Rotor manufacturing method and rotor manufacturing apparatus

Abstract

To provide a rotor manufacturing method and a rotor manufacturing apparatus which can suppress lowering of productivity of a rotor.SOLUTION: A rotor manufacturing method and a rotor manufacturing apparatus are applied to a rotor including a rotor core, a magnet, and a resin material for fixing the magnet to the rotor core. When each process in manufacture of the rotor is normally carried out, a predetermined number of workpieces are accumulated in a storage space SP1 of a first conveyance device 40, and a vacant space SP2 for accumulating a predetermined number or more of workpieces is set to a second conveyance device 60. When at least one of a previous process and a post process is stopped, a first conveyance process conveys the workpieces accumulated in the storage space SP1 to a molding device 50. A molding process executes molding of the resin material by the molding device 50 on the conveyed workpieces. A second conveyance process conveys the molded workpieces to the vacant space SP2.SELECTED DRAWING: Figure 5

Description

[Technical field]

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

[0002] A rotating electric machine includes a cylindrical stator and a rotor that rotates inside the stator. Patent Document 1 discloses a rotor used in a magnet-embedded rotating electric machine. This rotor includes a rotor core having magnet accommodating holes, magnets accommodated in the magnet accommodating holes, and a resin material that fills the magnet accommodating holes and fixes the magnets to the rotor core.

[0003] When manufacturing a rotor, a series of steps described below are repeatedly performed. First, in a pre-process, magnets are accommodated in the magnet accommodating holes of a rotor core. In a subsequent molding process, a molding machine molds a resin material into the magnet accommodating holes. In a post-process, post-processing such as removing the jig is performed. Through these steps, the rotor is manufactured. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2016-119766 A Summary of the Invention [Problem to be solved by the invention]

[0005] Here, during the manufacture of rotors, a pre-processing device used in a pre-processing or a post-processing device used in a post-processing may stop due to an abnormality or the like. In this case, it may become impossible to feed a workpiece before molding the resin material into the molding machine, or it may become impossible to discharge a workpiece after molding the resin material from the molding machine. Therefore, even if the molding machine is operating normally at this time, it may become impossible to operate the molding machine. In this case, the operating rate of the molding machine may decrease, leading to a decrease in rotor productivity. [Means for solving the problem]

[0006] A manufacturing method of a rotor for solving the above-mentioned problems includes a rotor core having magnet accommodating holes, magnets accommodated in the magnet accommodating holes, and a resin material filled in the magnet accommodating holes to fix the magnets to the rotor core, the manufacturing method including the steps of: a pre-process of forming a workpiece with the magnet accommodated in the magnet accommodating hole; a first conveying process of conveying the workpiece to a molding device including a molding machine by a first conveying device after the pre-process; a molding process of molding the resin material in the magnet accommodating hole by the molding device after the first conveying process; a second conveying process of conveying the workpiece from the molding device to a post-process device by a second conveying device after the molding process; and a second conveying process of conveying the workpiece to a post-process device after the second conveying process. and a subsequent process in which post-processing is performed on the workpieces by a subsequent process device, and when each process related to the manufacture of the rotor is performed normally, each process is performed so that a predetermined number of the workpieces are stored in the storage space of the first conveying device and free space is set in the second conveying device for storing more than the predetermined number of the workpieces, and when at least one of the previous process and the subsequent process is stopped, the first conveying process conveys the workpieces stored in the storage space to the molding device, and in the molding process, the molding device molds the resin material on the transported workpieces, and the second conveying process conveys the workpieces after molding to the free space.

[0007] According to the above manufacturing method, when each process is normally performed, the molding machine can be operated intermittently and continuously by repeatedly performing each process. Moreover, even if the pre-process or post-process is stopped, as long as the first conveying process, molding process, and second conveying process can be performed, the molding machine can continue molding the resin material by using the work stored in the storage space of the first conveying device and the free space set in the second conveying device. According to the above manufacturing method, even if the pre-process or post-process is stopped, the decrease in the operating rate of the molding machine due to the stop can be suppressed, and therefore the decrease in productivity of the rotor can be suppressed.

