Manufacturing apparatus for rotor and manufacturing method of rotor

Abstract

To provide a manufacturing apparatus for a rotor capable of suppressing erroneous assembly of end plates, and a manufacturing method of the rotor.SOLUTION: A manufacturing apparatus 50 comprises: a first weld device 62A for welding a first end plate 40A to a first end portion of a rotor core 11; a first detection section 100A for detecting whether or not an end plate 40 supplied to the first weld device 62A is the first end plate 40A; a second weld device 62B for welding a second end plate 40B to a second end portion of the rotor core 11 to which the first end plate 40A is welded; and a second detection section 100B for detecting whether or not the end plate 40 supplied to the second weld device 62B is the second end plate 40B.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 discloses a rotor including a rotor core having insertion holes in which permanent magnets are housed, and two end plates welded to both axial ends of the rotor core. Each end plate is welded to the rotor core so as to close the opening of an insertion hole formed in the rotor core, thereby preventing the permanent magnets housed in the insertion holes from jumping out. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-114039 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, when the shapes of the two end plates welded to both ends of the rotor core are different from each other, there is a risk of so-called erroneous assembly occurring, in which an end plate other than a normal end plate is welded to one end of the rotor core. [Means for solving the problem]

[0005] A rotor manufacturing apparatus for solving the above problem is a rotor manufacturing apparatus that manufactures a rotor including a rotor core having a first end and a second end located opposite each other in the axial direction, and two end plates having different shapes which are welded to the first end and the second end, respectively, and includes a first welding device that welds the first end plate to the first end, a first detection unit that detects whether the end plate supplied to the first welding device is the first end plate, a second welding device that welds the second end plate to the second end of the rotor core having the first end plate welded to the first end, and a second detection unit that detects whether the end plate supplied to the second welding device is the second end plate.

[0006] According to the above configuration, the first detector detects whether the end plate supplied to the first welding device is the first end plate. The second detector detects whether the end plate supplied to the second welding device is the second end plate. This makes it possible to prevent an end plate other than a regular end plate from being welded to the rotor core. This makes it possible to prevent erroneous assembly of the end plate.

[0007] A rotor manufacturing method for solving the above problem is a rotor manufacturing method for manufacturing a rotor including a rotor core having a first end and a second end located opposite each other in the axial direction, and two end plates having different shapes welded to the first end and the second end, respectively, the method including: a first welding process of welding the first end plate to the first end using a first welding device; a first detection process of detecting whether the end plate supplied to the first welding device is the first end plate; a second welding process of welding the second end plate to the second end of the rotor core having the first end plate welded to the first end using a second welding device; and a second detection process of detecting whether the end plate supplied to the second welding device is the second end plate.

[0008] According to the above method, in the first detection step, it is detected whether or not the end plate welded to the first end of the rotor core is the first end plate. In addition, in the second detection step, it is detected whether or not the end plate welded to the second end of the rotor core is the second end plate. This makes it possible to prevent an end plate other than a regular end plate from being welded to the rotor core in the first welding step and the second welding step. Therefore, it is possible to prevent erroneous assembly of the end plate. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is an exploded perspective view of a rotor according to one embodiment. [Diagram 2] FIG. 2 is a plan view of the first end plate of FIG. [Diagram 3] FIG. 3 is a plan view of the second end plate of FIG. [Figure 4] FIG. 4 is a schematic diagram showing a rotor manufacturing apparatus according to one embodiment. [Diagram 5]FIG. 5 is a perspective view showing the first jig and the first support stand of FIG. [Figure 6] 6 is a perspective view showing the second jig and the second support stand of FIG. [Figure 7] FIG. 7 is a cross-sectional view showing the first conveying device and the second conveying device of FIG. [Figure 8] FIG. 8 is a cross-sectional view showing a first detector that detects the first end plate. [Figure 9] FIG. 9 is a cross-sectional view showing a first detector that detects the second end plate. [Figure 10] FIG. 10 is a side view showing a first welding device that welds the first end plate to the rotor core. [Figure 11] FIG. 11 is a side view showing a second welding device that welds the second end plate to the rotor core. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, an embodiment of a rotor manufacturing apparatus and a rotor manufacturing method will be described with reference to FIGS. First, a rotor 10 manufactured by the rotor manufacturing apparatus will be described.

[0011] (Rotor 10) 1, the rotor 10 includes a rotor core 11, a plurality of magnets 20, a plurality of resin materials 30, and two end plates 40. The rotor 10 is a rotor used in, for example, an embedded magnet motor.

[0012] (Rotor core 11) The rotor core 11 has a substantially cylindrical shape. Hereinafter, the axial direction of rotor core 11 will be simply referred to as the axial direction, the radial direction of rotor core 11 will be simply referred to as the radial direction, and the circumferential direction of rotor core 11 will be simply referred to as the circumferential direction.

[0013] Rotor core 11 is formed, for example, by laminating a plurality of core pieces punched out from electromagnetic steel sheets. The rotor core 11 has a first end 11a and a second end 11b located opposite to each other in the axial direction.

[0014] Rotor core 11 has a central hole 12 into which a shaft (not shown) is inserted, a plurality of magnet accommodating holes 13 in which magnets 20 are accommodated, and a plurality of cooling flow paths 14 through which a cooling medium flows. Central hole 12, magnet accommodating holes 13, and cooling flow paths 14 penetrate rotor core 11 in the axial direction. That is, central hole 12, magnet accommodating holes 13, and cooling flow paths 14 all open to the end face of first end portion 11a and the end face of second end portion 11b.

[0015] The central hole 12 has a substantially circular shape in a plan view. Two keys 12a protruding opposite each other in the radial direction are provided on the inner surface of the central hole 12. The two keys 12a fit into key grooves provided in a shaft (not shown), thereby restricting relative movement between the rotor core 11 and the shaft in the circumferential direction.

[0016] The magnet accommodating holes 13 are located radially outward of the center hole 12 and are equally spaced in the circumferential direction. The rotor core 11 has, for example, 16 magnet accommodating holes 13. The opening of each magnet accommodating hole 13 has a substantially rectangular shape in a plan view. Two magnet accommodating holes 13 adjacent to each other in the circumferential direction are inclined in opposite directions to each other with respect to the circumferential direction.

