Rotor manufacturing device and rotor manufacturing method

Abstract

To provide a rotor manufacturing device and a rotor manufacturing method that allow a jig to be made common in a resin filling process and a welding process.SOLUTION: A rotor manufacturing device includes: a lamination jig 20 that contacts with an end face of a rotor core 11 and closes a first opening of a magnet accommodating hole 13 that opens in the end face; and a cull plate that is arranged to close a second opening 13b on the opposite side of the first opening of the magnet accommodating hole 13, and has a supply section that supplies resin to the second opening 13b. A first relief section 24 located closer to an inner circumferential side than an outer circumferential surface 11e of the rotor core 11 is provided in a part of the lamination jig 20 that faces a welding point W where iron core pieces are welded to each other in an axial direction of the rotor core 11.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to a rotor manufacturing apparatus and a rotor manufacturing method. [Background technology]

[0002] Patent Document 1 describes a manufacturing method for a rotor that constitutes an embedded magnet motor. This manufacturing method includes a process of inserting magnets into magnet holes in a rotor core formed by stacking multiple metal plates, and then sealing the magnet holes with resin (hereinafter referred to as the resin filling process), and a process of bonding the metal plates together by welding (hereinafter referred to as the welding process).

[0003] In the resin filling step, for example, a manufacturing device described in Patent Document 2 is used. This manufacturing apparatus includes a fixed mold, a cull plate, and a movable mold that is movable toward and away from the fixed mold.

[0004] The fixed die includes a die body, a support member, and a spacer. The support member has a base portion fixed to the upper surface of the die body and a cylindrical post portion protruding from the center of the base portion and inserted into the central hole of the rotor core. The spacer is disposed on the upper surface of the support member and abuts against the lower surface of the rotor core.

[0005] The cull plate is placed on the upper surface of the rotor core and is provided with a plurality of filling pots for filling resin into each of the magnet receiving holes of the rotor core. The movable die has a die body and a plate portion. The plate portion is fixed to the lower surface of the die body and abuts against the upper surface of the cull plate. The plate portion is provided with a plurality of first resin supply passages connected to the filling pot. The die body is provided with a plurality of second resin supply passages communicating with the first resin supply passages.

[0006] In such a manufacturing device, by supplying resin to the second resin supply passage of the mold body, the resin is filled into the magnet accommodating holes of the rotor core via the first resin supply passage and the filling pot. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Patent Publication No. 2021-48674 [Patent Document 2] JP 2019-140842 A Summary of the Invention [Problem to be solved by the invention]

[0008] Incidentally, in conventional manufacturing apparatuses including the manufacturing apparatus described in Patent Document 2, it is desirable to share a jig having a support member and a spacer between the resin filling step and the subsequent welding step from the viewpoint of reducing the number of parts. However, in this case, problems arise such as the rotor core and the spacer being welded together during welding, or the welding machine interfering with the support member and the spacer. Therefore, in the past, after the resin filling step, it was necessary to remove the jig from the rotor core and attach a welding jig separate from the jig to the rotor core, which was time-consuming. [Means for solving the problem]

[0009] A rotor manufacturing apparatus for solving the above problem is an apparatus for manufacturing a rotor in which the iron core pieces are welded and connected to each other, the apparatus comprising: a cylindrical rotor core formed by stacking a plurality of iron core pieces and having a plurality of magnet accommodating holes in which magnets are accommodated; and resin filled into the magnet accommodating holes, the iron core pieces being welded to each other. The apparatus comprises: a first member that abuts one end face of the rotor core and blocks a first opening of the magnet accommodating hole that opens to the end face; and a second member that is arranged to block a second opening on the opposite side to the first opening of the magnet accommodating hole and has a supply portion that supplies the resin to the second opening. When the direction in which the axis of the rotor core extends is the axial direction, a portion of the first member that faces the welding point where the iron core pieces are welded to each other in the axial direction is provided with a relief portion that is located inner than the outer circumferential surface of the rotor core.

