Motor manufacturing method and motor manufacturing apparatus

Abstract

The present application provides a motor manufacturing method and a motor manufacturing device that can reduce the height of equipment in a motor core manufacturing process and contribute to an increase in productivity in the motor core manufacturing process. The motor manufacturing method includes: at a first position, feeding a material sheet into a lower mold in a state in which a plurality of cores arranged in a state of being spaced apart along an axial direction by an intermediate plate are spaced apart from the upper side of the lower mold; lowering the plurality of cores toward the lower mold; moving the lower mold and the plurality of cores to a second position opposite to an upper mold; and at the second position, filling a resin into resin filling portions formed in the plurality of cores, respectively.

Description

Technical Field

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

[0002] A rotating electric motor includes a motor core (e.g., a rotor core and a stator core; hereinafter, the rotor core and stator core will be collectively referred to as the core). Within the core, permanent magnets are mounted in multiple annular slots arranged at predetermined intervals. As a method for mounting permanent magnets into the core, a method is known that involves inserting the permanent magnets into the slots, filling the surrounding area with resin, and allowing the resin to cure (e.g., see Japanese Invention Patent No. 5681027). Summary of the Invention

[0003] The problem that the invention aims to solve

[0004] However, in the technology described in Japanese Invention Patent No. 5681027, when resin is filled with multiple iron cores arranged axially, a gap needs to be formed between the overlapping iron cores and the lower mold in order to insert the tablet into the lower mold of the molding apparatus after the multiple iron cores are set, which increases the height of the equipment. On the other hand, if the tablet is pre-inserted before the iron cores are placed in the molding apparatus, the tablet will be heated before the multiple iron cores are set, and the resin forming the tablet will solidify, which may make resin filling difficult.

[0005] In view of the above-mentioned problems, the present disclosure aims to provide a motor manufacturing method and motor manufacturing apparatus that can reduce the equipment height in the motor core manufacturing process and help improve the productivity in the motor core manufacturing process.

[0006] Solution for solving the problem

[0007] To achieve the above objectives, the first aspect of the present disclosure is a motor manufacturing method, comprising: in a first position, with a plurality of iron cores arranged axially with a middle plate spaced apart from each other in a lower mold, inserting a sheet into a lower mold; lowering the plurality of iron cores toward the lower mold; moving the lower mold and the plurality of iron cores to a second position opposite to an upper mold; and in the second position, filling resin into resin-filled portions formed on the plurality of iron cores respectively.

[0008] The second aspect of the technology disclosed herein is the motor manufacturing method of the first aspect, wherein a plurality of lower molds are disposed on a support platform, and the motor manufacturing method is configured to feed a sheet into the lower mold located at a first position among the plurality of lower molds.

[0009] A third aspect of the technology disclosed in the present disclosure is the motor manufacturing method according to the first aspect, in which the lower mold is provided to the support table, and the lower mold and the plurality of iron cores are moved to the second position by rotating the support table.

[0010] A fourth aspect of the technology disclosed in the present disclosure is the motor manufacturing method according to the first aspect, in which the lower mold is provided to the support table, and the lower mold and the plurality of iron cores are moved to the second position by moving the support table in a sliding manner.

[0011] A fifth aspect of the technology disclosed in the present disclosure is the motor manufacturing method according to the first aspect, in which a plurality of lower molds are provided to the support table, and the plurality of iron cores filled with the resin are separated from the lower mold located at the third position among the plurality of lower molds.

[0012] A sixth aspect of the technology disclosed in the present disclosure is the motor manufacturing method according to the first aspect, in which a plurality of lower molds are provided to the support table, and the plurality of iron cores placed on the lower mold located at the third position among the plurality of lower molds are heated for additional curing of the resin.

[0013] A seventh aspect of the technology disclosed in the present disclosure is the motor manufacturing method according to the first aspect, in which a plurality of lower molds are provided to the support table, and the plurality of iron cores before filling with the resin are arranged above the lower mold located at the fourth position among the plurality of lower molds.

[0014] An eighth aspect of the technology disclosed in the present disclosure is the motor manufacturing method according to the first aspect, in which a plurality of lower molds are provided to the support table, and the lower mold located at the fourth position among the plurality of lower molds and / or the plurality of iron cores before filling with the resin are preheated.

[0015] A ninth aspect of the technology disclosed in the present disclosure is a motor manufacturing apparatus including: a support mechanism that supports a plurality of iron cores arranged in a state of being aligned along an axial direction with an intermediate plate interposed therebetween in a first position so as to be movable up and down until the plurality of iron cores reach a position at which a material sheet can be fed into a lower mold; a moving mechanism that moves the lower mold and the plurality of iron cores to a second position opposite to an upper mold; and a resin filling mechanism that fills a resin into resin filling portions formed in the plurality of iron cores at the second position.

[0016] Effects of Invention

[0017] According to the present disclosure, in view of the above problems, a motor manufacturing method and a motor manufacturing apparatus that can achieve a reduction in the height of a motor iron core manufacturing apparatus and contribute to an improvement in productivity in a motor iron core manufacturing process are provided. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 is a schematic explanatory view showing one example of a schematic structure of a rotor iron core manufacturing apparatus of an embodiment.

[0019] Figure 2 is a perspective view showing a schematic structure of a rotor iron core and an intermediate plate of an embodiment.

[0020] Figure 3 This is a schematic diagram illustrating an example of the general structure of a rotor core manufacturing apparatus according to an embodiment.

[0021] Figure 4 This is a schematic diagram illustrating an example of the general structure of a rotor core manufacturing apparatus according to an embodiment.

[0022] Figure 5 This is a schematic diagram illustrating an example of the general structure of a rotor core manufacturing apparatus according to an embodiment.

[0023] Figure 6 This is a schematic diagram illustrating an example of the general structure of a rotor core manufacturing apparatus according to an embodiment.

[0024] Figure 7 This is a schematic top view of an example of the schematic structure of a rotor core manufacturing apparatus according to an embodiment.

[0025] Figure 8 This is a flowchart illustrating an example of the rotor core manufacturing process in an embodiment.

[0026] Figure 9 This is a schematic diagram illustrating an example of the general structure of a rotor core manufacturing apparatus for a comparative example.

[0027] Figure 10 This is a schematic top view of an example of the schematic structure of a rotor core manufacturing apparatus according to an embodiment.

[0028] Figure 11 This is a schematic top view of an example of the schematic structure of a rotor core manufacturing apparatus according to an embodiment.

[0029] Figure 12 This is a schematic top view of an example of the schematic structure of a rotor core manufacturing apparatus according to an embodiment.

[0030] Figure 13 This is a schematic top view of an example of the schematic structure of a rotor core manufacturing apparatus according to an embodiment.

[0031] Figure 14 This is a schematic top view of an example of the schematic structure of a rotor core manufacturing apparatus according to an embodiment.

[0032] Figure 15 This is a schematic top view of an example of the schematic structure of a rotor core manufacturing apparatus according to an embodiment.

[0033] Figure 16 This is a schematic top view of an example of the schematic structure of a rotor core manufacturing apparatus according to an embodiment. Detailed Implementation

[0034] Hereinafter, various embodiments for implementing this disclosure will be described with reference to the accompanying drawings. It should be noted that the scope of explanation required to achieve the purposes of this disclosure is shown schematically below, and the explanation mainly focuses on the scope of this disclosure for that specific part; parts omitted from the description are known technologies. Furthermore, identical or corresponding components in the drawings are labeled with the same or similar reference numerals, and repeated descriptions are omitted. Moreover, when a single drawing contains multiple identical or corresponding components, sometimes only a few components are labeled for ease of observation.

