Motor manufacturing method, motor manufacturing apparatus, and motor manufacturing system

Abstract

The present application provides a motor manufacturing method, a motor manufacturing device, and a motor manufacturing system that can contribute to an increase in productivity in a motor core manufacturing process. The motor manufacturing method includes: transporting a plurality of cores each placed on a plurality of first plates to a mold by a transport mechanism; placing the plurality of cores each on a plurality of second plates through the first plates, the plurality of second plates being provided at predetermined positions in the mold by a holding mechanism; and filling a resin into resin filling portions each formed in the plurality of cores in a state in which the plurality of cores are arranged in an axial direction through intermediate plates each including the first plate and the second plate.

Description

Technical Field

[0001] This disclosure relates to a method for manufacturing a motor, an apparatus for manufacturing a motor, and a system 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 while the iron cores are arranged axially, the iron cores are integrally formed and then placed in a mold with an intermediate plate sandwiched between them. This results in both the integral forming operation and the mold setting operation. Consequently, the number of steps increases, leading to a decrease in the productivity of the motor iron core manufacturing process.

[0005] In view of the above-mentioned problems, the present disclosure aims to provide a motor manufacturing method, motor manufacturing apparatus, and motor manufacturing system that can help improve 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: conveying a plurality of iron cores respectively placed on a plurality of first plates to a mold via a conveying mechanism; placing the plurality of iron cores respectively on a plurality of second plates through the first plates, the plurality of second plates being disposed in predetermined positions within the mold by a holding mechanism; and filling resin into resin-filled portions respectively formed on the plurality of iron cores while the plurality of iron cores are arranged axially through an intermediate plate comprising the first plates and the second plates.

[0008] The second aspect of the technology disclosed herein is the motor manufacturing method of the first aspect, wherein the holding mechanism is configured to lower the second plate, which is in a state of having an iron core placed on top of the first plate.

[0009] The third aspect of the technology disclosed herein is the motor manufacturing method of the first aspect, wherein, in a state in which multiple iron cores are arranged axially with a middle plate between them, the engagement of the second plate by the retaining mechanism can be released.

[0010] The fourth aspect of the technology disclosed herein is the motor manufacturing method of the first aspect, wherein the second plate is configured to move freely up and down within the mold via a holding mechanism.

[0011] The fifth aspect of the technology disclosed herein is the motor manufacturing method of the fourth aspect, wherein a plurality of second plates are respectively configured to move up and down freely within the mold independently of each other.

[0012] The sixth aspect of the technology disclosed herein is the motor manufacturing method of the first aspect, wherein the retaining mechanism comprises a plurality of shaft members that can extend and retract axially, and when the plurality of shaft members extend, the plurality of shaft members are respectively configured to engage with the engaging portion of their respective corresponding second plates.

[0013] The seventh aspect of the technology disclosed herein is the motor manufacturing method of the sixth aspect, wherein multiple shaft components are configured as telescope-type structures.

[0014] The eighth aspect of the technology disclosed herein is the motor manufacturing method of the first aspect, wherein the conveying mechanism comprises a plurality of support portions for multiple iron cores to be respectively placed across a first plate.

[0015] The ninth aspect of the technology disclosed herein is the motor manufacturing method of the eighth aspect, wherein the support portion is arranged axially along a plurality of iron cores.

[0016] The tenth aspect of the technology disclosed herein is a motor manufacturing method of the first aspect, wherein a through hole is formed on the first plate and the second plate at a position corresponding to the resin filling portion, and the opening area of ​​the through hole is smaller along the direction orthogonal to the through direction as it tends to the side opposite to the iron core in the through direction.

[0017] The eleventh aspect of the present disclosure is the tenth aspect of the motor manufacturing method, wherein, when the through hole is viewed in section along the through direction, and the angle formed by a pair of imaginary straight lines along the outer edge of the through hole is set as a cone angle, the cone angle of the through hole formed in the first plate is larger than the cone angle of the through hole formed in the second plate.

[0018] The twelfth aspect of the present disclosure is a motor manufacturing method of the first aspect, wherein a positioning part is provided on the first plate and / or the second plate, and the positioning part, in the state where the first plate is placed on the second plate, makes the first plate and the second plate have a predetermined positional relationship with each other.

[0019] A thirteenth aspect of the technology disclosed herein is a motor manufacturing apparatus including: a holding mechanism that holds a plurality of second plates at predetermined positions in a mold, the plurality of second plates being configured to be able to place a plurality of cores that are transported into the mold in a state of being placed on a plurality of first plates with the first plates interposed; and a resin filling mechanism that fills resin into resin filling portions formed in the plurality of cores in a state in which the plurality of cores are arranged in an axial direction with an intermediate plate including the first plates and the second plates interposed.

[0020] A fourteenth aspect of the technology disclosed herein is a motor manufacturing system including: a transport mechanism that transports a plurality of cores placed on a plurality of first plates into a mold; a holding mechanism that holds a plurality of second plates at predetermined positions in the mold, the plurality of second plates being configured to be able to place the plurality of cores with the first plates interposed; and a resin filling mechanism that fills resin into resin filling portions formed in the plurality of cores in a state in which the plurality of cores are arranged in an axial direction with an intermediate plate including the first plates and the second plates interposed.

[0021] Effects of Invention

[0022] According to the present disclosure, a motor manufacturing method, a motor manufacturing apparatus, and a motor manufacturing system that can contribute to an increase in productivity in a motor core manufacturing process are provided. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 is a schematic explanatory view that shows one example of a schematic structure of a rotor manufacturing system of an embodiment.

[0024] Figure 2 is a perspective view that shows a schematic structure of a rotor core and an upper side plate of an embodiment.

[0025] Figure 3 is a schematic explanatory view that shows one example of a situation in which a plurality of rotor cores are transported by a robot arm of an embodiment.

[0026] Figure 4 is a schematic explanatory view that shows one example of a situation in which a plurality of rotor cores are transported by a robot arm of an embodiment.

[0027] Figure 5 is a schematic explanatory view that shows one example of a situation in which a rotor core is placed on a lower side plate with an upper side plate interposed of an embodiment.

[0028] Figure 6 is a schematic explanatory view that shows one example of a situation in which a rotor core is placed on a lower mold with an upper side plate interposed of an embodiment.

[0029] Figure 7 is a schematic explanatory view that shows one example of a situation in which a robot arm retreats from a molding apparatus of an embodiment.

[0030] Figure 8 is a schematic explanatory view showing one example of a case where a plurality of rotor cores of the embodiment are stacked along the axial direction.

[0031] Figure 9 is a schematic explanatory view showing one example of a case where molding of the embodiment and a case where the plurality of rotor cores are separated.

[0032] Figure 10 is a flowchart showing one example of a process of manufacturing the rotor core of the embodiment.

[0033] Figure 11 is a schematic explanatory view showing one example of a case where preheating of the lower side plate of the embodiment.

[0034] Figure 12 is a schematic explanatory view showing one example of a case where the plurality of rotor cores are transported by the robot arm of the embodiment.

[0035] Figure 13 is a schematic explanatory view showing one example of a case where a plurality of rotor cores of the embodiment are stacked along the axial direction.

[0036] Figure 14 is a schematic explanatory view showing one example of a case where the plurality of rotor cores are transported by the robot arm of the embodiment.