[0010] According to this configuration, the resin is supplied to the second openings of the magnet accommodating holes via the supply portion of the second member, thereby filling the magnet accommodating holes with the resin. Moreover, according to the above configuration, the first member has a relief portion. Therefore, when the welding machine welds the portion of the welding spot located on the end face side in the axial direction, welding of the rotor core and the first member is suppressed. Even if the welding machine interferes with the first member when welding the portion, the welding machine is allowed to escape by the relief portion, thereby suppressing interference between the welding machine and the first member. As a result, it is possible to weld the welding spot of the rotor core without removing the first member. Therefore, the first member can be shared between the resin filling process and the welding process.

[0011] Furthermore, a rotor manufacturing method for solving the above problem is a method of manufacturing the rotor using the rotor manufacturing apparatus described above, and includes a first conveying process of conveying the first member, the rotor core, and the second member between a first mold and a second mold that is arranged to be able to approach and move away from the first mold, a resin filling process of filling the magnet accommodating hole with the resin by supplying the resin from the second mold to the second opening via the supply section, a second conveying process of removing the first member and the rotor core from between the first mold and the second mold and conveying them to a welding line where the core pieces are welded together, and a welding process of welding the weld points of the rotor core in a state where the rotor core is abutted against the first member on the welding line.

[0012] According to this method, in the resin filling step, the magnet accommodating holes are filled with resin. Furthermore, according to the above method, the welding step can be performed in a state in which the rotor core is attached to the first member having the relief portion, and therefore the first member can be used in both the resin filling step and the welding step. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a perspective view of a rotor manufactured using a rotor manufacturing apparatus according to one embodiment. [Diagram 2] FIG. 2 is a cross-sectional view of the rotor of FIG. [Diagram 3] FIG. 3 is a cross-sectional view showing a rotor manufacturing apparatus and a rotor core according to one embodiment. [Figure 4] FIG. 4 is a plan view showing the first member and the rotor core in the embodiment. [Diagram 5] FIG. 5 is a cross-sectional view of the manufacturing apparatus and rotor core of FIG. 3, focusing on the relief portion. [Figure 6] FIG. 6 is a plan view of the manufacturing apparatus and the rotor core of FIG. [Figure 7] FIG. 7 is a cross-sectional view showing a resin filling step, which corresponds to FIG. [Figure 8] FIG. 8 is a cross-sectional view showing a resin filling step in which the magnet accommodating hole is filled with resin. [Figure 9] FIG. 9 is a cross-sectional view showing a welding process and corresponds to FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Hereinafter, an embodiment of a rotor manufacturing apparatus and a rotor manufacturing method will be described with reference to FIGS. <Rotor 10> First, a rotor 10 of an embedded magnet motor manufactured using a manufacturing apparatus 70 of the present embodiment will be described with reference to FIGS.

[0015] As shown in FIGS. 1 and 2, the rotor 10 includes a rotor core 11, a magnet 14, and a resin 15. The rotor core 11 has a cylindrical shape and an axis C.

[0016] In the following description, the axial direction of rotor core 11 is simply referred to as the axial direction, the radial direction of rotor core 11 is simply referred to as the radial direction, and the circumferential direction of rotor core 11 is simply referred to as the circumferential direction. The rotor core 11 is formed by stacking a plurality of core pieces 12, which are punched out from electromagnetic steel sheets, in the axial direction.

[0017] The rotor core 11 has a central hole 11a and a plurality of magnet accommodating holes 13. The central hole 11a has a circular shape and penetrates the rotor core 11 in the axial direction. A pair of keys 11b facing each other with the axis C interposed therebetween protrude from the inner circumferential surface of the central hole 11a.

[0018] The magnet accommodating holes 13 are located radially outward of the central hole 11a and are spaced apart from one another in the circumferential direction. Each of the magnet accommodating holes 13 has a rectangular shape in a plan view and penetrates the rotor core 11 in the axial direction. Thus, the magnet accommodating holes 13 have a first opening 13a that opens into one end face 11c of the rotor core 11 in the axial direction (the lower side in the up-down direction in FIG. 1), and a second opening 13b on the opposite side to the first opening 13a.