[0017] The cooling passages 14 are located radially inward of the magnet accommodating holes 13 and are provided at equal intervals in the circumferential direction. The rotor core 11 has, for example, eight cooling passages 14.

[0018] (Magnet 20) For example, one magnet 20 is accommodated in each magnet accommodating hole 13. Two magnets 20 may be accommodated in each magnet accommodating hole 13. The magnets 20 are fixed to the rotor core 11 via a resin material 30 filled in the magnet accommodating hole 13.

[0019] The magnet 20 is, for example, a permanent magnet such as a neodymium magnet. (Resin material 30) The resin material 30 is filled, for example, between the inner surface of the magnet accommodating hole 13 and the outer surface of the magnet 20 around the entire periphery of the magnet 20 .

[0020] The resin material 30 may be, for example, a thermosetting resin such as an epoxy resin, or a thermoplastic resin such as a liquid crystal polymer. (End plate 40) The two end plates 40 include a first end plate 40A and a second end plate 40B. Hereinafter, when there is no need to distinguish between the first end plate 40A and the second end plate 40B, they will be simply referred to as end plates 40.

[0021] The material of the end plate 40 is, for example, a metallic material such as stainless steel. The plate thickness of the first end plate 40A and the plate thickness of the second end plate 40B are, for example, the same.

[0022] The first end plate 40A is welded to the first end 11a of the rotor core 11 so as to cover the end face of the first end 11a. More specifically, the outer periphery of the first end plate 40A is welded to the outer periphery of the first end 11a. The second end plate 40B is welded to the second end 11b of the rotor core 11 so as to cover the end face of the second end 11b. More specifically, the outer periphery of the second end plate 40B is welded to the outer periphery of the second end 11b. The end plates 40 prevent the magnets 20 from jumping out of the magnet accommodating holes 13.

[0023] 2, the first end plate 40A has a disk shape corresponding to the shape of the end face of the first end portion 11a. The first end plate 40A has a first communication hole 41 communicating with the center hole 12, a plurality of second communication holes 42 communicating with the magnet accommodating holes 13, and a plurality of third communication holes 43 communicating with the cooling flow passage 14.

[0024] Two first keys 41a protruding radially opposite to each other are provided on the inner surface of the first communication hole 41. The first keys 41a have a shape corresponding to the keys 12a of the rotor core 11. The opening of the second communication hole 42 is smaller than the opening of the magnet accommodating hole 13. The opening of the third communication hole 43 is smaller than, for example, the opening of the cooling flow passage 14. The opening of the third communication hole 43 may be the same size as the opening of the cooling flow passage 14, or may be larger than the opening of the cooling flow passage 14. The third communication hole 43 is an example of a "first through hole."

[0025] 3, the second end plate 40B has a disk shape corresponding to the shape of the end face of the second end portion 11b. The second end plate 40B has a fourth communication hole 44 communicating with the center hole 12, a plurality of fifth communication holes 45 communicating with the magnet accommodating holes 13, and a plurality of sixth communication holes 46 communicating with the cooling flow passage 14.

[0026] Two second keys 44a are provided on the inner surface of the fourth communication hole 44, protruding opposite each other in the radial direction. The second keys 44a have a shape corresponding to the key 12a of the rotor core 11. The shape of the fifth communication hole 45 is different from the shape of the second communication hole 42. The opening of the fifth communication hole 45 is smaller than, for example, the opening of the magnet accommodating hole 13 and the opening of the second communication hole 42. The opening of the fifth communication hole 45 may be the same size as the opening of the second communication hole 42. The shape of the sixth communication hole 46 is different from the shape of the third communication hole 43. The opening of the sixth communication hole 46 is smaller than the opening of the cooling flow passage 14 and the opening of the third communication hole 43. The sixth communication hole 46 is an example of a "second through hole".

[0027] 3, the sixth communication hole 46 is formed in a portion of the second end plate 40B corresponding to the area of ​​the first end plate 40A where the third communication hole 43 is formed. Therefore, when the first end plate 40A is projected onto the second end plate 40B in the rotor 10, the area where the sixth communication hole 46 is formed is included in the area where the third communication hole 43 is formed.

[0028] (Rotor 10 manufacturing device 50) Next, a manufacturing apparatus 50 for the rotor 10 (hereinafter simply referred to as the manufacturing apparatus 50) will be described.

[0029] As shown in FIG. 4, the manufacturing apparatus 50 includes a first welding station 60A, a second welding station 60B, a reversing device 70, a first supply station 80A, and a second supply station 80B. The first welding station 60A welds a first end plate 40A to a first end 11a of the rotor core 11 to which the magnet 20 is fixed by the resin material 30. The second welding station 60B welds a second end plate 40B to a second end 11b of the rotor core 11. The reversing device 70 reverses the rotor core 11 located at the first welding station 60A and transports it to the second welding station 60B. The first supply station 80A supplies the first end plate 40A to the first welding station 60A. The second supply station 80B supplies the second end plate 40B to the second welding station 60B.

[0030] (First welding station 60A) The first welding station 60A includes a welding table 61 and a first welding device 62A. The first end plate 40A supplied from the first supply station 80A is placed on the welding table 61. The first welding device 62A includes a plurality of welding torches. The first welding device 62A welds the first end plate 40A to the first end portion 11a of the rotor core 11 placed on the first end plate 40A. The welding method of the first welding device 62A is, for example, laser welding.

[0031] (Second welding station 60B) The second welding station 60B includes a welding table 61 and a second welding device 62B. The second end plate 40B supplied from the second supply station 80B is placed on the welding table 61. The second welding device 62B includes a plurality of welding torches. The second welding device 62B welds the second end plate 40B to the second end 11b of the rotor core 11 placed on the second end plate 40B. The second welding device 62B welds the second end plate 40B to the second end 11b of the rotor core 11 having the first end 11a welded to the first end 11a. The welding method of the second welding device 62B is, for example, laser welding.