[0035] <<First Implementation>>

[0036] <Overview of Rotor Core Manufacturing Apparatus>

[0037] First, refer to Figure 1 and Figure 2 An overview of the rotor core manufacturing apparatus 10 of this embodiment will be described. Figure 1 This is a schematic diagram showing the outline of the rotor core manufacturing apparatus 10 of this embodiment. Figure 2 This is a perspective view showing the schematic structure of the rotor core 2 and intermediate plate 22 in this embodiment.

[0038] like Figure 1 As shown, the rotor core manufacturing apparatus 10 is an apparatus capable of filling the magnet insertion holes 4 of a plurality of rotor cores 2 with resin (i.e., molding). Specifically, the rotor core manufacturing apparatus 10 is an apparatus for filling the magnet insertion holes 4 formed on a plurality of rotor cores 2 arranged along the axial direction with resin. The rotor core manufacturing apparatus 10 is an example of a "motor manufacturing apparatus" of the present disclosure. The plurality of rotor cores 2 is an example of a "plural core" of the present disclosure.

[0039] The rotor core manufacturing apparatus 10 includes an upper mold support 11 and a platform 30. The upper mold support 11 is a mechanism that supports the upper mold 33. When the rotor core 2 is filled with resin, the upper mold support 11 positions the upper mold 33 opposite to the rotor core 2.

[0040] The upper mold support 11 includes a support column 12 extending in the vertical direction and a horizontal portion 14 extending from the upper end of the support column 12 toward the platform 30. A plurality of lifting rods 16 (three in this case) are provided on the horizontal portion 14, through which the upper mold 33 is located below the horizontal portion 14. The upper mold 33 is configured to be movable in the vertical direction via the lifting rods 16. The upper mold 33 is an example of the "upper mold" of the present disclosure.

[0041] The platform 30 comprises a rotary platform 31 and multiple lower molds 32 disposed on the rotary platform 31. The rotary platform 31 is a platform-shaped component with a generally rectangular parallelepiped shape when viewed from above. The rotary platform 31 is provided with multiple lower molds 32. Figure 1 In the example shown, two lower molds 32A and 32B are disposed on the upper surface of the rotary table 31. A rotating shaft 36 is provided at the center of the rotary table 31. The rotating shaft 36 is configured to receive power from a drive source (not shown) and rotate. Furthermore, the rotary table 31 is configured to rotate with the rotation of the rotating shaft 36. The table 30 is an example of a "moving mechanism" of the present disclosure. The rotary table 31 is an example of a "support table" of the present disclosure.

[0042] Support plates 20A and 20B are respectively provided above the lower molds 32A and 32B. Multiple rotor cores 2 are mounted on the lower molds 32A and 32B, separated by the support plates 20A and 20B. Resin-filled channels 23 are formed on the support plates 20A and 20B. In the following description, unless it is necessary to distinguish between the lower molds 32A and 32B, they will be referred to simply as "lower mold 32". Furthermore, in the following description, unless it is necessary to distinguish between the support plates 20A and 20B, they will be referred to simply as "support plate 20". The lower mold 32 is an example of a "lower mold" according to the technology of this disclosure.

[0043] A support rod 21 is assembled between the support plate 20B and the lower die 32B. The support rod 21 is designed to be telescopically movable. By extending and retracting the support rod 21, the support plate 20B is configured to be able to rise and fall relative to the lower die 32B. Specifically, the support rod 21 supports the support plate 20B, which carries a plurality of rotor cores 2, in a telescopically movable manner until the support plate 20B reaches a position where the sheet T can be inserted. The support plate 20 and the support rod 21 are an example of the "support mechanism" of the present disclosure.

[0044] The number and shape of the support rods 21 are not particularly limited, as long as they can ensure the strength to lift and lower the multiple rotor cores 2 mounted on the support plate 20. Furthermore, the support plate 20B provided on the lower mold 32B is taken as an example, but the lower mold 32A is also provided with a support plate 20A and support rods 21 of the same structure.

[0045] A plunger 34A is provided at the center of the lower mold 32A. The plunger 34A is received within a through hole that communicates with both the lower mold 32A and the rotary table 31. Similarly, a plunger 34B is provided at the center of the lower mold 32B. The plunger 34B is received within a through hole that communicates with both the lower mold 32B and the rotary table 31. In the following description, unless there is a need to distinguish between the plunger 34A and the plunger 34B, they will be referred to simply as "plunger 34". The plunger 34 is an example of the "resin filling mechanism" of the present disclosure.

[0046] The device is designed to allow the feeding of a sheet T (i.e., resin material cured into a predetermined shape) above plungers 34A and 34B. In other words, the space within the through-hole above plungers 34A and 34B functions as a resin reservoir, i.e., a pot. Furthermore, the rotor core manufacturing apparatus 10 operates under the control of the control device 15. The sheet T is an example of a "sheet" in the technology of this disclosure.

[0047] In this embodiment, multiple rotor cores 2 are arranged in a manner that follows the axial direction of the rotor core 2 (i.e., the direction of the central axis of the cylindrical rotor core 2). That is, the multiple rotor cores 2 are arranged in a multi-layer configuration.

[0048] Specifically, multiple rotor cores 2 are arranged axially with a spacer between them and an intermediate plate 22. In other words, multiple rotor cores 2 are stacked axially with a spacer between them and an intermediate plate 22. Thus, before being installed in the rotor core manufacturing apparatus 10, the rotor cores 2 and the intermediate plate 22 are pre-stacked without gaps. The stacking operation of the rotor cores 2 is achieved, for example, by using a robotic arm to stack the rotor cores 2 placed on the intermediate plate 22. In this case, the bottommost rotor core 2 may not be placed on the intermediate plate 22. The intermediate plate 22 is an example of the "intermediate plate" of the technology disclosed herein.

[0049] Furthermore, when multiple rotor cores 2 are arranged in a manner that runs along the axial direction, the magnet insertion holes 4 of each rotor core 2 are connected via through holes 22A in the intermediate plate 22. In other words, the through holes 22A are formed at positions corresponding to the magnet insertion holes 4 of the rotor cores 2 placed on the intermediate plate 22.

[0050] exist Figure 1 In the example shown, the four rotor cores 2 are arranged axially with the intermediate plate 22 between them. It should be noted that this is just an example; of course, it can also be arranged with two or three rotor cores 2 stacked together, or even with more than five rotor cores 2 stacked together.

[0051] It should be noted that the example given here is of multiple rotor cores 2 having the same shape (in this case, the same core height (i.e., axial length), but this is only one example. Multiple rotor cores 2 can also have different shapes (e.g., different core heights). Furthermore, not only can the core heights differ, but the configuration, number, and / or diameter of the magnet insertion holes 4 can also vary.

[0052] Furthermore, the multiple rotor cores 2 manufactured by the rotor core manufacturing apparatus 10 of this embodiment can be stacked and used for the same motor core or for different motor cores. It should be noted that the motor in this specification also includes a semi-finished product state in which some component is assembled on the motor core (rotor core, stator core).