[0019] 2, a magnet 14 is accommodated in each magnet accommodating hole 13. The magnet 14 has a rectangular parallelepiped shape extending in the axial direction. The magnet 14 is, for example, a permanent magnet. 2, the inside of each magnet accommodating hole 13 is filled with resin 15 for fixing the magnets 14 to the rotor core 11. The resin 15 is, for example, a thermosetting resin such as an epoxy resin.

[0020] As shown in FIG. 1, the iron core pieces 12 of the rotor 10 are connected to each other by welding a plurality of welding points W provided on the outer peripheral surface 11e of the rotor core 11 with the magnets 14 fixed to each magnet accommodating hole 13 of the rotor core 11 by resin 15.

[0021] 1, each welding point W extends along the axial direction from the end face 11c to the end face 11d opposite to the end face 11c. The welding points W are provided at equal intervals in the circumferential direction. In this embodiment, the welding points W are provided at positions radially corresponding to the gaps between the magnet accommodating holes adjacent in the circumferential direction.

[0022] Next, a manufacturing apparatus 70 for the rotor 10 will be described with reference to Fig. 3 to Fig. 6. In Fig. 4 and Fig. 6, parts that are the same and arranged in a row are partially omitted and indicated by two-dot chain lines. For ease of explanation, magnets 14 are also omitted.

[0023] The manufacturing apparatus 70 includes a lamination jig 20 that supports the rotor core 11, and a cull plate 30 that is disposed on the opposite side of the lamination jig 20 in the axial direction across the rotor core 11. In this embodiment, the lamination jig 20 corresponds to a first member according to the present invention, and the cull plate 30 corresponds to a second member according to the present invention.

[0024] In the following description, the side of the lamination jig 20 relative to the rotor core 11 in the axial direction will be referred to as the "bottom" or "lower side", and the side of the cull plate 30 relative to the rotor core 11 will be referred to as the "top" or "upper side".

[0025] <Lamination jig 20> As shown in FIGS. 3 and 4, the lamination jig 20 has a plate portion 21 and a post portion .

[0026] The plate portion 21 has a lower plate 22 and an upper plate 23 disposed on an upper surface 22 a of the lower plate 22 . The lower plate 22 is flat.

[0027] The upper plate 23 has a substantially circular plate shape. An upper surface 23a of the upper plate 23 abuts against an end surface 11c of the rotor core 11 so as to close the first opening 13a of the magnet accommodating hole 13. 4 and 5, the upper plate 23 has a first relief portion 24 as a recess provided in an outer circumferential surface 23b of the upper plate 23. A bottom surface 24a of the first relief portion 24 is located on the inner circumferential side of the outer circumferential surface 11e of the rotor core 11.

[0028] The first relief portions 24 are provided in portions facing each of the multiple welded portions W in the axial direction. The first relief portions 24 are provided in positions that do not overlap with the multiple magnet accommodating holes 13 in the axial direction.

[0029] The upper plate 23 has a shape in which portions 25 located on the outer circumferential side of the outer circumferential surface 11e of the rotor core 11 and first relief portions 24 are arranged alternately in the circumferential direction (see FIG. 4). 3 and 5, the post portion 26 is cylindrical and protrudes upward from the center of the lower plate 22. The post portion 26 penetrates the upper plate 23. The post portion 26 is inserted into the central hole 11a of the rotor core 11.

[0030] A pair of key grooves 27, into which the respective key portions 11b of rotor core 11 are inserted, are provided on the outer circumferential surface of post portion 26. By inserting key portions 11b of rotor core 11 into key grooves 27 of post portion 26, the phase of rotor core 11 relative to lower plate 22, more specifically, the phase of each laminated block constituting rotor core 11, is determined.

[0031] A plurality of positioning pins 28 protruding upward are provided on the upper end 26a of the post portion 26. The positioning pins 28 are provided at intervals from one another in the circumferential direction. Note that the positioning pins 28 are not shown in FIG.