[0032] (reversal device 70) The reversing device 70 reverses the rotor core 11 with the first end plate 40A welded to the first end portion 11a at the first welding station 60A and places it on the second end plate 40B at the second welding station 60B. The reversing device 70 may be configured to transport the rotor core 11 before the first end plate 40A is welded to the first welding station 60A, and to remove the rotor 10 with the two end plates 40 welded to it from the second welding station 60B.

[0033] The reversing device 70 is configured, for example, by a robot arm to which a chuck 71 that clamps the outer circumferential surface of the rotor core 11 is attached. (First supply station 80A) The first supply station 80A includes a first jig 81A, a first support stand 86A, a first transport section 90A, a first detection section 100A, and a first plate thickness measurement section 110A.

[0034] (First jig 81A) 5, the first jig 81A supports the first end plate 40A before it is supplied to the first welding station 60A. The first jig 81A supports a plurality of stacked first end plates 40A. The first jig 81A can also support the second end plate 40B.

[0035] The first jig 81A has a mounting table 82, a post 83, and a plurality of first legs 85A. The first jig 81A has, for example, three first legs 85A. The mounting table 82 of the first jig 81A is an example of a "first mounting table."

[0036] The first end plate 40A is placed on the mounting table 82. The mounting table 82 is in the shape of a disk. The diameter of the mounting table 82 is, for example, equal to or greater than the diameter of the first end plate 40A. The post 83 protrudes from the center of the mounting base 82. The post 83 has a cylindrical shape. The post 83 is inserted into the first communicating hole 41 of the first end plate 40A. The post 83 has two grooves 84 into which the two first keys 41a are respectively inserted. The two grooves 84 extend in the longitudinal direction of the post 83 on opposite sides of the central axis of the post 83.

[0037] Each of the first legs 85A extends from the mounting table 82 to the opposite side to the post 83. Each of the first legs 85A has, for example, a cylindrical shape. The three first legs 85A are provided at intervals from one another in the circumferential direction centered on the central axis of the mounting table 82. The three first legs 85A are provided at equal intervals in the circumferential direction, for example.

[0038] (1st support stand 86A) The first support base 86A has a first engagement portion 87A that engages with the first jig 81 A. The first support base 86A supports the first jig 81A by engaging the first engagement portion 87A with the first jig 81A.

[0039] The first engagement portion 87A has a plurality of first recesses 88A into which the plurality of first legs 85A are inserted. The first engagement portion 87A has the same number of first recesses 88A as the first legs 85A. The first recesses 88A are, for example, circular in plan view. The plurality of first recesses 88A allow the insertion of the plurality of first legs 85A, while restricting the insertion of the plurality of second legs 85B, which will be described later. When the first legs 85A are inserted into the respective first recesses 88A, the lower surface of the mounting base 82 contacts the upper surface of the first support base 86A.

[0040] (First conveying section 90A) 4, the first transfer section 90A transfers the end plate 40 to the first welding station 60A. The first transfer section 90A includes a first transfer device 91A, a second transfer device 93A, and a third transfer device 97A.

[0041] (First conveying device 91A) 4 and 7, the first conveying device 91A conveys the end plate 40 supported by the first jig 81A to a detection position Pd1. The detection position Pd1 is a position where the first detection unit 100A detects whether the type of the end plate 40 is the first end plate 40A.

[0042] The first transfer device 91A uses negative pressure to adsorb and lift the end plate 40. The first transfer device 91A has a plurality of suction pads 92 that adsorb the upper surface of the end plate 40. The first transfer device 91A may adsorb the end plate 40 in a contact state, or may adsorb the end plate 40 in a non-contact state.

[0043] (Second conveying device 93A) 4, the second conveying device 93A conveys the end plate 40 conveyed to the detection position Pd1 by the first conveying device 91A to the plate thickness measurement position Pm1. The plate thickness measurement position Pm1 is a position where the plate thickness of the end plate 40 is measured by the first plate thickness measurement unit 110A.

[0044] The second conveying device 93A includes a support plate 94 and a linear actuator 95 that horizontally reciprocates the support plate 94. The support plate 94 is U-shaped in a plan view. The end plate 40 is placed on the support plate 94 by the first conveying device 91A. The support plate 94 supports the lower surface of the outer periphery of the end plate 40.

[0045] The support plate 94 has a plurality of positioning pins 96 that contact the outer peripheral surface of the end plate 40 to position the end plate 40. The support plate 94 has, for example, four positioning pins 96. Each positioning pin 96 protrudes from the upper surface of the support plate 94.

[0046] (First detection unit 100A) The first detection unit 100A detects whether the end plate 40 supplied to the first welding station 60A is the first end plate 40A. More specifically, the first detection unit 100A detects whether the end plate 40 transported to the detection position Pd1 by the first transport device 91A is the first end plate 40A.

[0047] 8, the first detection unit 100A is, for example, a photoelectric sensor including a light-projecting unit 101 that projects detection light and a light-receiving unit 102 that receives the detection light. The light-projecting unit 101 is configured to project detection light every time the end plate 40 is transported to the detection position Pd1. The light-receiving unit 102 is located, for example, below the light-projecting unit 101.

[0048] The light projection area of ​​the first detection unit 100A with respect to the end plate 40 is the area where the third communication hole 43 is formed in the first end plate 40A. 9, the light projection area of ​​the first detection unit 100A onto the end plate 40 is an area that does not include the area where the sixth communication hole 46 is formed in the second end plate 40B, but is an area that constitutes the surface of the second end plate 40B. It can also be said that the light projection area of ​​the first detection unit 100A onto the end plate 40 is an area that corresponds to the area where the third communication hole 43 is formed in the second end plate 40B.

[0049] As shown in FIG. 8, when the end plate 40 located at the detection position Pd1 is the first end plate 40A, the detection light from the light projecting unit 101 passes through the third communication hole 43 and reaches the light receiving unit .