[0037] Figure 15 is a schematic explanatory view showing one example of a schematic structure of the rotor manufacturing system of the embodiment. DETAILED DESCRIPTION

[0038] Hereinafter, each embodiment for carrying out the present disclosure will be described with reference to the drawings. Note that hereinafter, the range to be explained for the purpose of the present disclosure will be schematically shown, and mainly the range to be explained of the present disclosure will be explained, and the portion to be omitted of the explanation is publicly known technology. Further, the same or similar signs are attached to the members which are the same or corresponding to each other in the drawings, and the repeated explanation is omitted. Also, in a case where a plurality of members which are the same or corresponding to each other are included in one drawing, sometimes only some of the members are attached with the signs for the convenience of observing the drawing.

[0039] <<First Embodiment>>

[0040] <<Outline of Rotor Manufacturing System>>

[0041] First, the outline of the rotor manufacturing system 1 of the embodiment will be explained with reference to Figure 1 and Figure 2 Figure 1 is a schematic explanatory view showing the outline of the rotor manufacturing system 1 of the embodiment.​Figure 2 This is a perspective view showing the schematic structure of the rotor core 2 and the upper side plate 22 in this embodiment.

[0042] like Figure 1 As shown, rotor manufacturing system 1 is a manufacturing system capable of manufacturing rotor core 2. Rotor manufacturing system 1 is an example of a "motor manufacturing system" according to the present disclosure. Rotor manufacturing system 1 comprises a robotic arm 10 and a molding apparatus 30. The robotic arm 10 is an arm capable of conveying rotor core 2. The robotic arm 10 comprises an arm body 11 and an end effector 12. Under the control of a control device 14, the arm body 11 moves the rotor core 2 to a predetermined position. The end effector 12 is mounted at the front end of the arm body 11. In the arm body 11, the link portion 11B is rotated via multiple joints 11A, thereby realizing the movement of the end effector 12. Rotor core 2 is an example of a "core" according to the present disclosure. The robotic arm 10 is an example of a "conveyor mechanism" according to the present disclosure.

[0043] The end effector 12 has a frame-like structure capable of supporting multiple rotor cores 2. Specifically, the end effector 12 includes a main body 12A and support parts 12B. The main body 12A is a member extending in the vertical direction, and multiple support parts 12B are spaced apart in the vertical direction of the main body 12A. In other words, the support parts 12B are arranged along the axial direction of the multiple rotor cores 2 (that is, the direction of the central axis of the cylindrical rotor cores 2). The support parts 12B are an example of the "support parts" of the present disclosure.

[0044] Support portion 12B is a part that supports the upper side plate 22 on which the rotor core 2 is mounted. In other words, multiple rotor cores 2 are respectively mounted on multiple support portions 12B with respect to the upper side plate 22. The support portions 12B support the upper side plate 22 from below. The structure of the support portion 12B will be described later. Figure 1 In the example shown, there are four support sections 12B, and the end effector 12 has a four-layer frame structure.

[0045] The rotor core 2 is transported by the robotic arm 10 in a position where it is placed on the upper side plate 22. The robotic arm 10 can transport multiple rotor cores 2. Figure 1 In the example shown, four rotor cores 2 are transported by the robotic arm 10, each mounted on the upper side plate 22. It should be noted that this is just an example; of course, two or three rotor cores 2 can also be transported, and even more than five rotor cores 2 can be transported.

[0046] 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.

[0047] Furthermore, the multiple rotor cores 2 manufactured by the rotor manufacturing system 1 of this embodiment can be stacked for use in the same motor core or for different motor cores. Additionally, the motor described in this specification also includes a semi-finished product state in which certain components are assembled into the motor core (rotor core, stator core).

[0048] 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, around 10 to 40. The magnet insertion hole 4 is an example of the "resin-filled part" of the technology disclosed herein.

[0049] The magnet insertion hole 4 of the rotor core 2 is a hole for inserting and fixing a permanent magnet 3 inside it. 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 not necessary for the permanent magnet 3 to be magnetized at the time of insertion into the magnet insertion hole 4. Also, it is not necessary for the permanent magnet 3 to be 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 upper through hole 22A provided on the upper side plate 22.

[0050] 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 31 and the lower mold 32 are molds with generally flat abutment surfaces, but the shape of the abutment surfaces of the upper mold 31 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 molding apparatus 30 of this embodiment is used for resin molding of an inner rotor type stator core, it is preferable that the upper mold 31 and the lower mold 32 are molds that include protrusions to be inserted into the space formed in the center of the stator core.

[0051] exist Figure 2 In the example shown, the upper side plate 22 has a quadrilateral shape when viewed from above. The rotor core 2 is mounted on the upper surface of the upper side plate 22. The rotor core 2 is mounted on the upper side plate 22 with the central axis of the upper side plate 22 approximately aligned with the central axis of the rotor core 2. Furthermore, the upper side 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 sufficient to provide rigidity for supporting the rotor core 2). The upper side plate 22 is an example of a "first plate" of the present disclosure.

[0052] An upper through hole 22A is formed in the upper side plate 22, extending through the plate thickness direction. The upper 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 upper side plate 22, the upper through hole 22A communicates with the magnet insertion hole 4. The number and arrangement of the upper through holes 22A are determined according to the number and arrangement of the magnet insertion holes 4 in the rotor core 2. The upper through hole 22A is an example of a "through hole" in the technology of this disclosure.

[0053] Furthermore, the upper side plate 22 has a protrusion 22B that protrudes from the surface on which the rotor core 2 is mounted (here, the upper surface). The protrusion 22B is cylindrical and is configured 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 upper side plate 22. Furthermore, by engaging the protrusion 22B with the through hole 5, the rotor core 2 is prevented from falling off the mounting surface of the upper side 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.

[0054] 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).

[0055] like Figure 1 As shown, the molding apparatus 30 is an apparatus capable of filling the magnet insertion holes 4 of a plurality of rotor cores 2 with resin (i.e., performing molding). Specifically, the molding apparatus 30 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.

[0056] The molding apparatus 30 includes an upper mold 31, a lower mold 32, and a plunger 34. A holding mechanism 40 is provided in the molding apparatus 30. The holding mechanism 40 is a mechanism that holds the lower side plates 24A to 24C in a predetermined position within the molding apparatus 30. In other words, the lower side plates 24A to 24C are positioned in a predetermined position between the upper mold 31 and the lower mold 32 (hereinafter referred to as "within the mold") by the holding mechanism 40. Multiple rotor cores 2 are respectively mounted on the lower side plates 24A to 24C, separated by the upper side plate 22. In the following description, the lower side plates 24A to 24C are referred to simply as "lower side plate 24" unless it is necessary to distinguish between them.

[0057] The retaining mechanism 40 is an example of a "retaining mechanism" according to the present disclosure. Furthermore, the lower side plate 24 is an example of a "second plate" according to the present disclosure. The molding apparatus 30 is an example of a "motor manufacturing apparatus" according to the present disclosure. The plunger 34 is an example of a "resin filling mechanism" according to the present disclosure.

[0058] A lower through hole 26 is formed in the lower side plate 24, extending along the plate thickness direction. The lower through hole 26 is formed opposite to the upper through hole 22A of the upper side plate 22. That is, when the upper side plate 22 is placed on the lower side plate 24, the upper through hole 22A communicates with the lower through hole 26. The lower through hole 26 is an example of a "through hole" in the present disclosure.