[0053] like Figure 2 As shown, the rotor core 2 is formed by stacking multiple thin electromagnetic steel plates. The rotor core 2 is cylindrical, and a through hole 5 is provided in the central portion of the rotor core 2 (i.e., the region containing the cylindrical central axis). When the rotor core 2 is assembled into a motor, a shaft constituting the rotating shaft is inserted into the through hole 5. Furthermore, in the rotor core 2, a plurality of (…) extending along the axial direction of the rotor core 2 are arranged circumferentially around the through hole 5. Figure 2 There are four magnet insertion holes 4. These magnet insertion holes 4 can be in a shape into which a permanent magnet 3 can be inserted, such as a cuboid or arc-shaped through hole penetrating the thickness direction of the rotor core 2; their specific shape is not particularly limited. Similarly, the number of magnet insertion holes 4 can be arbitrarily changed, and can be set to be more than... Figure 2 The number shown is more than four, for example, about 10 to 40. The magnet insertion hole 4 is an example of the "resin filling part" of the technology disclosed herein.

[0054] The magnet insertion hole 4 of the rotor core 2 is a hole for inserting and fixing a permanent magnet 3 inside. The permanent magnet 3 can be, for example, a cuboid or a block shaped like a circular arc when viewed from above, slightly smaller than the magnet insertion hole 4. Furthermore, it is acceptable whether the permanent magnet 3 is magnetized at the point of insertion into the magnet insertion hole 4. Also, it is acceptable whether the permanent magnet 3 is divided in the stacking direction or in a direction orthogonal to the stacking direction. When the permanent magnet 3 is inserted into the magnet insertion hole 4, at least partially, a gap is formed between the outer peripheral surface of the permanent magnet 3 and the inner peripheral surface of the magnet insertion hole 4. The gap formed in the magnet insertion hole 4 functions as a space for resin filling. These multiple spaces communicate with the through hole 22A provided in the intermediate plate 22.

[0055] In this embodiment, the magnet insertion hole 4 of the rotor core 2 is exemplified as a cuboid-shaped hole that is open in the vertical direction and substantially has no gaps in the front-back and left-right directions. Therefore, the upper mold 33 and the lower mold 32 are molds with generally flat abutment surfaces, but the shape of the abutment surfaces of the upper mold 33 and the lower mold 32 can be appropriately modified to match the shape of the rotor core 2 to be held. For example, when the rotor core manufacturing apparatus 10 of this embodiment is used for resin molding of an inner rotor type stator core, it is preferable to use molds that include protrusions to be inserted into the space formed in the center of the stator core.

[0056] exist Figure 2 In the example shown, the intermediate plate 22 is quadrilateral when viewed from above. The rotor core 2 is mounted on the upper surface of the intermediate plate 22. The rotor core 2 is mounted on the intermediate plate 22 with the central axis of the intermediate plate 22 approximately aligned with the central axis of the rotor core 2. Furthermore, the intermediate plate 22 has a shape capable of supporting the rotor core 2 (e.g., a width larger than the outer diameter of the rotor core 2, and a plate thickness that provides sufficient rigidity to support the rotor core 2).

[0057] A through hole 22A extending through the thickness direction is formed in the intermediate plate 22. The through hole 22A is formed at a position opposite to the magnet insertion hole 4 of the rotor core 2. That is, when the rotor core 2 is mounted on the intermediate plate 22, the through hole 22A communicates with the magnet insertion hole 4. The number and arrangement of the through holes 22A are determined according to the number and arrangement of the magnet insertion holes 4 in the rotor core 2.

[0058] Furthermore, the intermediate plate 22 has a protrusion 22B that protrudes from the surface (in this case, the upper surface) on which the rotor core 2 is mounted. The protrusion 22B is cylindrical and is designed to be inserted into a through hole formed in the rotor core 2. By inserting the protrusion 22B into the through hole 5, the rotor core 2 is positioned relative to the intermediate plate 22. Furthermore, by engaging the protrusion 22B with the through hole 5, the rotor core 2 is prevented from detaching from the mounting surface of the intermediate plate 22. The protrusion length of the protrusion 22B (i.e., the height from the mounting surface to the front end) is appropriately set according to positioning accuracy, etc.

[0059] It should be noted that the cylindrical protrusion 22B is just one example, and it can also be cylindrical. Furthermore, the protrusion 22B can also be a plurality of pin-shaped members arranged along the circumference of the rotor core 2. In this case, the pin-shaped member serving as the protrusion 22B is inserted into a hole formed in the rotor core 2 (e.g., a through hole in the rotor core 2 for weight reduction, or a through hole forming a flow path for cooling the core).

[0060] Next, refer to Figures 3-6 The following describes the molding process of the rotor core 2. Figure 3 This is a schematic diagram illustrating an example of a rotor core 2 being disposed within a mold according to this embodiment. Figure 4 This is a schematic diagram illustrating an example of molding the rotor core 2 of this embodiment. Figure 5 This is a schematic diagram illustrating an example of molding the rotor core 2 of this embodiment. Figure 6 This is a schematic diagram illustrating an example of how the rotor core 2 of this embodiment moves from inside the mold.

[0061] likeFigure 3 As shown, multiple rotor cores 2 arranged axially are placed on a support plate 20. Here, the multiple rotor cores 2 are placed on the support plate 20B. A sheet T is then inserted into the lower die 32B. The sheet T is inserted into the lower die 32 between the support plate 20 and the lower die 32. That is, the sheet T is inserted into the lower die 32 with the multiple rotor cores 2 spaced apart from the lower die 32. Afterwards, by lowering the support plate 20B, the multiple rotor cores 2 descend toward the lower die 32B. Finally, the multiple rotor cores 2 are placed on the lower die 32 with the support plate 20B in between.

[0062] The multiple rotor cores 2 mounted on the support plate 20 can also be preheated by a heating furnace (not shown). Alternatively, the multiple rotor cores 2 can be preheated by a heating device (not shown) after being mounted on the support plate 20.

[0063] After that, as Figure 4 As shown, by rotating the rotary table 31 by 180 degrees, the lower mold 32B and the plurality of rotor cores 2 placed on the lower mold 32B are moved to a position opposite to the upper mold 33. Thus, the plurality of rotor cores 2 arranged along the axial direction are placed in the mold (i.e., between the upper mold 33 and the lower mold 32 (here, the lower mold 32B)).

[0064] By rotating the rotary table 31 180 degrees, the lower mold 32A, originally located below the upper mold 33, moves to the position where the lower mold 32B was originally located. That is, the positions of the lower molds 32B and 32A are swapped. In this case, resin filling can also be prepared in the lower mold 32A. Specifically, multiple rotor cores 2 are mounted on the support plate 20A. Then, sheet T is inserted into the lower mold 32A. Afterward, by lowering the support plate 20A, the multiple rotor cores 2 are mounted on the lower mold 32A across the support plate 20A.

[0065] The preparation work in the lower mold 32A as described above can be completed before the next rotation of the rotary table 31, and there is no particular limitation on the timing. For example, it can also be performed during the filling of resin into the rotor core 2 placed in the lower mold 32B, as described later.