[0050] 9, when the end plate 40 located at detection position Pd1 is the second end plate 40B, the detection light from the light-projecting unit 101 is reflected by the surface of the second end plate 40B and does not reach the light-receiving unit 102. The first detection unit 100A detects that the end plate 40 located at detection position Pd1 is the first end plate 40A when the light-receiving unit 102 receives the detection light. Moreover, the first detection unit 100A detects that the end plate 40 located at detection position Pd1 is the second end plate 40B when the light-receiving unit 102 does not receive the detection light.

[0051] (1st plate thickness measurement section 110A) 4, the first thickness measuring unit 110A measures the thickness of the end plate 40 transported to the thickness measuring position Pm1 by the second transport device 93A. The first thickness measuring unit 110A is, for example, a thickness sensor having a pair of measuring devices arranged on both sides of the end plate 40 in the thickness direction of the end plate 40. The first thickness measuring unit 110A may be a device that measures the thickness of the end plate 40 in a contact state, or may be a device that measures the thickness of the end plate 40 in a non-contact state.

[0052] (Third conveying device 97A) The third transport device 97A transports the end plate 40 located at the plate thickness measurement position Pm1 to the first welding station 60A or the discharge chute 120A in accordance with the detection result of the first detection unit 100A and the measurement result of the first plate thickness measurement unit 110A. The discharge chute 120A is for discharging the end plate 40 by its own weight to the outside of the manufacturing apparatus 50, and has, for example, a gutter-shaped inclined platform inclined relative to the horizontal direction.

[0053] The third transfer device 97A uses negative pressure to adsorb and lift the end plate 40. The third transfer device 97A has a plurality of suction pads 98 that adsorb the upper surface of the end plate 40. The third transfer device 97A may adsorb the end plate 40 in a contact state, or may adsorb the end plate 40 in a non-contact state.

[0054] (Second supply station 80B) The second supply station 80B has the same or corresponding configuration as the first supply station 80A.

[0055] Hereinafter, the same components of the second supply station 80B as those of the first supply station 80A are denoted by the same reference numerals, and redundant explanations may be omitted. Also, the components of the second supply station 80B corresponding to those of the first supply station 80A are denoted by the reference numerals in which the suffix "A" of the reference numerals indicating the components of the first supply station 80A is changed to "B", and redundant explanations may be omitted.

[0056] The second supply station 80B includes a second jig 81B, a second support stand 86B, a second transport section 90B, a second detection section 100B, and a second plate thickness measurement section 110B. (Second jig 81B) 6, the second jig 81B supports the second end plates 40B before they are supplied to the second welding station 60B. The second jig 81B supports the stacked second end plates 40B. The second jig 81B can also support the first end plates 40A.

[0057] The second jig 81B has a mounting table 82, a post 83, and a plurality of second legs 85B. The second jig 81B has, for example, four second legs 85B. The mounting table 82 of the second jig 81B is an example of a "second mounting table."

[0058] Each second leg 85B extends from the mounting table 82 on the opposite side to the post 83. Each second leg 85B has, for example, a cylindrical shape. The four second legs 85B are provided at intervals from one another in the circumferential direction centered on the central axis of the mounting table 82. The four legs are provided, for example, at equal intervals in the circumferential direction.

[0059] (Second support stand 86B) The second support base 86B has a second engagement portion 87B that engages with the second jig 81 B. The second support base 86B supports the second jig 81B by engaging the second engagement portion 87B with the second jig 81B.

[0060] The second engagement portion 87B has a plurality of second recesses 88B into which the plurality of second legs 85B are inserted. The second engagement portion 87B has the same number of second recesses 88B as the second legs 85B. The second recesses 88B are, for example, circular in plan view. The plurality of second recesses 88B allow the insertion of the plurality of second legs 85B, while restricting the insertion of the plurality of first legs 85A. When the second legs 85B are inserted into the respective second recesses 88B, the lower surface of the mounting base 82 contacts the upper surface of the second support base 86B.

[0061] (Second conveying section 90B) 4, the second transfer section 90B transfers the end plate 40 to the second welding station 60B. The second transfer section 90B includes a first transfer device 91B, a second transfer device 93B, and a third transfer device 97B.

[0062] (First conveying device 91B) The first transfer device 91B transfers the end plate 40 supported by the second jig 81B to the detection position Pd2. The detection position Pd2 is a position where the second detection unit 100B detects whether the type of the end plate 40 is the second end plate 40B or not.

[0063] (Second conveying device 93B) The second transfer device 93B transfers the end plate 40 transferred to the detection position Pd2 by the first transfer device 91B to the thickness measurement position Pm2. The thickness measurement position Pm2 is a position where the thickness of the end plate 40 is measured by the second thickness measurement unit 110B.

[0064] (Second detection unit 100B) The second detection unit 100B detects whether the end plate 40 supplied to the second welding station 60B is the second end plate 40B. More specifically, the second detection unit 100B detects whether the end plate 40 transported to the detection position Pd2 by the first transport device 91B is the second end plate 40B.

[0065] The second detection unit 100B has the same configuration as the first detection unit 100A. That is, the second detection unit 100B is a photoelectric sensor including a light projecting unit 101 and a light receiving unit . The second detection unit 100B detects that the end plate 40 located at the detection position Pd2 is the first end plate 40A when the light receiving unit 102 receives the detection light. The second detection unit 100B detects that the end plate 40 located at the detection position Pd2 is the second end plate 40B when the light receiving unit 102 does not receive the detection light.

[0066] (Second plate thickness measurement section 110B) The second thickness measuring unit 110B measures the thickness of the end plate 40 transported to the thickness measuring position Pm2 by the second transport device 93B.

[0067] (Third conveying device 97B) The third transport device 97B transports the end plate 40 located at the plate thickness measurement position Pm2 to the second welding station 60B or the discharge chute 120B depending on the detection result of the second detection unit 100B and the measurement result of the second plate thickness measurement unit 110B.

[0068] (Method of manufacturing rotor 10) Next, a method for manufacturing the rotor 10 will be described. The manufacturing method of the rotor 10 includes a first conveying step, a first detection step, a first plate thickness measuring step, a first welding step, a second conveying step, a second detection step, a second plate thickness measuring step, a second welding step, and a reversing step.