[0059] Furthermore, the retaining mechanism 40 holds the lower side plate 24 within the mold so that it can move freely up and down. In other words, the lower side plate 24 is configured to move freely up and down within the mold. More specifically, the lower side plates 24A to 24C are each configured to move freely up and down within the mold independently of each other.

[0060] exist Figure 1 In the example shown, the retaining mechanism 40 is configured to include a plurality of shaft members 42A to 42D. The plurality of shaft members 42A to 42D are configured to extend and retract freely along their axial direction. Specifically, the plurality of shaft members 42A to 42D are each configured to receive power from a drive source (e.g., an actuator) not shown and move in the vertical direction.

[0061] Multiple shaft members 42A to 42D are configured as telescopic structures. Specifically, the multiple shaft members 42A to 42D are arranged coaxially and are designed to extend and retract in the vertical direction. The diameters of the multiple shaft members 42A to 42D decrease sequentially, with the smaller diameter support inserted into the larger diameter support. Specifically, shaft member 42B is inserted inside shaft member 42A, shaft member 42C is inserted inside shaft member 42B, and shaft member 42D is inserted inside shaft member 42C. Shaft members 42A to 42D are an example of the "multiple shaft members" of the present disclosure.

[0062] Engaging portions 44A to 44C are provided on the lower side plates 24A to 24C respectively. The engaging portions 44A to 44C are portions extending from the ends of the lower side plates 24A to 24C. The engaging portions 44A to 44C are an example of the "engaging portion" of the technology of this disclosure.

[0063] Furthermore, the multiple shaft members 42A to 42C are respectively configured to engage with the engaging portions 44A to 44C when extended. Specifically, the upper surface of shaft member 42A abuts against the lower surface of engaging portion 44A as shaft member 42A extends. Similarly, the upper surface of shaft member 42B abuts against the lower surface of engaging portion 44B as shaft member 42B extends. Likewise, the upper surface of shaft member 42C abuts against the lower surface of engaging portion 44C as shaft member 42C extends. As a result, the lower side plate 24 rises to a predetermined position in the molding apparatus 30. Furthermore, by retracting the multiple shaft members 42A to 42C, the corresponding position of the lower side plate 24 also decreases. Thus, the lower side plate 24 is configured to move freely up and down within the mold.

[0064] Furthermore, through holes 46A to 46C are formed in the engaging portions 44A to 44C respectively. Shaft members 42B to 42D are inserted into the through holes 46A to 46C respectively. The diameter of the through holes 46A to 46C is set according to the diameter of the inserted shaft members 42B to 42D. Thus, the engaging portions 44A to 44C selectively engage with the shaft members 42A to 42C respectively, and the lower side plates 24A to 24C can be raised and lowered independently.

[0065] The molding device 30 operates under the control of the control device 35. It should be noted that the molding device 30 and the robotic arm 10 can also be controlled by a common control device.

[0066] Next, refer to Figure 3 and Figure 4 The following describes the scenario where multiple rotor cores 2 are transported via robotic arm 10. Figure 3 and Figure 4 This is a schematic diagram illustrating an example of how multiple rotor cores 2 are transported by a robotic arm 10 in this embodiment.

[0067] like Figure 3 As shown, multiple rotor cores 2 are preheated in a heating device 50. The heating device 50 is a device for heating multiple rotor cores 2. The heating device 50 includes a furnace body 52 and a conveying section 54. The multiple rotor cores 2 are preheated inside the furnace body 52 while being placed on an upper side plate 22. Heating methods include, for example, a hot air circulating furnace, but this is just one example. Of course, heating methods utilizing lamp heaters, high-frequency heaters, block heaters, and / or infrared heaters can also be used, such as those for the heating device 50. Furthermore, the heating device 50 may not be intermittent, but rather a continuous heating device.

[0068] The preheated rotor core 2 is removed from the furnace body 52 via the conveyor section 54. Specifically, the rotor core 2, placed on the upper side plate 22, is removed by rotating the furnace roller 54A provided on the conveyor section 54. The robotic arm 10 moves the end effector 12 to the vicinity of the heating device 50. Then, the robotic arm 10 picks up the rotor core 2 discharged from the heating device 50 via the support section 12B. Specifically, the robotic arm 10 places the rotor core 2 on the support section 12B with the upper side plate 22 in between. Figure 3 In the middle, the rotor core 2 is placed on the uppermost support part 12B, but the rotor core 2 is also placed on the remaining support parts 12B.

[0069] like Figure 4 As shown, the robotic arm 10 transports multiple rotor cores 2 to the molding apparatus 30. The multiple rotor cores 2 are respectively placed on multiple upper side plates 22, and in this state, the multiple rotor cores 2 are transported into the mold by the robotic arm 10.

[0070] Then, multiple rotor cores 2 are placed within the mold of the molding apparatus 30. Specifically, the multiple rotor cores 2 are respectively placed on lower side plates 24A to 24C within the molding apparatus 30, separated by an upper side plate 22. Furthermore, the lowermost rotor core 2 among the multiple rotor cores 2 is placed on a lower mold 32, separated by an upper side plate 22. When the rotor cores 2 are placed within the mold, a gap exists between the rotor core 2 and the lower side plate 24 located above the rotor core 2. Therefore, interference between the rotor core 2, the upper side plate 22, and the lower side plate 24 can be suppressed when the rotor core 2 is placed.

[0071] Furthermore, when multiple rotor cores 2 are disposed in the mold, a sheet T (i.e., a resin material solidified into a specified shape) is inserted into the interior of the lower mold 32 and above the plunger 34.

[0072] Next, refer to Figure 5 and Figure 6 The situation where the rotor core 2 is set in the mold via the upper side plate 22 will be explained.Figure 5 This is a schematic diagram illustrating an example of a rotor core 2 in this embodiment being placed on a lower side plate 24 with the upper side plate 22 in between. Figure 6 This is a schematic diagram illustrating an example of a rotor core 2 of this embodiment being placed on the lower mold 32 with the upper side plate 22 in between.

[0073] like Figure 5 As shown, the rotor core 2 is transported with the upper side plate 22 mounted on the support portion 12B. The support portion 12B has a pair of protrusions 12B1. The pair of protrusions 12B1 are portions that support the upper side plate 22 from below at both ends in the width direction (here, the vertical direction when viewed from the surface of the paper). The distance between the pair of protrusions 12B1 is longer than the width direction distance of the lower side plate 24. Thus, when the rotor core 2 and the upper side plate 22 are positioned above the lower side plate 24, the lower side plate 24 enters between the pair of protrusions 12B1. That is, the pair of protrusions 12B1 do not interfere with the lower side plate 24.

[0074] After the rotor core 2 and the upper side plate 22 are moved above the lower side plate 24, the rotor core 2 and the upper side plate 22 descend toward the lower side plate 24. Thus, the rotor core 2 is placed on the lower side plate 24 with respect to the upper side plate 22. In this case, the upper side plate 22 is positioned relative to the lower side plate 24. Specifically, a positioning part 33 is provided on the upper side plate 22 and the lower side plate 24, which, when the upper side plate 22 is placed on the lower side plate 24, positions the upper side plate 22 and the lower side plate 24 in a predetermined positional relationship. The positioning part 33 is an example of a "positioning part" in the present disclosure.