[0066] like Figure 5 As shown, multiple rotor cores 2 are held axially by an upper mold 33 and a lower mold 32, separated by an intermediate plate 22. The upper mold 33 supports the upper part of the uppermost rotor core 2, specifically its upper surface. The lower mold 32 supports the lowermost rotor core 2 by abutting against a support plate 20. The upper mold 33 is configured to be raised and lowered by a lifting rod 16 that receives power from an actuator (not shown). The raising and lowering of the upper mold 33 can be performed primarily when holding the rotor cores 2 within the mold, or when moving the rotor cores 2 out of the mold.

[0067] As described above, the upper mold 33 can move vertically. Furthermore, by lowering the upper mold 33 and pressing it against the upper surface of the rotor core 2 with a predetermined pressing force, the multiple rotor cores 2 can be held in a manner that clamps them between the upper mold 33 and the lower mold 32. The shape and material of the surfaces of the upper mold 33 and the lower mold 32 opposite to the rotor core 2 can be adjusted so that the resin filling the magnet insertion hole 4 does not leak out of the rotor core 2. Specifically, the contact surfaces can be adjusted to be sealed when the rotor core 2 is clamped by the upper mold 33 and the lower mold 32.

[0068] In this embodiment, the structure described above that directly moves the upper mold 33 up and down is used. However, other structures can be used as long as they can relatively change the up and down positions of the upper mold 33 and the lower mold 32. Specifically, for example, the structure that moves the lower mold 32 up and down in the vertical direction can be used instead of the structure that moves the upper mold 33 up and down in the vertical direction, or the structure that moves both the upper mold 33 and the lower mold 32 up and down in the vertical direction can be used.

[0069] A resin filling path 23 is formed between the lower mold 32 and the support plate 20 for supplying softened resin R to the plurality of magnet insertion holes 4 of the rotor core 2. The path structure of the resin filling path 23 is appropriately set to match the number, shape, and shape of the magnet insertion holes 4 of the rotor core 2.

[0070] The rotor core 2, which is to be filled with resin into the magnet insertion hole 4, may often be changed to a rotor core of other shapes. Therefore, regarding the support plate 20, it is advisable to prepare multiple support plates 20 with different structures of resin filling paths 23 and to replace them appropriately to match the rotor core 2 to be held in the upper mold 33 and the lower mold 32.

[0071] The plunger 34 presses against the resin R, which has been softened by heating the sheet T via a heater (not shown). Figure 5 In the example shown, the resin R is pressed by a cylindrical plunger 34B located in the center of the lower mold 32B. As a result, the softened resin R flows and, after passing through the resin filling path 23, fills the magnet insertion hole 4 of the rotor core 2.

[0072] The flowing resin R first enters the magnet insertion hole 4 of the bottommost rotor core 2, then enters the magnet insertion holes 4 of the second and third rotor cores 2. Finally, it enters the magnet insertion hole 4 of the topmost rotor core 2. In this way, the magnet insertion holes 4 of each of the multiple rotor cores 2 are filled with resin R.

[0073] Resin R primarily comprises thermosetting resin materials. Specifically, Resin R can be resins that primarily consist of thermosetting resin materials, such as epoxy resin, phenolic resin, unsaturated polyester resin, or cyanate ester resin. Furthermore, in addition to the thermosetting resin materials, Resin R may also contain curing agents, fillers, etc.

[0074] like Figure 6 As shown, after the resin R is filled, the rotary table 31 is rotated 180 degrees, and the lower mold 32B and the plurality of rotor cores 2 placed on the lower mold 32B move from below the upper mold 33. Thus, the plurality of rotor cores 2, arranged axially, are removed from the mold. The removed rotor cores 2 separate from the support plate 20 and are taken out of the rotor core manufacturing apparatus 10. Then, the plurality of rotor cores 2 are conveyed to the next process.

[0075] On the other hand, by rotating the rotary table 31, the positions of the lower mold 32B and the lower mold 32A are interchanged, so that the multiple rotor cores 2 placed on the lower mold 32A are set inside the mold. Then, the magnet insertion holes 4 of each of the multiple rotor cores 2 are filled with resin R.

[0076] Reference Figure 7 The positional relationship between the lower molds 32A and 32B in a series of molding processes is explained. Figure 7 This is a schematic top view showing an example of the structure of the rotor core manufacturing apparatus 10 of this embodiment.

[0077] like Figure 7 As shown, firstly, a plurality of rotor cores 2, arranged axially with a middle plate 22 between them, are placed on the lower mold 32 of the rotor core manufacturing apparatus 10. Here, the lower mold 32A is positioned for molding (i.e., filling position E2), and the lower mold 32B is positioned for preparation work such as molding (i.e., standby position E1). The plurality of rotor cores 2 are placed on the lower mold 32B located in the standby position E1.

[0078] In the standby position E1, the preparation work described above can be performed. Specifically, multiple rotor cores 2 are placed on the support plate 20B. Then, a sheet T is inserted into the lower die 32B. Afterward, by lowering the support plate 20B, the multiple rotor cores 2 are placed on the lower die 32B across the support plate 20B. The standby position E1 is an example of the "first position" of the technology disclosed herein.

[0079] After the preparation work is completed, the lower mold 32B and the plurality of rotor cores 2 are moved from the standby position E1 to the filling position E2 by rotating the rotary table 31 by 180 degrees. In the filling position E2, the plurality of rotor cores 2 placed on the lower mold 32B are filled with resin. Meanwhile, the lower mold 32A is moved from the filling position E2 to the standby position E1. The preparation work described above is performed in the lower mold 32A in the standby position E1. The filling position E2 is an example of the "second position" of the technology disclosed herein.

[0080] After resin filling, the rotary table 31 is rotated 180 degrees again, and the lower mold 32B moves from the filling position E2 to the standby position E1. Multiple rotor cores 2 are separated from the lower mold 32B, which has moved to the standby position E1. On the other hand, the lower mold 32A moves from the standby position E1 to the filling position E2, and the rotor cores 2 placed on the lower mold 32A are filled with resin.

[0081] For the lower mold 32B, which returns to the standby position E1, after cleaning, preparation for molding is performed again. In this way, the lower molds 32A and 32B continuously perform molding and preparation or cleaning operations for molding while exchanging positions.

[0082] <Rotor Manufacturing Method>

[0083] Next, refer to Figure 8 The rotor manufacturing method of this embodiment will be described. Figure 8 This is a flowchart illustrating an example of the rotor manufacturing process of this embodiment.

[0084] In the rotor manufacturing method of this embodiment, firstly, as... Figure 8 The rotor core 2 is placed on the intermediate plate 22 (step S01). In this case, the rotor core 2 is positioned relative to the intermediate plate 22 by inserting the protrusion 22B into the through hole 5 of the rotor core 2. It should be noted that the rotor core 2 located at the bottom in the stacked state may not be placed on the intermediate plate 22.

[0085] Next, a permanent magnet 3 and a rotor core 2 to which the permanent magnet 3 is to be assembled are prepared, and the permanent magnet 3 is inserted into the magnet insertion hole 4 of the rotor core 2 (step S02). Then, multiple rotor cores 2 are arranged in a state of being arranged axially with the intermediate plate 22 in between (step S03).

[0086] Next, the intermediate plate 22, rotor core 2, and permanent magnet 3 are preheated (step S04). These components are preheated using known heating methods (not shown). The heating temperature can be set to approximately 100°C to 180°C.