[0069] 4, in the first transport step, the first transport unit 90A transports the end plate 40 supported by the first jig 81A to the detection position Pd1 and then to the plate thickness measurement position Pm1. The first transport unit 90A then transports the end plate 40 located at the plate thickness measurement position Pm1 to the first welding station 60A or the discharge chute 120A. Prior to the first transport step, the first jig 81A supporting the multiple end plates 40 is engaged with the first support stand 86A by, for example, an operator.

[0070] 7, in the first transfer step, first, the first transfer device 91A adsorbs and lifts the uppermost end plate 40 stacked on the first jig 81A. The first transfer device 91A then places the end plate 40 on a support plate 94 of the second transfer device 93A, thereby transferring the end plate 40 to the detection position Pd1.

[0071] 4, when the end plate 40 is transported to the detection position Pd1, a first detection step is performed. In the first detection step, the first detection unit 100A detects whether the end plate 40 supplied to the first welding station 60A by the first transport unit 90A is the first end plate 40A.

[0072] In a first transport step performed after the first detection step, the second transport device 93A transports the end plate 40 from the detection position Pd1 to the plate thickness measurement position Pm1 by moving the support plate 94. The second transport device 93A transports the end plate 40 from the detection position Pd1 to the plate thickness measurement position Pm1 regardless of the detection result of the first detection step.

[0073] When the end plate 40 is transported to the plate thickness measurement position Pm1, a first plate thickness measurement step is performed. In the first plate thickness measurement step, the first plate thickness measurement unit 110A measures the plate thickness of the end plate 40. Note that if the detection result of the first detection step is the second end plate 40B, the first plate thickness measurement step does not need to be performed.

[0074] In the subsequent first transport step, the third transport device 97A adsorbs and lifts the end plate 40 located at the plate thickness measurement position Pm1. Then, the third transport device 97A transports the end plate 40 to the first welding station 60A or the discharge chute 120A depending on the detection result of the first detection step and the measurement result of the first plate thickness measurement step.

[0075] Here, in the first transport section 90A, it is preferable that the end plates 40 are transported one by one, but there is a possibility that the end plates 40 may be transported in an overlapping state. When the first end plates 40A overlap, the detection result of the first detection section 100A is the first end plate 40A. In this case, the measurement result of the first plate thickness measurement section 110A is greater than a predetermined first threshold value Th1. The first threshold value Th1 is set to, for example, a maximum value within the manufacturing tolerance range for the plate thickness of the first end plate 40A. In other words, when the measurement result of the first plate thickness measurement section 110A is greater than the first threshold value Th1, it indicates that the end plates 40 overlap.

[0076] When the detection result of first detection unit 100A is the first end plate 40A and the measurement result of first plate thickness measurement unit 110A is equal to or less than first threshold value Th1, third transfer device 97A transfers first end plate 40A to first welding station 60A. At this time, third transfer device 97A places first end plate 40A on welding table 61 of first welding station 60A.

[0077] Even if the detection result of the first detection unit 100A is the first end plate 40A, if the measurement result of the first plate thickness measurement unit 110A is greater than the first threshold value Th1, the third transfer device 97A stops the transfer of the first end plate 40A to the first welding station 60A. In addition, if the detection result of the first detection unit 100A is the second end plate 40B, the third transfer device 97A stops the transfer of the second end plate 40B to the first welding station 60A. When the third transfer device 97A stops the transfer of the end plate 40 to the first welding station 60A, it transfers the end plate 40 located at the plate thickness measurement position Pm1 to the discharge chute 120A.

[0078] 10, prior to the first welding step, a reversing device 70 places the rotor core 11 on the first end plate 40A placed on the welding table 61 of the first welding station 60A. This brings the first end portion 11a of the rotor core 11 into contact with the upper surface of the first end plate 40A.

[0079] In the first welding step, the first welding device 62A welds the first end plate 40A to the first end portion 11a of the rotor core 11. The second conveying step, the second detection step, the second plate thickness measuring step, and the second welding step correspond to the first conveying step, the first detection step, the first plate thickness measuring step, and the first welding step described above. The second conveying step, the second detection step, the second plate thickness measuring step, and the second welding step can be explained by appropriately replacing the explanations of the first conveying step, the first detection step, the first plate thickness measuring step, and the second welding step. Specifically, the detection position Pd1 can be replaced with the detection position Pd2, the plate thickness measuring position Pm1 with the plate thickness measuring position Pm2, the first threshold value Th1 with the second threshold value Th2, the names of the components "first**" with "second**", and the suffix "A" of the symbols of the components with "B". The second threshold value Th2 is set to, for example, the maximum value within the manufacturing tolerance range of the plate thickness of the second end plate 40B. The first threshold value Th1 and the second threshold value Th2 are set to, for example, the same value.

[0080] In the reversing step, the reversing device 70 reverses the rotor core 11 to which the first end plate 40A has been welded, and places it on the second end plate 40B placed on the welding table 61 of the second welding station 60B. This brings the second end 11b of the rotor core 11 into contact with the upper surface of the second end plate 40B. The reversing step is performed after the first welding step and the second transport step, and before the second welding step.

[0081] In the manner described above, the first end plate 40A and the second end plate 40B are welded to the first end portion 11a and the second end portion 11b of the rotor core 11, respectively, whereby the rotor 10 is manufactured.

[0082] The operation and effects of this embodiment will be described. (1) Manufacturing apparatus 50 includes a first welding device 62A and a first detection unit 100A that detects whether or not an end plate 40 supplied to first welding device 62A is a first end plate 40A. Manufacturing apparatus 50 also includes a second welding device 62B and a second detection unit 100B that detects whether or not an end plate 40 supplied to second welding device 62B is a second end plate 40B.

[0083] According to this configuration, the first detection unit 100A detects whether the end plate 40 supplied to the first welding device 62A is the first end plate 40A. Moreover, the second detection unit 100B detects whether the end plate 40 supplied to the second welding device 62B is the second end plate 40B. This makes it possible to prevent an end plate 40 other than the correct end plate 40 from being welded to the rotor core 11. This makes it possible to prevent erroneous assembly of the end plate 40.