[0075] The positioning part 33 includes a recess 33A on the upper side plate 22 and a protrusion 33B on the lower side plate 24. When the upper side plate 22 descends toward the lower side plate 24, the recess 33A and the protrusion 33B engage. Thus, the upper side plate 22 and the lower side plate 24 are in a predetermined positional relationship. After the rotor core 2 and the upper side plate 22 are placed on the lower side plate 24, the support part 12B retracts from the mold.

[0076] It should be noted that, in Figure 5 The example shown illustrates a configuration where protrusions 33B are located at the four corners of the lower side plate 24, and recesses 33A are located in the upper side plate 22 at positions corresponding to the protrusions 33B. However, this is only one example. The number and arrangement of the recesses 33A and protrusions 33B can be appropriately set according to factors such as positioning accuracy. Furthermore, an example is shown where recesses 33A are located in the upper side plate 22 and protrusions 33B are located in the lower side plate 24, but the technology disclosed herein is not limited to this. Alternatively, protrusions 33B may be located in the upper side plate 22, and recesses 33A may be located in the lower side plate 24.

[0077] like Figure 6As shown, the lowermost rotor core 2 among multiple rotor cores 2 is conveyed in a state where it is placed on the support portion 12B with the upper side plate 22 as a barrier. A pair of slots 32A are formed in the lower mold 32 on which the lowermost rotor core 2 is placed. The pair of slots 32A are located at positions corresponding to a pair of protrusions 12B1. When the rotor core 2 is placed on the lower mold 32 with the upper side plate 22 as a barrier, the pair of protrusions 12B1 are accommodated in the pair of slots 32A. After the rotor core 2 and the upper side plate 22 are placed on the lower mold 32, the support portion 12B retracts from the mold.

[0078] A through hole 32B is formed in the center of the lower mold 32. The through hole 32B is positioned opposite the injection port of the resin filling channel 23 located on the lowermost upper side plate 22. Furthermore, the aforementioned sheet T is inserted into the through hole 32B. Details will be described later. The through hole 32B communicates with the resin filling channel 23, thereby allowing the softened sheet T to flow within the resin filling channel 23 and enter the magnet insertion hole 4 through the upper through hole 22A.

[0079] Next, refer to Figures 7-9 The situation where the magnet insertion hole 4 of the opposing rotor core 2 is filled with resin will be explained. Figure 7 This is a schematic diagram illustrating an example of the robotic arm 10 of this embodiment retracting from the molding apparatus 30. Figure 8 This is a schematic diagram illustrating an example of a plurality of rotor cores 2 stacked along the axial direction in this embodiment. Figure 9 This is a schematic diagram illustrating an example of the molding process and the separation of multiple rotor cores 2 in this embodiment.

[0080] like Figure 7 As shown, after multiple rotor cores 2 are placed in the mold, the robotic arm 10 retracts from the molding apparatus 30. Specifically, multiple rotor cores 2 are placed on the lower side plate 24 with respect to the upper side plate 22, and the lowermost rotor core 2 is placed on the lower mold 32. Furthermore, by moving the robotic arm 10 in a direction spaced apart from the molding apparatus 30, the support portion 12B is pulled out of the mold.

[0081] like Figure 8 As shown, the rotor core 2 is mounted on the lower side plate 24, separated by the upper side plate 22. Here, the upper side plate 22 is mounted on the lower side plate 24, thereby the upper side plate 22 and the lower side plate 24 function as an intermediate plate 29. The intermediate plate 29 is an example of an "intermediate plate" in the technology of this disclosure.

[0082] Furthermore, the lower side plate 24 is lowered by the retaining mechanism 40. Specifically, the lower side plates 24A to 24C are lowered by sequentially contracting the shaft members 42A to 42D of the retaining mechanism 40. In this way, the retaining mechanism 40 can lower the lower side plate 24, which has the rotor core 2 mounted on the upper side plate 22.

[0083] Thus, multiple rotor cores 2 are arranged axially within the mold, separated by an intermediate plate 29. In other words, multiple rotor cores 2 are stacked axially, separated by an intermediate plate 29. In this way, the rotor cores 2 and the intermediate plate 29 are stacked without gaps before filling with resin.

[0084] Here, as Figure 8 As shown on the right, with the multiple rotor cores 2 arranged axially, the lower side plate 24 is not supported by the retaining mechanism 40. In other words, with the multiple rotor cores 2 arranged axially across the intermediate plate 29, the engagement of the retaining mechanism 40 with the lower side plate 24 can be released. Therefore, no force is transmitted from the lower side plate 24 to the retaining mechanism 40.

[0085] Even when the engagement by the retaining mechanism 40 is released, the shaft members 42B to 42D are still inserted into the through holes 46A to 46C in the lower side plate 24. Thus, the lower side plate 24 is positioned in a manner that does not apply axial load to the shaft members 42A to 42D.

[0086] Multiple rotor cores 2 are arranged in the molding apparatus 30. The multiple rotor cores 2 are arranged in a manner that follows the axial direction of the rotor core 2 (that is, the direction of the central axis of the cylindrical rotor core 2). That is, the multiple rotor cores 2 are arranged in multiple layers.

[0087] Furthermore, when multiple rotor cores 2 are arranged in a manner aligned along the axial direction, the magnet insertion holes 4 of each rotor core 2 are connected via an upper through hole 22A and a lower through hole 26 in the intermediate plate 29. In other words, the upper through hole 22A is formed at a position corresponding to the magnet insertion holes 4 of the rotor core 2 placed on the intermediate plate 29. Furthermore, the lower through hole 26 is formed at a position corresponding to the magnet insertion holes 4 of the rotor core 2 in the next layer.

[0088] like Figure 9As shown, multiple rotor cores 2 are held axially by a molding apparatus 30 with intermediate plates 29 as a barrier. The molding apparatus 30 comprises an upper mold 31 and a lower mold 32. The upper mold 31 supports the upper part of the uppermost rotor core 2, specifically its upper surface, by abutting against it. The lower mold 32 supports the upper side plate 22 on which the lowermost rotor core 2 is mounted. A support column (not shown) may be erected between the upper mold 31 and the lower mold 32, and the support column can be used with an actuator (not shown) to move the upper mold 31 up and down in the vertical direction. The lifting and lowering of the upper mold 31 can be performed primarily when the rotor core 2 is held in the molding apparatus 30 or when it is removed from the molding apparatus 30 and taken out.

[0089] As described above, the upper mold 31 can move vertically. Furthermore, by lowering the upper mold 31 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 31 and the lower mold 32. The shape and material of the surfaces of the upper mold 31 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 in a sealed state when the rotor core 2 is clamped by the upper mold 31 and the lower mold 32.

[0090] In this embodiment, the structure described above that directly moves the upper mold 31 up and down is used. However, any structure that can relatively change the vertical positions of the upper mold 31 and the lower mold 32 can be used. Specifically, for example, the structure that moves the lower mold 32 in the vertical direction can be used instead of the structure that moves the upper mold 31 in the vertical direction, or the structure that moves both the upper mold 31 and the lower mold 32 in the vertical direction can be used.

[0091] A resin filling path 23 is formed between the lower mold 32 and the upper side plate 22 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.