[0008] A rotor manufacturing apparatus for solving the above-mentioned problems is a manufacturing apparatus for manufacturing a rotor including a rotor core having magnet accommodating holes, magnets accommodated in the magnet accommodating holes, and a resin material filled in the magnet accommodating holes to fix the magnets to the rotor core, and includes a front-end process device that forms a workpiece with the magnets accommodated in the magnet accommodating holes, a molding device that includes a molding machine and molds the resin material into the magnet accommodating holes in the workpiece using the molding machine, a back-end process device that performs post-processing on the workpiece in which the resin material has been molded, a first conveying device that transports the workpiece from the front-end process device to the molding device, and a second conveying device that transports the workpiece from the molding device to the back-end process device, and controls the operation of each device that constitutes the manufacturing apparatus. and a control unit, which controls the operation of each of the devices so that, when each of the devices is operating normally, a predetermined number of the workpieces are accumulated in the first conveying device and free space for accumulating more than the predetermined number of the workpieces is set in the second conveying device, and which controls the operation of the molding device, the first conveying device, and the second conveying device so that, when the operation of at least one of the front-end process device and the back-end process device stops, the workpieces accumulated in the first conveying device are transported to the molding device, the molding device molds the resin material on the transported workpieces, and the workpieces after molding are discharged into the free space of the second conveying device.

[0009] According to the above configuration, when each device is operating normally, the operation control of each device is repeatedly executed, so that the molding machine can be operated intermittently. Moreover, even if the pre-process device or the post-process device is stopped, if the first conveying device, the molding device, and the second conveying device can be operated, the molding machine can continue to mold the resin material by using the work stored in the storage space of the first conveying device and the free space set in the second conveying device. According to the above configuration, even if the pre-process device or the post-process device is stopped, the decrease in the operating rate of the molding machine due to the stoppage can be suppressed, so that the decrease in the productivity of the rotor can be suppressed. [Brief description of the drawings]

[0010] [Figure 1] 1 is a plan view of a rotor manufactured by a rotor manufacturing method according to an embodiment of the present invention; [Diagram 2] FIG. [Diagram 3] 2 is a schematic diagram showing a schematic configuration of a manufacturing apparatus for the rotor. [Figure 4] FIG. 4 is a side cross-sectional view showing a workpiece formed in a previous process. [Diagram 5] 2 is a schematic diagram showing the operating state of the manufacturing apparatus when each device is operating normally. [Figure 6] 10 is a flowchart showing an execution procedure of an operation control process. [Figure 7] 13(a) to 13(d) are schematic diagrams showing the operating state of the manufacturing apparatus when the operation of the pre-processing apparatus and the post-processing apparatus is stopped while a workpiece is present inside the molding apparatus. [Figure 8] 13(a) to 13(c) are schematic diagrams showing the operating state of the manufacturing apparatus when the operation of the pre-processing apparatus and the post-processing apparatus has stopped with no workpiece present inside the molding apparatus. [Figure 9] 6(a) to 6(d) are schematic diagrams showing operating states of a manufacturing apparatus when the operations of a pre-processing device and a post-processing device are stopped in another embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, an embodiment of a rotor manufacturing method and rotor manufacturing apparatus will be described with reference to FIGS. <Rotor 10> First, a rotor to which the manufacturing method and manufacturing apparatus according to the present embodiment are applied will be described.

[0012] 1 and 2, the rotor 10 includes a rotor core 11, a plurality of magnets 12, and a plurality of resin materials 13. The rotor 10 is a rotor used in, for example, an embedded magnet motor.