[0032] <Calplate 30> As shown in FIGS. 3 and 5, the cull plate 30 is disposed on the end surface 11d of the rotor core 11 so as to close the second opening 13b of the magnet accommodating hole 13.

[0033] 3 and 6, the cull plate 30 has a plurality of supply parts 31 that fill the magnet accommodating holes 13 with the resin 15. The supply parts 31 are provided at equal intervals in the circumferential direction. Each supply part 31 is provided at a position corresponding to a portion between a pair of the magnet accommodating holes 13.

[0034] Each supply portion 31 has a runner portion 32 and a pair of communication holes 33 that communicate between the runner portion 32 and the magnet accommodating hole 13 . The runner portion 32 opens to the upper surface 30a of the cull plate 30. Each communication hole 33 opens to the bottom surface of the runner portion 32 and penetrates the cull plate 30 in the axial direction. That is, each communication hole 33 also opens to the lower surface 30b of the cull plate 30.

[0035] The cull plate 30 has a positioning hole 34 in the center thereof into which the positioning pin 28 is inserted. 5 and 6, the cull plate 30 has a second relief portion 35 as a recess provided in the outer peripheral surface 30c of the cull plate 30. A bottom surface 35a of the second relief portion 35 is located on the inner peripheral side of the outer peripheral surface 11e of the rotor core 11.

[0036] The second relief portions 35 are provided in portions facing each of the plurality of welding points W in the axial direction. The second relief portions 35 are provided in positions that do not overlap with the plurality of magnet accommodating holes 13 in the axial direction.

[0037] The cull plate 30 has a shape in which portions 36 located on the outer circumferential side of the outer circumferential surface 11e of the rotor core 11 and second relief portions 35 are alternately arranged in the circumferential direction (see FIG. 6). In this embodiment, the cull plate 30 has the same shape as the upper plate 23 in a plan view.

[0038] <Method of manufacturing the rotor 10> Next, a manufacturing method of the rotor 10 will be described with reference to FIG. 3 and FIGS. The manufacturing method of the rotor 10 includes a first conveying step, a resin filling step, a second conveying step, and a welding step.

[0039] First, as shown in Fig. 3, the rotor core 11 is placed on the top surface 23a of the upper plate 23 of the lamination jig 20. Next, the magnets 14 are inserted into the magnet accommodating holes 13 from the second openings 13b and accommodated therein. Next, the cull plate 30 is placed on the end surface 11d of the rotor core 11. At this time, the positioning pins 28 are inserted into the positioning holes 34 to position the cull plate 30 relative to the post portions 26, i.e., the lamination jig 20.

[0040] Then, the lamination jig 20, the rotor core 11, the magnets 14, and the cull plate 30 are transported between the first die 40 and the second die 50 that is arranged so as to be able to approach and move away from the first die 40 (this is the first transport step).

[0041] Next, as shown in FIG. 7, the second mold 50 is brought close to the first mold 40, and the lower surface 50a of the second mold 50 is brought into contact with the upper surface 30a of the cull plate 30. The second mold 50 is provided with a plurality of supply paths 51 for supplying the resin 15 to each of the plurality of supply units 31. Resin pellets P made of a thermosetting resin are placed in the supply paths 51. The resin pellets P are melted in the supply paths 51 by, for example, being heated to a predetermined temperature by a heater (not shown) provided in the second mold 50. The second mold 50 is provided with a plurality of plungers 52 configured to be insertable and removable from the supply paths 51. Each plunger 52 applies pressure to the resin 15 molten in the supply paths 51 so that the resin 15 is filled in the magnet accommodating hole 13 through the supply units 31. As a result, as shown in FIG. 8, the resin 15 is filled in the magnet accommodating hole 13 through the supply units 31. The resin 15 filled in the magnet accommodating hole 13 is solidified by being put into a heating device (not shown) together with the manufacturing device 70 (this is the resin filling step).