[0092] The rotor core 2, which is used to fill the magnet insertion hole 4 with resin, may often be changed to a rotor core of a different shape. Therefore, regarding the lowermost upper side plate 22, it is preferable to prepare multiple upper side plates 22 with different resin filling paths 23 and replace them appropriately to match the rotor core 2 to be held in the upper mold 31 and lower mold 32. In addition, it is preferable that the lower mold 32 also includes a lifting mechanism that can raise and lower the lower mold 32 to feed sheet into the barrel, perform cleaning, etc. In addition, for other upper side plates 22, multiple upper side plates 22 with different configurations and sizes of upper through holes 22A can also be prepared in advance and replaced appropriately to match the rotor core 2.

[0093] The molding apparatus 30 also includes a plunger 34. The plunger 34 presses against resin R softened by heating the sheet T via a heater (not shown). Figure 9 In the example shown, the resin R is pressed by a cylindrical plunger 34 located in the center of the lower mold 32. 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.

[0094] 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.

[0095] 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.

[0096] After the resin filling of the magnet insertion hole 4 is completed, multiple rotor cores 2 are removed from the mold. In this case, the upper side plate 22 separates from the lower side plate 24, and the rotor core 2 is removed together with the separated upper side plate 22.

[0097] As described above, an upper through hole 22A is formed in the upper side plate 22. Furthermore, a lower through hole 26 is formed in the lower side plate 24. The closer the upper through hole 22A and the lower through hole 26 are to the side opposite the rotor core 2 in the penetration direction, the smaller their opening area S in the direction orthogonal to the penetration direction. In other words, the upper through hole 22A and the lower through hole 26 are given a tapered shape.

[0098] Furthermore, the cone angle α of the upper through hole 22A formed in the upper side plate 22 is larger than the cone angle β of the lower through hole 26 formed in the lower side plate 24. Here, the cone angle is the angle formed by a pair of imaginary straight lines along the outer edge of the through hole when the through hole is viewed in a cross section including the central axis and along the through direction. Specifically, the cone angle α is the angle formed by a pair of imaginary straight lines A1 and A2 along the outer edge of the upper through hole 22A. In addition, the cone angle β is the angle formed by a pair of imaginary straight lines A3 and A4 along the outer edge of the lower through hole 26.

[0099] Because the cone angle α of the upper through hole 22A is larger than the cone angle β of the lower through hole 26, the resin R cured in the upper through hole 22A and the lower through hole 26 is more likely to remain on the upper side plate 22. Specifically, because the contact area between the inner circumferential surface of the upper through hole 22A and the resin R is ensured to be large, the adhesive force is increased, and the resin R will detach from the lower side plate 24 while still attached to the upper side plate 22.

[0100] Furthermore, the opening width L1 of the through hole on the rotor core 2 side of the upper through hole 22A and the opening width L2 of the rotor core 2 side of the lower through hole 26 are set to the same length. It should be noted that, in this embodiment, "same" means, in addition to being completely identical, also includes the degree of error that is generally permissible in the technical field to which this disclosure pertains and does not violate the technical spirit of this disclosure.

[0101] It should be noted that, as shown here, the upper through hole 22A and the lower through hole 26 are in the shape of a frustum of a cone, but the technology disclosed herein is not limited to this. The upper through hole 22A and the lower through hole 26 may also be in the shape of a multi-faceted frustum of a pyramid (e.g., a quadrangular frustum of a pyramid).

[0102] The rotor core 2, along with the upper side plate 22, is removed from the lower side plate 24. Then, multiple rotor cores 2 are removed from the molding apparatus 30. For the upper side plate 22 removed from the molding apparatus 30, the cured resin R remaining in the upper through-hole 22A (hereinafter referred to as "cull") is removed. Methods for removing the cull include pressing it off from above with a pin, removing it with a cleaner, or sucking it up from below or blowing it away from above with air. The removal process can be performed directly while the upper side plate 22 is supported by the robotic arm 10, or by placing the upper side plate 22 in the removal area. Afterwards, multiple rotor cores 2 are conveyed to the next process.

[0103] <Rotor Manufacturing Method>

[0104] Next, refer to Figure 10 The rotor manufacturing method of this embodiment will be described. Figure 10This is a flowchart illustrating an example of the rotor core manufacturing process of this embodiment.

[0105] In the manufacturing method of the rotor core 2 in this embodiment, firstly, as follows: Figure 10 As shown, the rotor core 2 is placed on the upper side plate 22 (step S01). In this case, the rotor core 2 is positioned relative to the upper side plate 22 by inserting the protrusion 22B into the through hole 5 of the rotor core 2.

[0106] Next, a permanent magnet 3 and a rotor core 2 to which the permanent magnet 3 is to be assembled are prepared. The permanent magnet 3 is inserted into the magnet insertion hole 4 of the rotor core 2 (step S02). Then, the rotor core 2 is conveyed to the preheating step with its upper side plate 22 as a support to preheat the rotor core 2 (step S03). The preheating of the rotor core 2 uses... Figure 3 The heating device 50 shown is used for heating. That is, the rotor core 2, which is placed on the upper side plate 22, is heated in the heating device 50.

[0107] The preheated rotor core 2 is conveyed to the molding process (process S04) in a state where it is placed on the upper side plate 22. Specifically, the rotor core 2 and the upper side plate 22 are supported by the support part 12B by the robotic arm 10. Furthermore, by moving the robotic arm 10, multiple rotor cores 2 are conveyed to the molding apparatus 30.

[0108] In the molding apparatus 30, the lower side plate 24 is held in a predetermined position by the holding mechanism 40. A plurality of rotor cores 2 are disposed within the mold, separated by the upper side plate 22 (step S05). Specifically, the plurality of rotor cores 2 are placed within the mold on the lower side plate 24, separated by the upper side plate 22. Furthermore, by lowering the lower side plate 24 via the holding mechanism 40, the plurality of rotor cores 2 are arranged in a state of axial alignment separated by the intermediate plate 29 (step S06).

[0109] For the sheet T fed into the lower mold 32 through the gap between the lowermost upper side plate 22 and the lower mold 32, a heater (not shown) is activated to soften the resin R (step S07). Specifically, by heating within the barrel of the molding apparatus 30, the viscosity of the resin forming the sheet T is reduced, 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 cause 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.

[0110] By moving the upper mold 31 downwards, the rotor core 2 is held within the upper mold 31 and the lower mold 32 (i.e., the mold) (step S08). At this time, the upper mold 31 is adjusted to press the upper surface of the rotor core 2 with a specified pressure, thereby making the upper mold 31 and the upper surface of the rotor core 2, and the lower mold 32 and the lower surface of the upper side plate 22, respectively, fit tightly together.

[0111] 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 S09). 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 S09, air holes (not shown) for venting air from the magnet insertion hole 4 can be provided at appropriate positions on the upper mold 31 and the upper side plate 22.

[0112] The mold heater (not shown) is activated to cure the softened resin R inside the magnet insertion hole 4 (step S10). 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 S09 and S10 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 S10 can be appropriately adjusted to match the specific composition of the resin used for the sheet T.

[0113] When the above series of resin molding processes are completed, the upper mold 31 is raised, and the mechanical arm 10 is used to remove the resin-molded rotor core 2 from the device (step S11). The removed rotor core 2 can be transferred to other devices for shaft assembly, etc. Furthermore, when the removal of the rotor core 2 is completed, the molding apparatus 30 is cleaned (step S12). Cleaning the molding apparatus 30 may include using cleaning components such as brushes to clean the inside of the lower through hole 26 of the lower side plate 24, the surfaces of the upper mold 31 and lower mold 32, or the inside of the barrel.