[0013] <Rotor core 11> The rotor core 11 has a substantially cylindrical shape. 2, rotor core 11 is formed, for example, by stacking a plurality of core pieces punched out from electromagnetic steel sheets. Rotor core 11 has a first end face 11a and a second end face 11b located opposite each other in the axial direction of rotor core 11 (hereinafter simply referred to as the axial direction). Rotor core 11 has a central hole 14 into which a shaft (not shown) is inserted, and a plurality of magnet accommodating holes 15 in which magnets 12 are accommodated. The plurality of magnet accommodating holes 15 are formed at intervals from each other in the circumferential direction of rotor core 11.

[0014] The center hole 14 and the magnet accommodating holes 15 penetrate the rotor core 11 in the axial direction. That is, the center hole 14 and the magnet accommodating holes 15 are both open to the first end face 11a and the second end face 11b. As shown in Fig. 1, the cross-sectional shape of the magnet accommodating hole 15 perpendicular to the axial direction is a substantially rectangular shape having long sides and short sides. The cross-sectional shape of the magnet accommodating hole 15 is the same throughout the axial direction.

[0015] <Magnet 12> The magnets 12 are housed one by one in each magnet accommodating hole 15. The magnets 12 are fixed to the rotor core 11 via the resin material 13 filled in the magnet accommodating hole 15.

[0016] 2, magnet 12 has an elongated shape that is long in the axial direction. The cross-sectional shape of magnet 12 perpendicular to the axial direction is a substantially rectangular shape having long sides and short sides. <Resin material 13> The resin material 13 is filled, for example, between the inner surface of the magnet accommodating hole 15 and the outer surface of the magnet 12, all around the magnet 12. The resin material 13 is made of a thermoplastic resin material.

[0017] <Manufacturing equipment> Next, a manufacturing apparatus 20 used to manufacture the rotor 10 will be described. 3, the manufacturing apparatus 20 includes a pre-processing apparatus 30, a first conveying apparatus 40, a molding apparatus 50, a second conveying apparatus 60, and a post-processing apparatus 70. The apparatuses 30, 40, 50, 60, and 70 are arranged in the following order from the upstream side (hereinafter simply referred to as the upstream side) in the movement direction of the rotor 10 (specifically, the workpiece W): pre-processing apparatus 30, first conveying apparatus 40, molding apparatus 50, second conveying apparatus 60, and post-processing apparatus 70.

[0018] <Pre-process equipment 30> The front-end process device 30 forms a workpiece W in a state in which magnets 12 are accommodated in the magnet accommodating holes 15 of the rotor core 11 (see FIG. 1). More specifically, as shown in FIG. 4, the rotor core 11 is placed on a pallet member 16. In this state, the magnets 12 are accommodated in the magnet accommodating holes 15 of the rotor core 11. Thereafter, a gate plate 17 is attached to the upper part of the rotor core 11 and the pallet member 16.

[0019] <First conveying device 40> As shown in FIG. 3, the first transfer device 40 transfers the workpiece W from the pre-process device 30 to the forming device 50.

[0020] The first conveying device 40 has three conveying sections 41A, 41B, and 41C. These conveying sections 41A to 41C are arranged in the order of conveying section 41A, conveying section 41B, and conveying section 41C from the upstream side (the left side in FIG. 3).

[0021] The transport unit 41A includes, for example, an electric roller conveyor 43A that transports the workpiece W downstream in the direction of movement (hereinafter simply referred to as the downstream side), and a stopper member 44A that regulates the movement of the workpiece W on the electric roller conveyor 43A. The transport unit 41A includes a workpiece sensor 45A that detects the presence or absence of the workpiece W on the electric roller conveyor 43A.

[0022] The transport unit 41B includes, for example, an electric roller conveyor 43B that transports the workpiece W downstream, and a stopper member 44B that regulates the movement of the workpiece W on the electric roller conveyor 43B. The transport unit 41B includes a workpiece sensor 45B for detecting the presence or absence of the workpiece W on the electric roller conveyor 43B.