[0084] (2) The light projection area of ​​the first detection unit 100A and the second detection unit 100B with respect to the end plate 40 is, in the first end plate 40A, the area where the third communication hole 43 is formed. On the other hand, in the second end plate 40B, the light projection area does not include the area where the sixth communication hole 46 is formed, and is the area that constitutes the surface of the second end plate 40B.

[0085] With this configuration, the detection light projected onto the first end plate 40A passes through the first end plate 40A via the third communication hole 43, while the detection light projected onto the second end plate 40B is reflected on the surface of the second end plate 40B. This allows the first detection unit 100A and the second detection unit 100B to detect whether the end plate 40 to be welded to the rotor core 11 is a genuine end plate 40 or not. Therefore, erroneous assembly of the end plate 40 can be easily prevented.

[0086] (3) When the first transport unit 90A detects that the end plate 40 to be transported to the first welding station 60A is not the first end plate 40A, the first transport unit 90A stops transporting the end plate 40 to the first welding station 60A. When the second transport unit 90B detects that the end plate 40 to be transported to the second welding station 60B is not the second end plate 40B, the second transport unit 90B stops transporting the end plate 40 to the second welding station 60B.

[0087] According to this configuration, when the end plate 40 being transported by the first transport unit 90A and the second transport unit 90B is different from a regular end plate 40, the transport of the end plate 40 to the first welding station 60A and the second welding station 60B is stopped. This makes it possible to prevent an end plate 40 different from a regular end plate 40 from being welded to the rotor core 11. This makes it possible to prevent erroneous assembly of the end plate 40.

[0088] (4) When the measurement result of the first sheet thickness measurement unit 110A is greater than a predetermined first threshold value Th1, the first transport unit 90A stops transporting the end plate 40 to the first welding station 60A. When the measurement result of the second sheet thickness measurement unit 110B is greater than a predetermined second threshold value Th2, the second transport unit 90B stops transporting the end plate 40 to the second welding station 60B.

[0089] According to this configuration, by setting the first threshold value Th1 to the maximum value within the manufacturing tolerance range for the thickness of the first end plates 40A, it is possible to prevent multiple first end plates 40A from being transported in an overlapping state to the first welding station 60A. Similarly, by setting the second threshold value Th2 to the maximum value within the manufacturing tolerance range for the thickness of the second end plates 40B, it is possible to prevent multiple second end plates 40B from being transported in an overlapping state to the second welding station 60B.

[0090] (5) The manufacturing apparatus 50 includes a first jig 81A that supports the first end plate 40A, and a first support base 86A having a first engagement portion 87A that engages with the first jig 81A. The manufacturing apparatus 50 also includes a second jig 81B that supports the second end plate 40B, and a second support base 86B having a second engagement portion 87B that engages with the second jig 81B. The first engagement portion 87A allows engagement with the first jig 81A, but restricts engagement with the second jig 81B. The second engagement portion 87B allows engagement with the second jig 81B, but restricts engagement with the first jig 81A.

[0091] According to this configuration, the first jig 81A supporting the first end plate 40A is engaged with the first engagement portion 87A, but is not engaged with the second engagement portion 87B. Also, the second jig 81B supporting the second end plate 40B is engaged with the second engagement portion 87B, but is not engaged with the first engagement portion 87A. Therefore, the first jig 81A is prevented from being supported by the second support base 86B, and the second jig 81B is prevented from being supported by the first support base 86A. As a result, the end plate 40 taken out of the first jig 81A supported by the first support base 86A is supplied to the first welding station 60A, thereby preventing erroneous assembly of the end plate 40. Also, the end plate 40 taken out of the second jig 81B supported by the second support base 86B is supplied to the second welding station 60B, thereby preventing erroneous assembly of the end plate 40.

[0092] In this embodiment, the first end plate 40A is supported by the second jig 81B, and the second end plate 40B is supported by the first jig 81A. Even if the first end plate 40A is supported by the second jig 81B, the first end plate 40A is detected by the second detection unit 100B, and therefore erroneous assembly in which the first end plate 40A is welded to the second end portion 11b can be prevented. The same applies to the second end plate 40B.

[0093] (6) The first engagement portion 87A has a first recess 88A that allows the insertion of the first leg 85A of the first jig 81A while restricting the insertion of the second leg 85B of the second jig 81B. The second engagement portion 87B has a second recess 88B that allows the insertion of the second leg 85B of the second jig 81B while restricting the insertion of the first leg 85A of the first jig 81A.

[0094] According to this configuration, the first jig 81A can be easily supported by the first support stand 86A by inserting the first leg portion 85A into the first recess portion 88A. Moreover, the second jig 81B can be easily supported by the second support stand 86B by inserting the second leg portion 85B into the second recess portion 88B.

[0095] (7) In a first welding step, a first end plate 40A is welded to the first end portion 11a using a first welding device 62A. In a first detection step, it is detected whether the end plate 40 supplied to the first welding station 60A is the first end plate 40A. In a second welding step, a second end plate 40B is welded to the second end portion 11b of the rotor core 11 to which the first end plate 40A has been welded to the first end portion 11a using a second welding device 62B. In a second detection step, it is detected whether the end plate 40 supplied to the second welding station 60B is the second end plate 40B.

[0096] According to this method, in the first detection step, it is detected whether the end plate 40 to be welded to the first end 11a of the rotor core 11 is the first end plate 40A. In addition, in the second detection step, it is detected whether the end plate 40 to be welded to the second end 11b of the rotor core 11 is the second end plate 40B. This makes it possible to prevent an end plate 40 other than the correct end plate 40 from being welded to the rotor core 11 in the first welding step and the second welding step. As a result, erroneous assembly of the end plate 40 can be prevented.

[0097] <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.

[0098] The first jig 81A may have at least one first leg 85A, and the first support base 86A may have at least one first recess 88A. Similarly, the second jig 81B may have at least one second leg 85B, and the second support base 86B may have at least one second recess 88B.