[0087] Multiple rotor cores 2 arranged axially are placed on a support plate 20 (step S05). A sheet T is fed into the lower mold 32 from between the support plate 20 and the lower mold 32 (step S06). For the sheet T fed into the lower mold 32, a heater (not shown) is activated to soften the resin R (step S07). Specifically, heating within the barrel reduces the viscosity of the resin forming the sheet T, forming a softened resin (hereinafter referred to as "softened resin") R. The heater used for this heating is preferably controlled in a manner that does not create localized temperature differences in the sheet T. Through this heating, the sheet T melts and its viscosity decreases, changing into the highly fluid softened resin R.

[0088] Next, the support plate 20, on which multiple rotor cores 2 are placed, descends (step S08). Thus, the multiple rotor cores 2 are placed on the lower mold 32 across the support plate 20. Then, the rotary table 31 rotates (step S09). Thus, the multiple rotor cores 2, arranged axially across the intermediate plate 22, are placed inside the mold.

[0089] By moving the upper mold 33 downward, the rotor core 2 is held within the upper mold 33 and the lower mold 32 (i.e., the mold) (step S10). At this time, the upper mold 33 is adjusted to press the upper surface of the rotor core 2 with a specified pressure, thereby making the upper mold 33 and the upper surface of the rotor core 2, and the lower mold 32 and the lower surface of the intermediate plate 22, respectively, fit tightly together.

[0090] When the sheet material T changes to softened resin R, the softened resin R is filled into the magnet insertion hole 4 via the plunger 34 (step S11). Specifically, the resin R is pressed by moving the plunger 34 upward, injecting the softened resin R into the resin filling path 23. Then, the softened resin R flowing through the resin filling path 23 fills the magnet insertion holes 4 of the plurality of rotor cores 2 arranged along the axial direction. It should be noted that, in order to smoothly perform the filling of the magnet insertion hole 4 with softened resin R in step S10, air holes (not shown) for venting air from the magnet insertion hole 4 can be provided at appropriate positions on the upper mold 33 and the intermediate plate 22.

[0091] The mold heater (not shown) is activated to cure the softened resin R inside the magnet insertion hole 4 (step S12). For example, the mold heater can also be activated before, during, and / or after resin filling, allowing the resin to cure while filling. That is, steps S11 and S12 can be performed simultaneously. When curing the softened resin R, it is preferable to heat it at, for example, 100°C to 180°C for several minutes. The softened resin R is cured by this heating, thereby fixing the permanent magnet 3 to the magnet insertion hole 4 of the rotor core 2 through resin molding. It should be noted that the heating time in step S12 can be appropriately adjusted to match the specific composition of the resin used for the sheet T.

[0092] When the above series of resin molding processes are completed, the upper mold 33 is raised, and the rotary table 31 is rotated (step S13). As a result, the resin-molded rotor core 2 is removed from the mold. The removed rotor core 2 is taken to another device for shaft assembly, etc. (step S14). Then, when the removal of the rotor core 2 is complete, the lower mold 32 is cleaned (step S15). Cleaning the lower mold 32 may include using a brush or other cleaning components to clean the support plate 20, the lower mold 32, or the inside of the barrel.

[0093] As explained above, the rotor core manufacturing apparatus 10 according to this first embodiment allows multiple rotor cores 2 arranged axially in the standby position E1 to be spaced apart from the lower mold 32, and in this state, sheet T is fed into the lower mold 32. Therefore, compared to the case where multiple rotor cores 2 are arranged and sheet T is fed below the upper mold 33, the equipment height can be reduced accordingly to the height of the upper mold 33 and its supporting structure. Furthermore, since sheet T can be fed into the lower mold 32 while the rotor cores 2 are stacked, resin filling can be performed in a shorter time compared to the case where the rotor cores 2 are arranged after sheet T is fed. As a result, the situation where the resin over-cures before filling, making filling difficult, can be suppressed.

[0094] For example, such as Figure 9 As shown, consider the case where multiple rotor cores 2 are arranged axially between the upper mold 33 and the lower mold 132. In this case, in order to place the multiple rotor cores 2 on the support plate 120, the upper mold 33 must be raised accordingly to the amount of rise of the support plate 120 and the clearance required for the arrangement of the multiple rotor cores 2. Furthermore, when molding multiple rotor cores 2, the amount of resin required for filling also increases, the height of the sheet T increases, and therefore the amount of rise of the support plate 120 further increases. As a result, the height of the rotor core manufacturing apparatus 100 increases.

[0095] Furthermore, if the sheet T is pre-inserted into the lower mold 132, the support plate 120 can be lowered, thus reducing the equipment height. However, in this case, the time from insertion to the start of filling is longer compared to the case where multiple rotor cores 2 are installed before insertion. In particular, when multiple rotor cores 2 are arranged axially, the weight and height increase compared to a single core, requiring careful handling and time to place them in the molding apparatus. Therefore, if resin curing occurs further than expected due to the elapsed time since insertion, resin filling becomes difficult. According to this structure, as described above, the equipment height can be reduced accordingly to the height of the upper mold 33 and its support structure, and resin filling can be performed in a shorter time after the sheet T is inserted.

[0096] Furthermore, in the rotor core manufacturing apparatus 10 according to this first embodiment, the lower mold 32 is provided on the rotary table 31. It is also configured to allow the feeding of sheet T into the lower mold 32, which is located in the standby position E1. Therefore, sheet T can be fed into the lower mold 32, which is not located within the mold, thus improving work efficiency. That is, sheet T, which is used for resin filling preparation, can be fed into the mold outside the mold, thereby reducing mold occupancy time and contributing to improved work efficiency in the rotor core manufacturing process.

[0097] Furthermore, according to the rotor core manufacturing apparatus 10 of this first embodiment, the lower mold 32 is provided on the rotary table 31, and the rotation of the rotary table 31 moves the plurality of rotor cores 2 placed on the lower mold 32 to the filling position E2. Since a circular path can be used as the movement trajectory of the lower mold 32 and the plurality of rotor cores 2, the degree of freedom in the equipment layout of the rotor core manufacturing apparatus 10 is increased.

[0098] It should be noted that in this first embodiment, an example of rotating the rotary table 31 by 180 degrees has been described, but the technology disclosed herein is not limited to this. A scheme in which the rotary table 31 rotates by 90 degrees is also possible. In this case, the rotary table 31 is an L-shaped platform when viewed from above, and a rotating shaft portion 36 is provided at the curved portion of the L-shape.

[0099] <<Second Implementation>>

[0100] In the first embodiment described above, an example of using a rotary table 31 in the stage 30 was given, but the technology disclosed herein is not limited thereto. In this second embodiment, a sliding table 40 is used instead of the rotary table 31.

[0101] like Figure 10As shown, the sliding table 40 is a platform-shaped component with a generally cuboid shape when viewed from above. The sliding table 40 is a platform capable of sliding along its longitudinal direction. The sliding table 40 is supported, for example, by a guide rail mechanism and is configured to receive power from a drive source (not shown) and move along the guide rail. Multiple lower molds 32 are provided on the sliding table 40. Figure 10 In the example shown, the sliding table 40 is provided with lower molds 32A and 32B.

[0102] First, multiple rotor cores 2, arranged axially with a gap between them and an intermediate plate 22, are placed on the lower mold 32 of the rotor core manufacturing apparatus 10. Here, lower mold 32A is positioned in the standby position E1, and lower mold 32B is positioned in the filling position E2. The multiple rotor cores 2 are placed on lower mold 32A located in the standby position E1.