[0114] As explained above, according to the rotor manufacturing system 1 of this first embodiment, multiple rotor cores 2 placed on the upper side plate 22 are placed on the lower side plate 24 within the mold, resulting in a state in which the multiple rotor cores 2 are arranged axially within the mold, separated by an intermediate plate 29. Furthermore, in this state, the magnet insertion holes 4 of each of the multiple rotor cores 2 are filled with resin. Therefore, the operation of stacking the multiple rotor cores 2 separated by the intermediate plate 29 and the operation of placing them within the mold can be combined into one operation, which helps to improve the productivity of the motor core manufacturing process.

[0115] For example, consider the case where multiple rotor cores 2 are temporarily stacked outside the mold and then transported into the mold for molding. In this case, a stacking operation of multiple rotor cores 2 outside the mold and a setting operation of the stacked rotor cores 2 into the mold are performed separately. Therefore, the efficiency of the rotor manufacturing process is reduced. According to this structure, when multiple rotor cores 2 are set in the mold, the multiple rotor cores 2 are arranged axially with the intermediate plate 29 in between, thus improving the efficiency compared to the case where the stacking operation and the setting operation are performed separately.

[0116] Furthermore, according to the rotor manufacturing system 1 of this first embodiment, the holding mechanism 40 is configured to lower the lower side plate 24, which is in a state where the rotor core 2 is mounted across the upper side plate 22. Therefore, compared to the case where the lower side plate 24 is always kept at the same height, the rotor core 2 can be held in place by the mold after it has been stacked. That is, the mold can be closed after confirming the stacked state of the rotor core 2. Furthermore, compared to the case where the lower mold 32 is raised to stack the rotor core 2, only the holding mechanism 40 needs to be moved, thus making it easy to stack the rotor core 2 within the mold.

[0117] Furthermore, according to the rotor manufacturing system 1 of this first embodiment, when the plurality of rotor cores 2 are arranged axially with the intermediate plate 29 in between, the engagement of the retaining mechanism 40 with the lower side plate 24 can be released. As a result, the load applied during mold closing (retained by the mold) after the plurality of rotor cores 2 are stacked in the mold can be suppressed from being transmitted to the retaining mechanism 40 via the lower side plate 24.

[0118] Furthermore, according to the rotor manufacturing system 1 of this first embodiment, the lower side plate 24 is configured to move freely up and down within the mold via the holding mechanism 40. Thus, the distance between the lower side plates 24 can be adjusted according to the height of the rotor core 2.

[0119] Furthermore, according to the rotor manufacturing system 1 of this first embodiment, the plurality of lower side plates 24 are configured to move up and down freely within the mold independently of each other. Therefore, even if the rotor cores 2 have different heights, by adjusting the distance between the lower side plates 24, rotor cores 2 with different heights can be molded using the same mold.

[0120] Furthermore, according to the rotor manufacturing system 1 of this first embodiment, the holding mechanism 40 is configured to include shaft members 42A to 42D that are freely extendable along the axial direction. Moreover, when the shaft members 42A to 42D extend, the shaft members 42A to 42C are respectively configured to engage with the corresponding engaging portions 44A to 44C of the lower side plate 24. Thus, the lower side plate 24 is held by the shaft members 42A to 42C. As a result, compared to, for example, using a robotic arm 10 to hold the lower side plate 24 within the mold, the molding apparatus 30 can be simplified.

[0121] Furthermore, in the rotor manufacturing system 1 according to this first embodiment, the shaft members 42A to 42D in the holding mechanism 40 are configured as telescope-type structures. This achieves miniaturization of the holding mechanism 40 compared to cases where the shaft members 42A to 42D are located in different positions.

[0122] Furthermore, according to the rotor manufacturing system 1 of this first embodiment, the robotic arm 10 is configured to include multiple support portions 12B. Multiple rotor cores 2 are respectively mounted on the multiple support portions 12B with respect to the upper side plate 22. Therefore, for example, compared to the case where the robotic arm 10 directly holds the upper side plate 22, the structure of the robotic arm 10 is simplified.

[0123] Furthermore, in the rotor manufacturing system 1 according to this first embodiment, the support portion 12B in the robotic arm 10 is arranged along the axial direction of the plurality of rotor cores 2. Therefore, when the plurality of rotor cores 2 are conveyed into the mold, the rotor cores 2 can be arranged in a state along the axial direction.

[0124] Furthermore, according to the rotor manufacturing system 1 of this first embodiment, an upper through hole 22A is formed in the upper side plate 22, and a lower through hole 26 is formed in the lower side plate 24. When viewed in cross-section along the through direction, the opening area S of the upper through hole 22A and the lower through hole 26 is smaller the closer they are to the side opposite the rotor core 2 in the through direction. As a result, stress is concentrated in the finer portions of the resin cured within the upper through hole 22A and the lower through hole 26, thus facilitating the separation of the rotor core 2 from the upper side plate 22 and the lower side plate 24.

[0125] Furthermore, according to the rotor manufacturing system 1 of this first embodiment, the cone angle α of the upper through hole 22A formed in the upper side plate 22 is set to be larger than the cone angle β of the lower through hole 26 formed in the lower side plate 24. As a result, the contact area between the upper through hole 22A and the cured resin in the upper side plate 22 is increased, thus the cured resin remaining in the upper through hole 22A and the lower through hole 26 is more easily retained in the upper side plate 22. Consequently, the burden of cleaning the lower side plate 24 within the molding apparatus 30 is reduced.

[0126] Furthermore, according to the rotor manufacturing system 1 of this first embodiment, positioning portions 33 are provided on the upper side plate 22 and the lower side plate 24. These positioning portions 33, when the upper side plate 22 is placed on the lower side plate 24, ensure that the upper side plate 22 and the lower side plate 24 are in a predetermined positional relationship. This allows for highly accurate determination of the positional relationship between the upper side plate 22 and the lower side plate 24, thereby suppressing resin leakage and other issues caused by positional misalignment of the upper side plate 22 and the lower side plate 24.

[0127] (First variation)

[0128] Based on the first embodiment described above, in this first variation, the lower side plate 24 is preheated in the molding apparatus 30. For example... Figure 11 As shown, in the retaining mechanism 40, the shaft members 42A to 42D are in a retracted state. Therefore, the lower side plates 24A to 24C are stacked. In this state, the lower side plates 24A to 24C are preheated. Specifically, the lower mold 32 heats up through a mold heater (not shown) located within the lower mold 32, and the lower side plates 24A to 24C are heated through heat conduction from the lower mold 32.

[0129] Preheating of the lower side plates 24A to 24C can, for example, be performed during the idle time before the molding apparatus 30 is operated (e.g., before the start of operation). After preheating, the lower side plates 24A to 24C are held in a predetermined position within the mold. Specifically, in the holding mechanism 40, the lower side plates 24A to 24C are raised by extending the shaft members 42A to 42D. Furthermore, when the shaft members 42A to 42D are extended to a predetermined length, the lower side plates 24A to 24C are held in the predetermined position.

[0130] According to this first modification, the lower side plates 24A to 24C can be preheated. When filling the magnet insertion hole 4 with resin, if the lower side plates 24A to 24C are at a low temperature, the resin will cool down and its fluidity will decrease. As a result, the resin may not fill the magnet insertion hole 4 completely. In this structure, since the lower side plates 24A to 24C are sufficiently heated, it is easy to fill the preheated resin.