[0023] The transport section 41C includes, for example, an electric roller conveyor 43C that transports the workpiece W downstream, a stopper member 44C that restricts the movement of the workpiece W on the electric roller conveyor 43C, and a lift section 46C that moves the electric roller conveyor 43C in the vertical direction. The lift section 46C includes, for example, a linear motor. The vertical position of the electric roller conveyor 43C is controlled through the operation control of the lift section 46C. When the electric roller conveyor 43C is moving to the lower position, the electric roller conveyor 43C receives the workpiece W from the electric roller conveyor 43B of the transport section 41B. On the other hand, when the electric roller conveyor 43C is moving to the upper position, the electric roller conveyor 43C sends the workpiece W to the forming device 50. The transport section 41C includes a work sensor 45C for detecting the presence or absence of the workpiece W on the electric roller conveyor 43C.

[0024] As shown in Figure 5, in this embodiment, when each device 30, 40, 50, 60, 70 is operating normally, operation control of the first conveying device 40 is performed so that a predetermined number of works W (in this embodiment, two) are accumulated in the storage space SP1 of the first conveying device 40.

[0025] In this embodiment, the transport sections 41B and 41C of the first transport device 40 correspond to the storage space SP1 of the first transport device 40. In this embodiment, the transport of the work W stored in the storage space SP1 to the molding device 50 is executed on the condition that three workpieces W are stored in the first transport device 40, more specifically, that the workpieces W are stored in each of the transport sections 41A to 41C. More specifically, the transport of the workpiece W from the transport section 41C to the molding device 50 is executed on the condition that the workpieces W arrive at the transport section 41A while the workpieces W are stored in the transport sections 41B and 41C. In addition, in conjunction with this transport, the transport of the workpiece W from the transport section 41B to the transport section 41C and the transport of the workpiece W from the transport section 41A to the transport section 41B are executed.

[0026] <Forming equipment 50> The molding apparatus 50 includes a molding machine 51 and an input device 52 . <Forming machine 51> The molding machine 51 is an injection molding machine. The molding machine 51 molds the resin material 13 into the magnet accommodating holes 15 of the rotor core 11.

[0027] When molding is performed by the molding machine 51, a heated and molten thermoplastic resin material is prepared inside the molding machine 51. Therefore, if the operation of the molding machine 51 is stopped for a long period of time for some reason, the resin material inside the molding machine 51 deteriorates and becomes unusable. In this case, when molding is resumed by the molding machine 51, an operation to remove the resin material inside the molding machine 51 (hereinafter, a purging operation) is performed.

[0028] <Feeding device 52> The input device 52 is for inputting the workpiece W before the resin material 13 is molded into the molding machine 51, and for discharging the workpiece W after the resin material 13 has been molded from the molding machine 51. The input device 52 includes, for example, an arm member (not shown) that is hooked onto the workpiece W, a guide section 54 that guides the workpiece W, and an operation control section 55 that controls the operation of the arm member. When the workpiece W is to be moved, the arm member is hooked onto the workpiece W, more specifically, onto the pallet member 16, through the operation control of the operation control section 55. Then, the arm member is moved in this state. As a result, the workpiece W is moved while being guided by the guide section 54 together with the pallet member 16.

[0029] The molding device 50 has a standby position PA set outside the molding machine 51 and a processing position PB set inside the molding machine 51. The standby position PA is a position adjacent to the conveying section 41C. The workpiece W is sent from the conveying section 41C to this standby position PA.

[0030] When molding is performed by the molding machine 51, the input device 52 inputs the workpiece W into the molding machine 51 by moving the workpiece W from the standby position PA to the processing position PB. When molding by the molding machine 51 is completed, the input device 52 moves the workpiece W from the processing position PB to the standby position PA, thereby discharging the workpiece W from the molding machine 51. In this embodiment, the input device 52 constitutes a part of a transport device for transporting the workpiece W.

[0031] <Second conveying device 60> As shown in FIG. 3, the second conveying device 60 conveys the workpiece W after molding by the molding machine 51 from a standby position PA of the molding machine 50 to an empty space SP2 of the second conveying device 60 or to a post-process device .