[0103] After preparation work is performed in the standby position E1, the lower mold 32A and the plurality of rotor cores 2 are moved from the standby position E1 to the filling position E2 by sliding the sliding table 40 (moving to the left when viewed from the paper side). In the filling position E2, resin is filled into the plurality of rotor cores 2 placed on the lower mold 32A. Meanwhile, the lower mold 32B moves from the filling position E2 to the standby position E3. Preparation work is performed in the lower mold 32B in the standby position E3.

[0104] After resin filling, the lower mold 32A moves from the filling position E2 to the standby position E1 by sliding the sliding table 40 in the opposite direction to the previous movement (moving to the right when viewed from the paper surface side). Multiple rotor cores 2 are separated from the lower mold 32A in the standby position E1. Meanwhile, the lower mold 32B moves from the standby position E3 to the filling position E2, filling the rotor cores 2 placed on the lower mold 32A with resin.

[0105] After cleaning the lower mold 32A, which is in the standby position E1, preparation work for molding is performed again. In this way, while changing the positions of the lower molds 32A and 32B, molding and preparation or cleaning work for molding are performed continuously.

[0106] As explained above, the rotor core manufacturing apparatus 10 according to this second embodiment achieves the same effects as the first embodiment. Furthermore, in the rotor core manufacturing apparatus 10 according to this second embodiment, the lower mold 32 is mounted on a sliding table 40, and the plurality of rotor cores 2 placed on the lower mold 32 move to the filling position E2 by sliding the sliding table 40. Therefore, a straight path can be used as the movement trajectory of the lower mold 32 and the plurality of rotor cores 2, thus increasing the freedom of equipment layout for the rotor core manufacturing apparatus 10.

[0107] It should be noted that, in the second embodiment described above, an example of setting both lower molds 32A and 32B on the sliding table 40 was given, but the technology disclosed herein is not limited to this. For example, three or more lower molds 32 may be set on the sliding table 40.

[0108] <<Third Implementation Method>>

[0109] In the first embodiment described above, an example is given in which two lower molds 32A and 32B are provided in the rotor core manufacturing apparatus 10, but the technology disclosed herein is not limited thereto. In this third embodiment, four lower molds 62A to 62D are provided in the rotor core manufacturing apparatus 10.

[0110] like Figure 11 As shown, the rotor core manufacturing apparatus 10 of this embodiment has a platform 60. The platform 60 is composed of a rotating platform 61 and a plurality of lower dies 62 disposed on the rotating platform 61. The rotating platform 61 is a platform-shaped member with a circular shape when viewed from above. A plurality of lower dies 62 are provided on the upper surface of the rotating platform 61. Figure 1 In the example shown, four lower molds 62A to 62D are provided. A rotating shaft 63 is provided at the center of the rotary table 61. The rotating shaft 63 is configured to receive power from a drive source (not shown) and rotate. Furthermore, the rotary table 61 is configured to rotate with the rotation of the rotating shaft 63. The rotary table 61 is an example of a "support platform" of the present disclosure.

[0111] For ease of explanation, the following description will use lower mold 62A and the plurality of rotor cores 2 mounted on lower mold 62A as examples. The same operation may also be performed on lower molds 62B to 62D and the plurality of rotor cores 2 mounted on them. Furthermore, in the following description, lower molds 62A to 62D will be referred to simply as "lower mold 62" unless there is a need to distinguish between them. Lower mold 62 is an example of the "lower mold" of the present disclosure.

[0112] With the lower die 62A in the preparation position S1, a plurality of rotor cores 2 arranged axially are placed on the support plate 20A. That is, the plurality of rotor cores 2 are positioned above the lower die 62A. The preparation position S1 is an example of the "fourth position" of the present disclosure. Furthermore, with the plurality of rotor cores 2 placed on the support plate 20A, the lower die 62A is moved from the preparation position S1 to the insertion position S2 by rotating the rotary table 61 by 90 degrees. The insertion position S2 is an example of the "first position" of the present disclosure.

[0113] like Figure 12As shown, with the lower die 62A in the input position S2, a sheet T is input into the lower die 62A. The sheet T is input into the lower die 62A from between the support plate 20A and the lower die 62A. Then, by lowering the support plate 20A, multiple rotor cores 2 are placed on the lower die 62A across the support plate 20A. Furthermore, with the multiple rotor cores 2 placed on the lower die 62A, by rotating the rotary table 61 90 degrees, the lower die 62A and the multiple rotor cores 2 move from the input position S2 to the filling position S3. The filling position S3 is an example of the "second position" of the technology disclosed herein.

[0114] like Figure 13 As shown, with the lower mold 62A in the filling position S3, multiple rotor cores 2 are held by the upper mold 65 and the lower mold 62A in a state of axial arrangement separated by the intermediate plate 22. The plunger 64A presses down on the resin R softened by heating the sheet T with a heater (not shown). As a result, the softened resin R flows and, after passing through the resin filling path 23, fills the magnet insertion hole 4 of the rotor core 2.

[0115] With the resin R filled, the lower mold 62A and the plurality of rotor cores 2 are moved from the filling position S3 to the separation position S4 by rotating the rotary table 61 by 90 degrees. That is, the plurality of rotor cores 2, arranged axially, are removed from the mold. The separation position S4 is an example of the "third position" of the technology disclosed herein.

[0116] like Figure 14 As shown, with the lower mold 62A in the separation position S4, multiple rotor cores 2 separate from the support plate 20A. That is, multiple rotor cores 2 separate from the lower mold 62A. The multiple rotor cores 2 removed from the rotor core manufacturing apparatus 10 are conveyed to the next process.

[0117] As explained above, the rotor core manufacturing apparatus 10 according to this third embodiment can achieve the same effects as the first embodiment described above.

[0118] Furthermore, according to the rotor core manufacturing apparatus 10 of this third embodiment, a plurality of lower molds 62 are provided on the rotary table 61. The plurality of rotor cores 2 are separated from the lower molds 62 located at the separation position S4. Therefore, the separation operation of the plurality of rotor cores 2 can be performed on the lower molds 62 which are not located within the mold, thus improving work efficiency. That is, since the separation operation can be performed outside the mold, the mold occupancy time can be reduced, which contributes to improving the work efficiency of the rotor core manufacturing process.

[0119] Furthermore, in the case of multiple rotor cores 2 arranged along the axial direction, if multiple rotor cores 2 are to be separated within the mold, the upper mold 65 needs to be raised accordingly to the amount required for the separation operation. In this structure, since the separation operation is performed outside the mold, it is not necessary to raise the upper mold 65, thus reducing the equipment height.

[0120] Furthermore, according to the rotor core manufacturing apparatus 10 of this third embodiment, a plurality of lower molds 62 are provided on the rotary table 61. And, a plurality of rotor cores 2 are arranged on the lower molds 62 located in the preparation position S1, with the support plate 20 as a secondary consideration. Therefore, the arrangement of multiple rotor cores 2 can be performed on the lower molds 62, which are not located within the mold, thus improving work efficiency. That is, since the arrangement work can be performed outside the mold, the mold occupancy time can be reduced, contributing to improved work efficiency in the rotor core manufacturing process.