[0131] <<Second Implementation>>

[0132] In the first embodiment described above, an example was given in which the upper side plate 22 on which the rotor core 2 is mounted is supported by the support portion 12B; however, the technology disclosed herein is not limited thereto. In this second embodiment, the upper side plate 22 is directly supported by the end effector 12 of the robotic arm 10.

[0133] like Figure 12 As shown, in the robotic arm 10, the upper side plate 22 is directly mounted to the main body 12A of the end effector 12. Here, the upper side plate 22 is detachably mounted to the main body 12A. For example, the end of the upper side plate 22 is held by a clamping structure provided in the main body 12A. Thus, the upper side plate 22 is directly mounted to the main body 12A. The rotor core 2 is transported by the robotic arm 10 while being placed on the upper side plate 22.

[0134] It should be noted that the example given here is of supporting the upper side plate 22 by physical gripping, but this is only one example. For example, it is also possible to magnetically assemble and disassemble the magnetized component of the upper side plate 22 by switching the electromagnet on and off.

[0135] like Figure 13 As shown, the robotic arm 10 places multiple rotor cores 2 within the mold. The multiple rotor cores 2 are mounted on a lower side plate 24 via an upper side plate 22, and the lower side plate 24 is lowered by a holding mechanism 40. Here, the upper side plate 22 is configured to move vertically relative to the main body 12A of the end effector 12. Therefore, as the lower side plate 24 descends, the upper side plate 22 can also move vertically.

[0136] It should be noted that the example shown here is of moving the upper side plate 22 up and down relative to the main body 12A during molding, but this is only one example. For example, the upper side plate 22 can also be detached from the main body 12A after it has been set in the mold.

[0137] Multiple rotor cores 2 are held axially in a manner separated by an intermediate plate 29 by a molding apparatus 30. Then, resin R is flowed through a plunger 34, and after passing through a resin filling path 23, the resin R fills the magnet insertion holes 4 of the multiple rotor cores 2. In the rotor manufacturing system 1 of this second embodiment, the same effects as in the first embodiment described above can be obtained.

[0138] <<Third Implementation Method>>

[0139] In the first embodiment described above, an example of the retaining mechanism 40 being configured with shaft members 42A to 42D has been given, but the technology disclosed herein is not limited thereto. In this third embodiment, the retaining mechanism 60 includes a guide rail mechanism 62.

[0140] like Figure 14As shown, the molding apparatus 30 includes a holding mechanism 60. The holding mechanism 60 is configured to include a guide rail mechanism 62. The guide rail mechanism 62 supports the lower side plates 24A to 24C via guide rails extending in the vertical direction. Furthermore, the guide rail mechanism 62 allows the lower side plates 24A to 24C to be freely raised and lowered. The guide rail mechanism 62 is, for example, a feed screw mechanism, which is operated by power generated by a drive source (not shown).

[0141] The robotic arm 10 places multiple rotor cores 2 within a mold. The multiple rotor cores 2 are placed on a lower side plate 24 via an upper side plate 22. After the robotic arm 10 retracts, the lower side plate 24 is lowered by a holding mechanism 60. The multiple rotor cores 2 are held axially by a molding apparatus 30 in a state where they are arranged via an intermediate plate 29. Then, resin R is flowed through a plunger 34, and after passing through a resin filling path 23, the resin R fills the magnet insertion holes 4 of the multiple rotor cores 2. In the rotor manufacturing system 1 of this third embodiment, the same effects as in the first embodiment described above can be obtained.

[0142] It should be noted that, in this third embodiment, the structure of the end effector 12 of the second embodiment described above can also be applied.

[0143] <<Fourth Implementation>>

[0144] In the first embodiment described above, an example was given in which a holding mechanism 40 is provided in the molding apparatus 30 of the rotor manufacturing system 1, but the technology disclosed herein is not limited thereto. The holding mechanism 60 is configured to be separate from the molding apparatus 30.

[0145] like Figure 15 As shown, the rotor manufacturing system 1 comprises a robotic arm 10, a molding apparatus 30, and a holding mechanism 70. The holding mechanism 70 is a mechanism that holds the lower side plates 24A-24C in a predetermined position within the molding apparatus 30. In other words, the lower side plates 24A-24C are positioned in a predetermined position between the upper mold 31 and the lower mold 32 (hereinafter referred to as "within the mold") by means of the holding mechanism 70. The structure of the holding mechanism 70 is common to the holding mechanism 40 described above, therefore a detailed description is omitted. The holding mechanism 70 is an example of a "holding mechanism" of the present disclosure.

[0146] The holding mechanism 70 operates under the control of the control device 78. It should be noted that the holding mechanism 70, the molding device 30, and / or the robotic arm 10 can also be controlled by a common control device. In the rotor manufacturing system 1 of this fourth embodiment, the same effects as in the first embodiment described above can be achieved.

[0147] (Other variations)

[0148] It should be noted that, in the above embodiments, examples of the intermediate plate 29 being composed of an upper side plate 22 and a lower side plate 24 have been described, but the technology disclosed herein is not limited to this. A structure in which another plate is sandwiched between the upper side plate 22 and the lower side plate 24 is also possible. In this case, a through hole communicating with the upper through hole 22A and the lower through hole 26 is provided in the plate between the upper side plate 22 and the lower side plate 24.

[0149] Furthermore, in the above embodiments, examples of multiple rotor cores 2 being transported simultaneously have been described, but the technology disclosed herein is not limited to this. For example, it is also possible to transport three of the four rotor cores 2 from the top simultaneously, while the bottom rotor core 2 is transported at other times.

[0150] Furthermore, in the above embodiments, examples have been described where the positioning part 33 is configured with a recess 33A and a protrusion 33B, but the technology disclosed herein is not limited thereto. The positioning part 33 may also be an L-shaped guide structure provided on the upper side plate 22 or the lower side plate 24. Positioning is achieved by using the L-shaped guide structure to position the corner of the upper side plate 22 or the lower side plate 24 at a predetermined position.

[0151] Alternatively, the positioning part 33 can be a contact sensor (such as a photoelectric sensor or a mechanical switch) provided on the upper side plate 22 or the lower side plate 24. Positioning is achieved by detecting the position of the corner of the upper side plate 22 or the lower side plate 24 using a contact sensor.

[0152] Furthermore, in the above embodiments, examples of filling resin R from the lower mold 32 side in the molding apparatus 30 have been described, but the technology disclosed herein is not limited to this. For example, resin R may also be filled from the upper mold 31 side, or resin R may be filled from both the upper mold 31 and the lower mold 32.

[0153] Furthermore, in the above embodiments, the method of filling resin by means of a plunger 34 located in the center of the lower mold 32 has been described as an example, 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 method can be used where a multi-plunger consisting of multiple plungers presses the sheet disposed at the position opposite to the magnet insertion hole 4 along the circumference of the lower mold 32.

[0154] Furthermore, in the above embodiments, examples have been given of the upper side plate 22 being quadrilateral when viewed from above; however, the technology disclosed herein is not limited to this. The upper side plate 22 may also be other polygons, or it may be circular.

