…Setup Department (Workbench Department)

[0178] 52… Support section (top plate)

[0179] 55…Setup Table

[0180] 59…Drive Unit (Drive Device)

[0181] 60…flow channel

[0182] 60A…Input port

[0183] 60B…Second firing port (firing port)

[0184] 64…Second valve (shut-off valve)

[0185] 81…First temperature control device (temperature control device)

[0186] 82…Second temperature control device (temperature control device)

[0187] 160…flow channel

[0188] 160A…Inlet

[0189] 160B…Second firing port (firing port)

[0190] 164…Second valve (shut-off valve)

[0191] S5…Injection device setup procedure

[0192] S6…Resin injection process.

Claims

1. A rotor manufacturing apparatus, which is an apparatus for manufacturing rotors for rotating electric machines, comprising: A resin injection machine having a first injection port for injecting resin; The flow channel has an inlet that can connect to the first ejection outlet; and a plurality of second ejection outlets that communicate with the inlet and are disposed at positions corresponding to the holes in the rotor core where magnet components are installed; and The rotor core mounting section is provided, and the flow channel is detachably mounted on the mounting section. The above-mentioned setting unit has: A support portion that allows the aforementioned flow channel to be installed and removed, and provides positioning support when the aforementioned flow channel is installed; A mounting platform, positioned below the aforementioned support, is capable of mounting the rotor core and can be raised and lowered relative to the support; and The drive unit is capable of moving and driving the aforementioned mounting platform. By moving the mounting platform on which the rotor core is mounted, the hole of the rotor core is aligned with the second injection port of the flow channel, and resin can be injected from the resin injection machine.

2. The rotor manufacturing apparatus according to claim 1, wherein, The aforementioned rotor core is formed such that the aforementioned hole is the first one in the circumferential direction. The aforementioned flow channel has the aforementioned second injection outlet with a second number less than the first number. The aforementioned drive unit is configured to rotate and drive the aforementioned mounting platform.

3. The rotor manufacturing apparatus according to claim 1 or 2, wherein, have: A first temperature regulating device, which regulates the temperature of the resin in the resin injection machine; and The second temperature regulating device adjusts the temperature of the resin in the aforementioned flow channel.

4. The rotor manufacturing apparatus according to claim 1 or 2, wherein, The aforementioned flow channel includes: a first flow channel, and a second flow channel configured such that the radius from the inlet to the second outlet is different from the radius from the inlet to the second outlet of the first flow channel.

5. The rotor manufacturing apparatus according to claim 1 or 2, wherein, The aforementioned resin injection machine has a first valve capable of opening and closing the aforementioned first injection outlet. The aforementioned flow channel has a second valve capable of opening and closing the aforementioned second injection outlet.

6. The rotor manufacturing apparatus according to claim 1 or 2, wherein, The flow channel is formed such that the amount of resin filling from the inlet to the plurality of second ejection outlets is greater than the amount of resin ejected from the plurality of second ejection outlets toward the orifice in a single injection.

7. A method for manufacturing a rotor, comprising manufacturing a rotor of a rotating electric motor by disposing a magnet component in a hole in a rotor core, injecting and curing resin, and fixing the magnet component to the rotor core, characterized in that... It includes the following processes: The injection device setting process involves setting the aforementioned rotor core in the setting section; and In the resin injection process, a flow channel that can be attached and detached relative to the aforementioned mounting part is installed on the aforementioned mounting part. A first injection port of the resin injection machine is connected to the inlet of the flow channel. Resin from the resin injection machine is injected into the holes of the rotor core through a plurality of second injection ports arranged in the flow channel at positions corresponding to the holes of the rotor core. The above-mentioned setting unit has: A support portion that allows the aforementioned flow channel to be installed and removed, and provides positioning support when the aforementioned flow channel is installed; A mounting platform, positioned below the aforementioned support, is capable of mounting the rotor core and can be raised and lowered relative to the support; and The drive unit is capable of moving and driving the aforementioned mounting platform. In the above-described injection device setting process, the mounting platform on which the rotor core is mounted is moved so that the hole of the rotor core is aligned with the second injection outlet of the flow channel. In the above-mentioned resin injection process, resin from the above-mentioned resin injection machine is injected into the holes of the above-mentioned rotor core from multiple second injection outlets of the above-mentioned flow channel.

8. The method for manufacturing a rotor according to claim 7, wherein, The aforementioned rotor core is formed such that the aforementioned hole is the first one in the circumferential direction. The aforementioned flow channel has the aforementioned second injection outlet with a second number less than the first number. The aforementioned drive unit is configured to rotatably drive the aforementioned mounting platform. In the above resin injection process, Resin is injected into the second number of holes in the rotor core from the multiple second injection outlets of the aforementioned flow channel. The drive unit lowers the mounting platform, causing the rotor core to descend; rotates the mounting platform, causing the rotor core to rotate; and raises the mounting platform, causing the rotor core to rise. Resin is injected into the unreinjected holes of the rotor core through multiple second injection outlets in the aforementioned flow channel.

9. The method for manufacturing a rotor according to claim 7 or 8, wherein, The aforementioned flow channel includes: a first flow channel, and a second flow channel configured such that the radius from the inlet to the second outlet is different from the radius from the inlet to the second outlet of the first flow channel. The first flow channel and the second flow channel can be selectively installed in the above-mentioned setting unit.

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