[0099] The first leg 85A and the second leg 85B may have different shapes or sizes. In this case, the first recess 88A and the second recess 88B only need to have shapes or sizes corresponding to the first leg 85A and the second leg 85B.

[0100] The first jig 81A and the second jig 81B may not have the first leg 85A and the second leg 85B, respectively. In this case, if the shape or size of the mounting base 82 of the first jig 81A and the second jig 81B are different from each other, the first engagement portion 87A may have a shape that allows engagement of the mounting base 82 of the first jig 81A while restricting engagement of the mounting base 82 of the second jig 81B. Similarly, the second engagement portion 87B may have a shape that allows engagement of the mounting base 82 of the second jig 81B while restricting engagement of the mounting base 82 of the first jig 81A.

[0101] The first jig 81A may have a support protruding from the center of the mounting base 82 to the side opposite the post 83, and the first engagement portion 87A of the first support base 86A may have an insertion hole into which the support is inserted. The amount of protrusion of the support from the mounting base 82 is preferably greater than the amount of protrusion of each of the first legs 85A from the mounting base 82. In this configuration, the first legs 85A are inserted into the first recesses 88A after the support is inserted into the insertion hole, making it easier to support the first jig 81A on the first support base 86A compared to a configuration without a support. The above modification can be similarly applied to the second jig 81B and the second support base 86B.

[0102] The manufacturing apparatus 50 does not necessarily have to include the first support stage 86A and the second support stage 86B. The manufacturing apparatus 50 does not have to include the first jig 81A and the second jig 81B. In this case, for example, a worker may supply the end plate 40 to the first welding device 62A and the second welding device 62B.

[0103] When the plate thickness of the first end plate 40A and the plate thickness of the second end plate 40B are different, the first threshold value Th1 and the second threshold value Th2 may be set to different values. The manufacturing apparatus 50 does not necessarily have to include the first thickness measuring unit 110A and the second thickness measuring unit 110B.

[0104] When it is detected that the end plate 40 to be transported to the first welding station 60A is not the first end plate 40A, the first transport unit 90A may stop the transport operation to stop the transport of the end plate 40 to the first welding station 60A. Similarly, when it is detected that the end plate 40 to be transported to the second welding station 60B is not the second end plate 40B, the second transport unit 90B may stop the transport operation to stop the transport of the end plate 40 to the second welding station 60B. In these cases, for example, an operator may remove the end plate 40 that is different from the regular end plate 40 from the manufacturing apparatus 50.

[0105] The light receiving unit 102 may be disposed on the same side as the light projecting unit 101 when viewed from the end plate 40. In this case, the detection light reflected from the surface of the end plate 40 is received by the light receiving unit 102. In this configuration, the first detection unit 100A detects that the end plate 40 located at the detection position Pd1 is the first end plate 40A when the light receiving unit 102 does not receive the detection light. Moreover, the first detection unit 100A detects that the end plate 40 located at the detection position Pd1 is the second end plate 40B when the light receiving unit 102 receives the detection light. The above modification example can be similarly applied to the second detection unit 100B.

[0106] The third communication hole 43, which is an example of a "first through hole", and the sixth communication hole 46, which is an example of a "second through hole", may have the same shape but different sizes. In other words, the shapes of the third communication hole 43 and the sixth communication hole 46 may be similar to each other.

[0107] The second communication hole 42 may be regarded as the "first through hole" and the fifth communication hole 45 may be regarded as the "second through hole" to set the light projection areas of the first detection unit 100A and the second detection unit 100B with respect to the end plate 40.

[0108] The first detection unit 100A and the second detection unit 100B may detect the type of the end plate 40 by detecting the presence or absence of a recess formed on the outer circumferential surface of the end plate 40.

[0109] The first detection unit 100A and the second detection unit 100B may detect the type of end plate 40 based on image data captured by a camera that captures an image of the end plate 40. In this case, the first detection unit 100A and the second detection unit 100B may detect the type of end plate 40 by identifying characters, patterns, two-dimensional codes, etc. displayed on the surface of the end plate 40.

[0110] The above embodiment includes the configurations described in the following supplementary notes. [Appendix 1] A rotor manufacturing apparatus for manufacturing a rotor including a rotor core having a first end and a second end located opposite each other in an axial direction, and two end plates having different shapes welded to the first end and the second end, respectively, the rotor manufacturing apparatus comprising: a first welding device that welds the first end plate to the first end, a first detection unit that detects whether the end plate supplied to the first welding device is the first end plate, a second welding device that welds the second end plate to the second end of the rotor core having the first end plate welded to the first end, and a second detection unit that detects whether the end plate supplied to the second welding device is the second end plate.

[0111] [Appendix 2] The first end plate has a first through hole, and the second end plate has a second through hole different in shape or size from the first through hole, the first detection unit and the second detection unit are photoelectric sensors including a light-projecting unit that projects detection light and a light-receiving unit that receives the detection light, and the light-projection area of ​​the first detection unit and the second detection unit onto the end plates is the area in the first end plate where the first through hole is formed, while in the second end plate it is an area that does not include the area in the second end plate where the second through hole is formed, and is an area that constitutes the surface of the second end plate.

[0112] [Appendix 3] A rotor manufacturing apparatus as described in [Appendix 1] or [Appendix 2], comprising a first transport unit which transports the end plate to the first welding device and a second transport unit which transports the end plate to the second welding device, wherein the first detection unit detects whether the end plate transported by the first transport unit is the first end plate and the second detection unit detects whether the end plate transported by the second transport unit is the second end plate, and when it is detected that the end plate to be transported to the first welding device is not the first end plate, the first transport unit stops transporting the end plate to the first welding device, and when it is detected that the end plate to be transported to the second welding device is not the second end plate,

[0113] [Appendix 4] A rotor manufacturing apparatus as described in [Appendix 3], comprising a first plate thickness measuring unit that measures a plate thickness of the end plate detected by the first detection unit to be the first end plate, and a second plate thickness measuring unit that measures a plate thickness of the end plate detected by the second detection unit to be the second end plate, wherein the first transport unit stops transporting the end plate to the first welding device when the measurement result of the first plate thickness measuring unit is greater than a predetermined first threshold, and the second transport unit stops transporting the end plate to the second welding device when the measurement result of the second plate thickness measuring unit is greater than a predetermined second threshold.