[0155] Furthermore, in the above embodiments, examples of conveying multiple rotor cores 2 using a multi-jointed robotic arm 10 have been described, but the technology disclosed herein is not limited to this. For example, multiple rotor cores 2 can also be conveyed using a linear motion conveyor robot capable of moving in three dimensions, or using a robotic trolley. Alternatively, multiple rotor cores 2 supported by a suspension mechanism such as a crane can be conveyed by a worker.

[0156] 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.

[0157] 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.

[0158] 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.

[0159] Regarding the above-described embodiments, the following notes are further disclosed.

[0160] <Postscript 1>

[0161] A method for manufacturing a motor, comprising:

[0162] Multiple iron cores, each placed on a first plate, are conveyed into the mold via a conveying mechanism.

[0163] Multiple iron cores are respectively placed on multiple second plates through the first plate, and the multiple second plates are positioned in predetermined positions within the mold by a holding mechanism; and

[0164] With the plurality of iron cores arranged axially along an intermediate plate consisting of the first plate and the second plate, the magnet insertion holes formed on the plurality of iron cores are filled with resin.

[0165] <Appendix 2>

[0166] According to the motor manufacturing method described in Appendix 1, wherein,

[0167] The aforementioned retaining mechanism is configured to lower the aforementioned second plate, which is in a state where the aforementioned iron core is placed across the aforementioned first plate.

[0168] <Appendix 3>

[0169] According to the motor manufacturing method described in Appendix 1 or Appendix 2, wherein,

[0170] With the aforementioned multiple iron cores arranged axially with the aforementioned intermediate plate in between, the engagement of the aforementioned retaining mechanism with the aforementioned second plate can be released.

[0171] <Appendix 4>

[0172] According to any one of Annexes 1 to 3, in the motor manufacturing method, wherein,

[0173] The second plate is configured to move freely up and down within the mold via the aforementioned retaining mechanism.

[0174] <Appendix 5>

[0175] According to the motor manufacturing method described in Appendix 4, wherein,

[0176] The aforementioned multiple second plates are each configured to move up and down freely within the mold independently.

[0177] <Appendix 6>

[0178] According to any one of Annexes 1 to 5, in the motor manufacturing method, wherein,

[0179] The aforementioned retaining mechanism comprises multiple axially telescopic shaft members.

[0180] When the multiple shaft members extend, each of the multiple shaft members is configured to engage with the engaging portion of its corresponding second plate.

[0181] <Appendix 7>

[0182] According to the motor manufacturing method described in Appendix 6, wherein,

[0183] Multiple shaft components are designed with a telescope-like structure.

[0184] <Postscript 8>

[0185] According to any one of Annexes 1 to 7, in the motor manufacturing method, wherein,

[0186] The aforementioned conveying mechanism comprises multiple support portions for the aforementioned multiple iron cores to be placed across the aforementioned first plate.

[0187] <Postscript 9>

[0188] According to the motor manufacturing method described in Appendix 8, wherein...

[0189] The aforementioned support portions are arranged along the axial direction of the aforementioned plurality of iron cores.

[0190] <Postscript 10>

[0191] The motor manufacturing method according to any one of Annexes 1 to 9, wherein,

[0192] The first plate and the second plate respectively have through holes formed at positions corresponding to the resin-filled portions.

[0193] In the aforementioned through holes, the closer to the side opposite to the iron core in the aforementioned through direction, the smaller the opening area along the direction orthogonal to the aforementioned through direction.

[0194] <Postscript 11>

[0195] According to the motor manufacturing method described in Appendix 10, wherein,

[0196] When the through hole is viewed in section along the through direction, and the angle formed by a pair of imaginary straight lines along the outer edge of the through hole is defined as the cone angle, the cone angle of the through hole formed in the first plate is larger than the cone angle of the through hole formed in the second plate.

[0197] <Postscript 12>

[0198] The motor manufacturing method according to any one of Annexes 1 to 11, wherein,

[0199] The first plate and / or the second plate are provided with positioning parts, which, when the first plate is placed on the second plate, make the first plate and the second plate have a predetermined positional relationship with each other.

[0200] Furthermore, the entire disclosure of Japanese Invention Patent Application No. 2024-058081, filed on March 29, 2024, is incorporated herein by reference. 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 and separately described and incorporated herein by reference.

Claims

1. A method for manufacturing a motor, comprising: Multiple iron cores, each placed on a first plate, are conveyed into the mold via a conveying mechanism. Multiple iron cores are respectively placed on multiple second plates through the first plate, and the multiple second plates are positioned in predetermined positions within the mold by a holding mechanism; and With the plurality of iron cores arranged axially with an intermediate plate consisting of the first plate and the second plate in between, 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, The retaining mechanism is configured to lower the second plate, which is in a state where the iron core is placed across the first plate.

3. The motor manufacturing method according to claim 1, wherein, With the plurality of iron cores arranged axially with the intermediate plate in between, the engagement of the retaining mechanism with the second plate can be released.

4. The motor manufacturing method according to claim 1, wherein, The second plate is configured to move freely up and down within the mold via the retaining mechanism.

5. The motor manufacturing method according to claim 4, wherein, The plurality of second plates are each configured to move up and down freely within the mold independently of each other.

6. The motor manufacturing method according to claim 1, wherein, The retaining mechanism comprises multiple axially telescopic shaft members. When the multiple shaft members extend, each of the multiple shaft members is configured to engage with the corresponding engaging portion of the second plate.

7. The motor manufacturing method according to claim 6, wherein, Multiple shaft components are designed with a telescope-like structure.

8. The motor manufacturing method according to claim 1, wherein, The conveying mechanism comprises multiple support portions for the multiple iron cores to be placed across the first plate.

9. The motor manufacturing method according to claim 8, wherein, The support portion is arranged along the axial direction of the plurality of iron cores.

10. The motor manufacturing method according to claim 1, wherein, The first plate and the second plate each have through holes formed at positions corresponding to the resin-filled portion. In the through hole, the closer it is to the side opposite the iron core in the through direction, the smaller the opening area is along the direction orthogonal to the through direction.

11. The motor manufacturing method according to claim 10, wherein, When the through hole is viewed in section along the through direction, and the angle formed by a pair of imaginary straight lines along the outer edge of the through hole is defined as the cone angle, the cone angle of the through hole formed in the first plate is larger than the cone angle of the through hole formed in the second plate.

12. The motor manufacturing method according to claim 1, wherein, The first plate and / or the second plate are provided with positioning parts, which, when the first plate is placed on the second plate, make the first plate and the second plate have a predetermined positional relationship with each other.

13. A motor manufacturing apparatus, comprising: A holding mechanism holds a plurality of second plates in a predetermined position within a mold, the plurality of second plates being configured to hold, through a first plate, a plurality of iron cores that have been conveyed into the mold in a state where they are respectively placed on a plurality of first plates; and The resin filling mechanism fills the resin filling portions formed on the plurality of iron cores with resin in a state in which the plurality of iron cores are arranged axially with an intermediate plate consisting of the first plate and the second plate in between.

14. A motor manufacturing system, comprising: The conveying mechanism transports multiple iron cores, which are respectively placed on multiple first plates, into the mold; A holding mechanism holds a plurality of second plates in predetermined positions within the mold, the plurality of second plates being configured to respectively mount a plurality of iron cores through the first plate; and The resin filling mechanism fills the resin filling portions formed on the plurality of iron cores with resin in a state in which the plurality of iron cores are arranged axially with an intermediate plate consisting of the first plate and the second plate in between.

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