[0042] Next, the stacking jig 20, the rotor core 11 with magnets 14 fixed in each magnet accommodating hole 13 by resin 15, and the cull plate 30 are removed from between the first die 40 and the second die 50 and transported to the welding line (this is the second transport process).

[0043] 9, a welding machine 60 having a plurality of welding torches 61 for welding each of the iron core pieces 12 of the rotor core 11 is provided on the welding line. As the welding method, for example, laser welding is used.

[0044] Each welding torch 61 is provided so as to be capable of ascending and descending in the axial direction of rotor core 11. Welding torches 61 weld weld points W while moving in the axial direction as indicated by the two-dot chain line in Fig. 9. This welds core pieces 12 together (this is the welding process).

[0045] In this manner, the rotor 10 is manufactured. Next, the effects of this embodiment will be described. (1) The manufacturing device 70 includes a lamination jig 20 that contacts the end face 11c of the rotor core 11 and closes the first opening 13a of the magnet accommodating hole 13 that opens into the end face 11c. The manufacturing device 70 also includes a cull plate 30 that is disposed so as to close the second opening 13b of the magnet accommodating hole 13 and has a supply unit 31 that supplies resin 15 to the second opening 13b.

[0046] According to this configuration, the resin 15 is supplied to the second openings 13b of the magnet accommodating holes 13 via the supply portion 31 of the cull plate 30. As a result, the resin 15 is filled into the magnet accommodating holes 13.

[0047] (2) A first escape portion 24 is provided in a portion of the upper plate 23 of the stacking jig 20 that faces the welding point W where the core pieces 12 are welded to each other in the axial direction, and is located more inward than the outer circumferential surface 11e of the rotor core 11.

[0048] According to this configuration, when the welding torch 61 of the welding machine 60 welds the portion of the welding spot W located on the end face 11c side in the axial direction, welding of the rotor core 11 and the upper plate 23 is suppressed. Even if the welding torch 61 interferes with the upper plate 23 when welding the above-mentioned portion, the welding torch 61 is allowed to escape by the first escape portion 24, thereby suppressing interference between the welding torch 61 and the upper plate 23. As a result, it is possible to weld the welding spot W of the rotor core 11 without removing the upper plate 23 and, ultimately, the lamination jig 20. Therefore, the lamination jig 20 can be used in common for the resin filling process and the welding process.

[0049] Furthermore, according to the above configuration, the step of removing the lamination jig 20 from the rotor core 11 between the resin filling step and the welding step is omitted. Therefore, damage to the rotor core 11 when the lamination jig 20 is removed from the rotor core 11 can be reduced.

[0050] (3) The second relief portion 35 located radially inward relative to the outer circumferential surface 11e of the rotor core 11 is provided in the portion of the cull plate 30 facing the welded portion W in the axial direction. According to this configuration, the same effect as effect (2) can be achieved with the cull plate 30. Therefore, the lamination jig 20 and the cull plate 30 can be used in common in the resin filling process and the welding process.

[0051] Furthermore, according to the above configuration, the step of removing the cull plate 30 from the rotor core 11 between the resin filling step and the welding step is omitted. Therefore, damage to the rotor core 11 when the cull plate 30 is removed from the rotor core 11 can be reduced.

[0052] (4) The method for manufacturing the rotor 10 includes a first conveying step, a resin filling step, a second conveying step, and a welding step. According to this method, it is possible to achieve the same effects as effects (1) to (3).

[0053] <Example of change> This embodiment can be modified as follows: This embodiment and the following modifications can be combined with each other to the extent that there is no technical contradiction.

[0054] The cull plate 30 is not limited to a shape in which the portion 36 located on the outer circumferential side of the outer circumferential surface 11e of the rotor core 11 and the second relief portion 35 are alternately arranged in the circumferential direction. The cull plate 30 may have a shape in which the portion of the outer circumferential surface 30c other than the second relief portion 35 is flush with the outer circumferential surface 11e of the rotor core 11. In addition, the cull plate 30 may have a shape in which the outer circumferential surface 30c is located on the inner circumferential side of the outer circumferential surface 11e of the rotor core 11 over the entire circumferential direction, as long as it closes the second openings 13b of the multiple magnet accommodating holes 13.