[0032] The second conveying device 60 has four conveying sections 61D, 61E, 61F, and 61G. These conveying sections 61D to 61G are arranged in the following order from the upstream side (the left side in FIG. 3): conveying section 61D, conveying section 61E, conveying section 61F, and conveying section 61G.

[0033] The transport section 61D includes, for example, an electric roller conveyor 63D that transports the workpiece W downstream, a stopper member 64D that restricts the movement of the workpiece W on the electric roller conveyor 63D, and a lift section 66D that moves the electric roller conveyor 63D in the vertical direction. The lift section 66D includes, for example, a linear motor. The electric roller conveyor 63D moves in the vertical direction through the operation control of the lift section 66D. When the electric roller conveyor 63D moves to the upper position, the electric roller conveyor 63D receives the workpiece W from the waiting position PA of the molding device 50. On the other hand, when the electric roller conveyor 63D moves to the lower position, the electric roller conveyor 63D sends the workpiece W to the transport section 61E. The transport section 61D includes a work sensor 65D for detecting the presence or absence of the workpiece W on the electric roller conveyor 63D.

[0034] The transport units 61E, 61F, 61G are equipped with, for example, electric roller conveyors 63E, 63F, 63G that transport the workpiece W downstream and stopper members 64E, 64F, 64G that regulate the movement of the workpiece W on the electric roller conveyors 63E, 63F, 63G. The transport units 61E, 61F, 61G are equipped with workpiece sensors 65E, 65F, 65G for detecting the presence or absence of the workpiece W on the electric roller conveyors 63E, 63F, 63G.

[0035] In this embodiment, when each of the devices 30, 40, 50, 60, 70 is operating normally, the operation control of the second conveying device 60 is executed so that a free space SP2 for storing a number of workpieces W obtained by adding "1" to a predetermined number (three in this embodiment) is set in the second conveying device 60. As shown in FIG. 5, in detail, when each of the devices 30, 40, 50, 60, 70 is operating normally, the workpieces W discharged from the molding device 50 are conveyed to the conveying section 61G by passing through the conveying sections 61D, 61E, 61F without being retained therein. As a result, the conveying sections 61D, 61E, 61F are spaces where no workpieces W are accumulated.

[0036] <Post-process equipment 70> 3, the post-processing device 70 performs post-processing on the workpiece W on which the resin material 13 has been molded. The post-processing includes a process of removing the pallet member 16 and the gate plate 17 from the workpiece W. When the post-processing is performed by the post-processing device 70, the workpiece W is sent from the transport section 61G of the second transport device 60 to the post-processing device 70.

[0037] <Electronic control device 80> The manufacturing apparatus 20 of this embodiment has an electronic control device 80. The electronic control device 80 is mainly composed of, for example, a microcomputer. The electronic control device 80 is connected to the pre-process device 30, the first conveying device 40, the molding device 50, the second conveying device 60, and the post-process device 70. The electronic control device 80 receives various signals indicating the operating states of the devices 30, 40, 50, 60, and 70, and detection signals of the work sensors 45A to 45C, 65D to 65G. The electronic control device 80 performs various calculations based on the received signals, and executes operation control of the devices 30, 40, 50, 60, and 70 based on the calculation results. In this embodiment, the electronic control device 80 corresponds to a control unit that controls the operation of the devices 30, 40, 50, 60, and 70 that constitute the manufacturing apparatus 20.

[0038] <Method of manufacturing the rotor 10> The manufacturing procedure for the rotor 10 will now be described. Fig. 6 shows the execution procedure of the process (operation control process) related to the operation control of each device 30, 40, 50, 60, 70. Note that the series of processes shown in the flowchart of Fig. 6 conceptually show the execution procedure of the operation control process, and the actual process is executed by the electronic control device 80 as a process at a predetermined interval.