[0114] [Appendix 5] A rotor manufacturing apparatus as described in any one of [Appendix 1] to [Appendix 4], comprising: a first jig that supports the first end plate before it is supplied to the first welding device; a first support stand having a first engagement portion that engages with the first jig and supporting the first jig; a second jig that supports the second end plate before it is supplied to the second welding device; and a second support stand having a second engagement portion that engages with the second jig and supporting the second jig, wherein the first engagement portion allows engagement with the first jig while restricting engagement with the second jig, and the second engagement portion allows engagement with the second jig while restricting engagement with the first jig.

[0115] [Appendix 6] The first jig has a first mounting table on which the first end plate is placed and a first leg extending from the first mounting table, the second jig has a second mounting table on which the second end plate is placed and a second leg extending from the second mounting table, the first engagement portion has a first recess that allows insertion of the first leg while restricting insertion of the second leg, and the second engagement portion has a second recess that allows insertion of the second leg while restricting insertion of the first leg. A rotor manufacturing apparatus as described in [Appendix 5]. [Explanation of symbols]

[0116] Th1: First threshold Th2: Second threshold 10...Rotor 11...Rotor core 11a...first end 11b…Second end 40…End plate 40A…First end plate 40B…Second end plate 43…Third communication hole (first through hole) 46…6th communication hole (2nd through hole) 50...Manufacturing equipment 62A…First welding device 62B…Second welding device 81A…First jig 81B…Second jig 82…Placement table 85A…1st leg 85B…Second leg 86A…1st support stand 86B…Second support stand 87A…First engaging part 87B…Second engagement part 88A…First recess 88B…Second recess 90A…First conveyor section 90B…Second conveying section 100A…First detector 100B…Second detection section 101…Light projector 102...Light receiving section 110A…1st plate thickness measurement section 110B…Second plate thickness measurement section

Claims

1. 1. A rotor manufacturing apparatus for manufacturing a rotor including a rotor core having a first end and a second end located opposite to each other in an axial direction, and two end plates welded to the first end and the second end, respectively, and having different shapes, comprising: When the end plate welded to the first end portion is a first end plate, and the end plate welded to the second end portion is a second end plate, a first welding device for welding the first end plate to the first end portion; a first detection unit that detects whether the end plate supplied to the first welding device is the first end plate; a second welding device that welds the second end plate to the second end of the rotor core having the first end plate welded to the first end; a second detection unit that detects whether the end plate supplied to the second welding device is the second end plate. Rotor manufacturing equipment.

2. The first end plate has a first through hole, the second end plate has a second through hole having a different shape or size from the first through hole, the first detection unit and the second detection unit are photoelectric sensors including a light-projecting unit that projects detection light and a light-receiving unit that receives the detection light, a light projection area of ​​the first detection unit and the second detection unit with respect to the end plate is a region in the first end plate where the first through hole is formed, while a light projection area of ​​the second end plate is a region not including a region in the second end plate where the second through hole is formed, and is a region constituting a surface of the second end plate; An apparatus for manufacturing a rotor according to claim 1.

3. a first conveying unit that conveys the end plate to the first welding device; a second conveying unit that conveys the end plate to the second welding device, the first detection unit detects whether the end plate transported by the first transport unit is the first end plate; the second detection unit detects whether the end plate transported by the second transport unit is the second end plate; the first transport unit stops transporting the end plate to the first welding device when it is detected that the end plate to be transported to the first welding device is not the first end plate; the second transport unit stops transporting the end plate to the second welding device when it is detected that the end plate to be transported to the second welding device is not the second end plate. An apparatus for manufacturing a rotor according to claim 1.

4. A first plate thickness measuring unit that measures a plate thickness of the end plate detected as the first end plate by the first detection unit; A second plate thickness measuring unit that measures a plate thickness of the end plate detected as the second end plate by the second detection unit, The first transport unit stops transporting the end plate to the first welding device when a measurement result of the first plate thickness measurement unit is greater than a predetermined first threshold value, The second transport unit stops transporting the end plate to the second welding device when a measurement result of the second plate thickness measurement unit is greater than a predetermined second threshold value. An apparatus for manufacturing a rotor according to claim 3.

5. a first jig for supporting the first end plate before it is fed to the first welding device; a first support base having a first engagement portion that engages with the first jig and supporting the first jig; a second jig for supporting the second end plate before it is fed to the second welding device; a second support base having a second engagement portion that engages with the second jig and supporting the second jig; the first engagement portion allows engagement with the first jig while restricting engagement with the second jig; The second engagement portion allows engagement with the second jig while restricting engagement with the first jig. An apparatus for manufacturing a rotor according to claim 1.

6. the first jig has a first mounting table on which the first end plate is placed and a first leg extending from the first mounting table, the second jig has a second mounting table on which the second end plate is placed and a second leg extending from the second mounting table, the first engagement portion has a first recess that allows insertion of the first leg portion while restricting insertion of the second leg portion; The second engagement portion has a second recess that allows the second leg portion to be inserted while restricting the first leg portion from being inserted. An apparatus for manufacturing a rotor according to claim 5.

7. A method for manufacturing a rotor including a rotor core having a first end and a second end located opposite to each other in an axial direction, and two end plates welded to the first end and the second end, respectively, and having different shapes, comprising: When the end plate welded to the first end portion is a first end plate, and the end plate welded to the second end portion is a second end plate, a first welding step of welding the first end plate to the first end portion using a first welding device; a first detection step of detecting whether the end plate supplied to the first welding device is the first end plate; a second welding step of welding the second end plate to the second end of the rotor core having the first end plate welded to the first end by using a second welding device; and a second detection step of detecting whether the end plate supplied to the second welding device is the second end plate. A method for manufacturing a rotor.

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