[0121] (First variation)

[0122] In the third embodiment described above, an example is given of separating the plurality of rotor cores 2 from the lower mold 62 at the separation position S4, but the technology disclosed herein is not limited thereto. In this first variation, the plurality of rotor cores 2 placed on the lower mold 62 are heated at the separation position S4 for additional curing of resin.

[0123] like Figure 15 As shown, with the lower mold 62A in the separated position S4, additional heating is performed on the plurality of rotor cores 2 mounted on the support plate 20A. This additional heating is performed by a heating device 66. The heating device 66 includes a main body 66A covering the periphery of the plurality of rotor cores 2 and a resistance heater 66B disposed inside. The heating device 66 is configured to be movable relative to the plurality of rotor cores 2, and except when heating is performed, it is retracted to a position that does not interfere with the rotational movement of the plurality of rotor cores 2. In this modified example, the separated position S4 is an example of the "third position" of the technology disclosed herein.

[0124] It should be noted that the heating method is not particularly limited. For example, the heating device 66 can be a hot air circulating furnace, or it can utilize a lamp heater, a high-frequency heater, a block heater, and / or an infrared heater. Furthermore, the example described here is that the heating device 66 heats the rotor cores 2 from the radially outer side, but this is only one example. For example, heating can also be performed using a mold heater (not shown) provided on the lower mold 62A. Additionally, heating can also be performed using a heater that abuts against the upper surface of the uppermost rotor core 2 among the rotor cores 2. Moreover, the rotor cores 2 can be heated while being held between the lower mold 62A and the heater.

[0125] The resin R filling the magnet insertion holes 4 of the multiple rotor cores 2 is further cured by heating using heating device 66. When further curing the resin R, it is preferable to heat it at, for example, 100°C to 180°C for several minutes to several hours. The softened resin R is cured by this heating, thereby fixing the permanent magnets 3 into the magnet insertion holes 4 of the rotor cores 2 by resin molding. It should be noted that the heating time can be adjusted appropriately according to the specific composition of the resin used in the sheet T.

[0126] By additionally curing the resin R, the heat resistance and elastic modulus of the cured resin R are improved, thus improving the performance of the rotary motor when the rotor core 2 is used as a motor. After additionally curing the multiple rotor cores 2 at the separation position S4, the multiple rotor cores 2 separate from the lower mold 62A.

[0127] As explained above, in this first modified example, multiple lower molds 62 are provided on the rotary table 61. Furthermore, at the separation position S4, multiple rotor cores 2 are heated for additional curing. Therefore, additional curing of multiple rotor cores 2 can be performed on the lower molds 62 that are not located within the mold, thus improving work efficiency. In other words, since additional curing can be performed outside the mold, mold occupancy time is reduced, contributing to improved work efficiency in the rotor core manufacturing process.

[0128] Here, an example has been given of heating for additional curing at the separation position S4, after which the plurality of rotor cores 2 separate from the lower mold 62A; however, the technology of this disclosure is not limited thereto. For example, heating for additional curing may also be performed at an additional curing position located between the separation position S4 and the filling position S3. In this case, the additional curing position functions as a "third position" of the technology of this disclosure. Furthermore, it is preferable that the heating for additional curing also takes place during the rotation of the rotary table 61.

[0129] Furthermore, while an example of additional curing by heating with heating device 66 has been described here, the technology disclosed herein is not limited to this. For example, it is also possible to promote resin curing by placing multiple rotor cores 2 in a unified manner without using heating device 66, and utilizing the heat storage of the rotor cores 2. In this case, the time for placing the multiple rotor cores 2 is, for example, several minutes to several hours.

[0130] (Second variation)

[0131] In the third embodiment described above, an example was given in which multiple rotor cores 2 were arranged in the lower mold 62 located in the preparation position S1, but the technology disclosed herein is not limited thereto. In this first variation, the multiple rotor cores 2 are preheated in the preparation position S1.

[0132] like Figure 16 As shown, with the lower mold 62A in the preparation position S1, the plurality of rotor cores 2 placed on the support plate 20A are preheated. Preheating is performed by a heating device 68. The heating device 68 includes a main body 68A covering the periphery of the plurality of rotor cores 2 and a resistance heater 68B disposed inside. The heating device 68 is configured to be movable relative to the plurality of rotor cores 2, except when heating is being performed, and to be retracted to a position that does not interfere with the rotational movement of the plurality of rotor cores 2. In this modified example, the preparation position S1 is an example of the "fourth position" of the technology disclosed herein.

[0133] It should be noted that the heating method is not particularly limited. For example, the heating device 68 can be a hot air circulating furnace, or it can utilize a lamp heater, a high-frequency heater, a block heater, and / or an infrared heater. Furthermore, the example described here is that the heating device 68 heats the rotor cores 2 from the radially outer side, but this is only one example. For example, heating can also be performed using a mold heater (not shown) provided on the lower mold 62A. Additionally, heating can also be performed using a heater that abuts against the upper surface of the uppermost rotor core 2 among the rotor cores 2. Moreover, the rotor cores 2 can be heated while being held between the lower mold 62A and the heater.

[0134] When filling the magnet insertion hole 4 with resin, if the multiple rotor cores 2 are at low temperatures, the resin will cool down and its fluidity will decrease. As a result, the resin may not fill the magnet insertion hole 4 completely. By preheating the multiple rotor cores 2, the fluidity of the resin is ensured, making it easier to fill the hole.

[0135] After preheating multiple rotor cores 2 at the preparation position S1, the lower mold 62A and multiple rotor cores 2 are moved to the insertion position S2.

[0136] As explained above, in this second variation, multiple lower molds 62 are provided on the rotary table 61. Furthermore, multiple rotor cores 2 are preheated at the preparation position S1. Therefore, multiple rotor cores 2 can be preheated even though the lower molds 62 are not located within the mold, thus improving work efficiency. In other words, since preheating can be performed outside the mold, mold occupancy time is reduced, contributing to improved work efficiency in the rotor core manufacturing process.

[0137] Here, an example of preheating is given after placing multiple rotor cores 2 on the support plate 20A at the preparation position S1, but the technology of this disclosure is not limited to this. For example, preheating can also be performed at a preheating position located between the preparation position S1 and the input position S2. In this case, the preheating position functions as a "fourth position" of the technology of this disclosure. Furthermore, it is preferable that preheating is also performed during the rotation of the rotary table 61.

[0138] Furthermore, in this second variation, an example of preheating multiple rotor cores 2 has been described, but the technology disclosed herein is not limited to this. The lower mold 62 may be preheated in place of the multiple rotor cores 2 or together with the preheating of the multiple rotor cores 2. In this case, the preheating of the lower mold 62 may be performed by a mold heater (not shown).

[0139] It should be noted that the first modified example and this second modified example can also be combined. That is, the resin can be added and cured at the separation position S4, and the rotor core 2 can be preheated at the preparation position S1.

[0140] Furthermore, in the third embodiment described above, additional resin curing and separation of the multiple rotor cores 2 from the lower mold 62 can also be performed at the filling position S3. However, as mentioned above, from the viewpoint of reducing mold occupation time, it is preferable to perform additional resin curing and separation of the multiple rotor cores 2 from the lower mold 62 at the separation position S4.

[0141] Furthermore, in the third embodiment described above, multiple rotor cores 2 can be set up, multiple rotor cores 2 can be preheated, and sheet T can be added at the preparation position S1.