[0055] The cull plate 30 is not limited to a shape having a plurality of second relief portions 35, and may be, for example, circular in plan view. In other words, the outer peripheral surface 30c of the cull plate 30 may be the second relief portion over the entire circumferential direction.

[0056] The resin 15 is not limited to the thermosetting resin exemplified in this embodiment, and may be a thermoplastic resin such as liquid crystal polymer (LCP). In this case, a runner plate having a runner and a gate for supplying molten thermoplastic resin to each magnet accommodating hole 13 may be used in place of the cull plate 30. Even in this case, a second escape portion may be provided in the runner plate.

[0057] The second relief portion 35 may be omitted from the cull plate 30. In this case, the cull plate 30 is removed from the rotor core 11 in the welding process, and a welding jig is placed on the end face 11d of the rotor core 11.

[0058] Upper plate 23 is not limited to a shape in which portions 25 located outer circumferentially of outer circumferential surface 11e of rotor core 11 and first reliefs 24 are alternately arranged in the circumferential direction. Upper plate 23 may have outer circumferential surface 23b of which portions other than first relief portions 24 are flush with outer circumferential surface 11e of rotor core 11. Furthermore, as long as upper plate 23 closes first openings 13a of multiple magnet accommodating holes 13, outer circumferential surface 23b may be shaped to be located inner circumferentially of outer circumferential surface 11e of rotor core 11 throughout the entire circumferential direction.

[0059] The upper plate 23 is not limited to a shape having a plurality of first relief portions 24, and may be, for example, a circular shape in a plan view. In other words, the outer circumferential surface 23b of the upper plate 23 may be the first relief portion over the entire circumferential direction. [Explanation of symbols]

[0060] C…Axis line W: Welding point 10...Rotor 11...Rotor core 11a...Center hole 11b...Key section 11c...end face 11d...end face 11e...Outer surface 12...Iron core piece 13...Magnet receiving hole 13a...first opening 13b…Second opening 14…Magnet 15…Resin 20…Lamination jig 21…Plate section 22…Lower plate 23…Upper plate 24…First relief section 30…Calplate 31...Supply section 35…Second relief section 40...Type 1 50…2nd type 60…Welding machine 70...Manufacturing equipment

Claims

1. An apparatus for manufacturing a rotor including a cylindrical rotor core formed by stacking a plurality of iron core pieces and having a plurality of magnet accommodating holes for accommodating magnets, and a resin filled in the magnet accommodating holes, the iron core pieces being welded together and connected to each other, a first member that contacts one end surface of the rotor core and closes a first opening of the magnet accommodating hole that opens into the end surface; a second member disposed to close a second opening on the opposite side of the magnet accommodating hole from the first opening, the second member having a supply portion that supplies the resin to the second opening, When the direction in which the axis of the rotor core extends is defined as the axial direction, a relief portion is provided in a portion of the first member that faces a welding portion where the core pieces are welded to each other in the axial direction, the relief portion being located on the inner circumferential side relative to an outer circumferential surface of the rotor core. Rotor manufacturing equipment.

2. When the relief portion is a first relief portion, a second relief portion is provided in a portion of the second member facing the welded portion in the axial direction and located on an inner peripheral side than the outer peripheral surface of the rotor core; An apparatus for manufacturing a rotor according to claim 1.

3. A method for manufacturing a rotor using the rotor manufacturing apparatus according to claim 1, comprising the steps of: a first conveying step of conveying the first member, the rotor core, and the second member between a first die and a second die that is provided so as to be capable of approaching and separating from the first die; a resin filling step of filling the magnet accommodating hole with the resin by supplying the resin from the second mold to the second opening through the supply unit; a second conveying step of removing the first member and the rotor core from between the first die and the second die and conveying them to a welding line where the core pieces are welded together; a welding process of welding the welded portion of the rotor core in a state in which the rotor core is in contact with the first member in the welding line, A method for manufacturing a rotor.

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