[0142] Furthermore, in the third embodiment described above, an example of having four lower dies 62 on the rotary table 61 was given, but the technology disclosed herein is not limited to this. For example, three lower dies 62 may be provided, or even five or more lower dies 62 may be provided. In addition, the shape of the rotary table 61 may not be circular; for example, it may be polygonal.

[0143] (Other variations)

[0144] Furthermore, in the above embodiments, examples of filling resin by means of a plunger 34 or 64 located in the center of the lower mold 32 or 62 have been described, but the technology disclosed herein is not limited to this. For example, resin can also be filled by an annular plunger that presses an annular resin sheet. Alternatively, a solution can be made by using a multi-plunger consisting of multiple plungers to press the sheet disposed at a position opposite to the magnet insertion hole 4 along the circumference of the lower mold 32 or 62.

[0145] Furthermore, in the above embodiments, examples have been given of the intermediate plate 22 being quadrilateral when viewed from above; however, the technology disclosed herein is not limited to this. The intermediate plate 22 may also be other polygons, or it may be circular.

[0146] The descriptions and illustrations shown above are detailed explanations related to the parts of the technology disclosed herein, and are merely examples of the technology disclosed herein. For example, the descriptions related to the structure, function, role, and effect described above are descriptions related to an example of the structure, function, role, and effect of the parts of the technology disclosed herein. Therefore, it goes without saying that unnecessary parts can be deleted, new elements can be added, or substitutions can be made to the descriptions and illustrations shown above without departing from the spirit of the technology disclosed herein. Furthermore, to avoid confusion and facilitate understanding of the parts of the technology disclosed herein, descriptions of common technical knowledge and other related information that do not require special explanation in terms of implementing the technology disclosed herein have been omitted from the descriptions and illustrations shown above.

[0147] In this specification, "A and / or B" has the same meaning as "at least one of A and B". That is, "A and / or B" means either only A, only B, or a combination of A and B. Furthermore, in this specification, the same concept applies when "and / or" is used to associate more than three items.

[0148] All documents, patent applications and technical standards described in this specification are incorporated herein by reference to the same extent that each document, patent application and technical standard is specifically described and incorporated herein by reference.

[0149] Regarding the above-described embodiments, the following notes are further disclosed.

[0150] <Postscript 1>

[0151] A method for manufacturing a motor, comprising:

[0152] In the first position, with multiple iron cores arranged axially with a gap between them from the lower die upwards, the sheet is inserted into the lower die.

[0153] The aforementioned multiple iron cores are lowered toward the aforementioned lower mold;

[0154] Move the lower mold and the plurality of iron cores to a second position opposite to the upper mold; and

[0155] At the second position mentioned above, resin is filled into the resin-filled portions formed on the plurality of iron cores respectively.

[0156] <Appendix 2>

[0157] According to the motor manufacturing method described in Appendix 1, wherein,

[0158] Multiple lower molds are mounted on a support platform.

[0159] The motor manufacturing method is configured to feed the aforementioned sheet into the aforementioned lower die located in the aforementioned first position among a plurality of the aforementioned lower dies.

[0160] <Appendix 3>

[0161] According to the motor manufacturing method described in Appendix 1 or Appendix 2, wherein,

[0162] The aforementioned lower mold is mounted on a support platform.

[0163] By rotating the support platform, the lower mold and the plurality of iron cores are moved to the second position.

[0164] <Appendix 4>

[0165] According to the motor manufacturing method described in Appendix 1 or Appendix 2, wherein,

[0166] The aforementioned lower mold is mounted on a support platform.

[0167] By sliding the support platform, the lower mold and the plurality of iron cores move to the second position.

[0168] <Appendix 5>

[0169] According to any one of Annexes 1 to 4, in the motor manufacturing method, wherein,

[0170] Multiple lower molds are mounted on a support platform.

[0171] The plurality of iron cores filled with the resin are separated from the third lower mold among the plurality of the aforementioned lower molds.

[0172] <Appendix 6>

[0173] According to any one of Annexes 1 to 5, in the motor manufacturing method, wherein,

[0174] Multiple lower molds are mounted on a support platform.

[0175] The plurality of iron cores of the lower molds, which are placed in the third position among the plurality of lower molds, are subjected to heating for additional curing of the resin.

[0176] <Appendix 7>

[0177] According to any one of Annexes 1 to 6, in the motor manufacturing method, wherein,

[0178] Multiple lower molds are mounted on a support platform.

[0179] Above the fourth lower mold in one of the plurality of the aforementioned lower molds, the plurality of iron cores are disposed prior to the filling of the aforementioned resin.

[0180] <Postscript 8>

[0181] According to any one of Annexes 1 to 7, in the motor manufacturing method, wherein,

[0182] Multiple lower molds are mounted on a support platform.

[0183] The lower mold located at the fourth position among the plurality of the aforementioned lower molds and / or the plurality of iron cores before the aforementioned resin filling are preheated.

[0184] Furthermore, the entire disclosure of Japanese Invention Patent Application No. 2024-057132, filed on March 29, 2024, is incorporated herein by reference. All documents, patent applications, and technical standards described herein are incorporated herein by reference to the same extent that each document, patent application, and technical standard is specifically and separately described and incorporated herein by reference.

Claims

1. A method for manufacturing a motor, comprising: In the first position, with multiple iron cores arranged axially with a gap between them from the lower die upwards, the sheet is inserted into the lower die. The plurality of iron cores are lowered toward the lower mold; Move the lower mold and the plurality of iron cores to a second position opposite to the upper mold; as well as At the second position, resin is filled into the resin-filled portions formed on the plurality of iron cores respectively.

2. The motor manufacturing method according to claim 1, wherein, Multiple lower molds are mounted on a support platform. The motor manufacturing method is configured to feed the material sheet into the lower mold located at the first position among a plurality of lower molds.

3. The motor manufacturing method according to claim 1, wherein, The lower mold is mounted on a support platform. By rotating the support platform, the lower mold and the plurality of iron cores move to the second position.

4. The motor manufacturing method according to claim 1, wherein, The lower mold is mounted on a support platform. By sliding the support platform, the lower mold and the plurality of iron cores move to the second position.

5. The motor manufacturing method according to claim 1, wherein, Multiple lower molds are mounted on a support platform. The resin-filled iron cores are separated from the lower mold located in the third position of the plurality of lower molds.

6. The motor manufacturing method according to claim 1, wherein, Multiple lower molds are mounted on a support platform. The plurality of iron cores of the lower molds, which are placed in the third position among the plurality of lower molds, are heated for additional curing of the resin.

7. The motor manufacturing method according to claim 1, wherein, Multiple lower molds are mounted on a support platform. Above the fourth lower mold in one of the plurality of lower molds, the plurality of iron cores are configured prior to the filling of the resin.

8. The motor manufacturing method according to claim 1, wherein, Multiple lower molds are mounted on a support platform. The lower mold located at the fourth position among the plurality of lower molds and / or the plurality of iron cores before the resin filling are preheated.

9. A motor manufacturing apparatus, comprising: The support mechanism supports multiple iron cores arranged axially with a middle plate in a first position so that they can be raised and lowered freely until the multiple iron cores reach a position where the sheet can be inserted into the lower mold. A moving mechanism moves the lower mold and the plurality of iron cores to a second position opposite to the upper mold; as well as The resin filling mechanism fills the resin filling portions formed on the plurality of iron cores respectively at the second position with resin.

Images