[0039] <When devices 30, 40, 50, 60, and 70 are operating normally> <Pre-process> As shown in FIG. 6, in this process, when each of the devices 30, 40, 50, 60, 70 is operating normally (step S11: YES), the previous process is executed (step S12).

[0040] In the front-end process, a workpiece W in which magnets 12 are accommodated in magnet accommodating holes 15 of a rotor core 11 (see FIG. 4) is formed through the operation control of a front-end process device 30. In the front-end process, a pallet member 16 and a gate plate 17 are attached to the rotor core 11.

[0041] <First conveying process> After the previous step, a first transfer step is performed (step S13). In the first conveying process, the workpiece W is conveyed from the conveying section 41C of the first conveying device 40 to the waiting position PA of the molding device 50 through the operation control of the first conveying device 40. In the first conveying process, the operation control of the first conveying device 40 is executed so that two workpieces W are maintained in a state of being accumulated in the storage space SP1 of the first conveying device 40.

[0042] <Forming process> After the first conveying step, a molding step is carried out (step S14). In the molding process, the resin material 13 is molded into the magnet accommodating holes 15 of the rotor core 11 through the operation control of the molding device 50.

[0043] Specifically, first, the workpiece W is moved from a standby position PA outside the molding machine 51 to a processing position PB inside the molding machine 51 through the operation control of the feeding device 52. Then, the resin material 13 is molded in the magnet accommodating hole 15 of the rotor core 11 through the operation control of the molding machine 51. Then, the workpiece W is returned from the processing position PB to the standby position PA through the operation control of the feeding device 52. Note that in the molding device 50 of this embodiment, the workpiece W returned to the standby position PA after molding is sent out to the second conveyor device 60 without remaining at the standby position PA.

[0044] <Second conveying process> After the molding step, a second transfer step is carried out (step S15). In the second conveying process, the workpiece W is conveyed from the waiting position PA of the molding device 50 to the post-process device 70 through the operation control of the second conveying device 60. In the second conveying process, the operation control of the second conveying device 60 is executed so that an empty space SP2 for storing three workpieces W is set in the second conveying device 60.

[0045] <Post-process> After the second transfer step, a post-process is performed (step S16). In the post-process, post-processing is performed on the workpiece W through the operation control of the post-processing device 70.

[0046] 5, when the devices 30, 40, 50, 60, 70 are operating normally, i.e., when each process is being performed normally, two workpieces W are stored in the storage space SP1, and an empty space SP2 for storing three workpieces W is set in the second conveying device 60. In this embodiment, when each process is being performed normally, the molding machine 51 is operated continuously and intermittently by repeatedly performing each process.

[0047] <When at least one of the front-end process device 30 and the back-end process device 70 stops operating> On the other hand, when at least one of the upstream process apparatus 30 and the downstream process apparatus 70 stops operating and the first conveying apparatus 40, the molding apparatus 50, and the second conveying apparatus 60 are operating normally (S11: NO and S17: YES), the following processes (S18 to S21) are executed. Note that in this embodiment, "when at least one of the upstream process apparatus 30 and the downstream process apparatus 70 stops operating" in the process of S17 means "when the operation of at least one of the upstream process apparatus 30 and the downstream process apparatus 70 is stopped due to some kind of abnormality."

[0048] In the series of steps (S18 to S21), first, it is determined whether a predetermined time T (e.g., 30 minutes) has elapsed since the previous molding was performed (S18). In this embodiment, the duration for which the molding machine 51 will continue to be stopped is determined in advance, more specifically, the duration for which the deterioration of the resin material in the molding machine 51 will be suppressed to a level that will not cause the resin material to become unusable, even if the deterioration occurs due to the continued stoppage of the operation. In this embodiment, such a duration is stored in advance in the electronic control device 80 as the above-mentioned predetermined time T.

[0049] Then, when the predetermined time T has elapsed since the previous molding was performed (S18: YES), molding of the resin material 13 is performed by the molding device 50 using the workpiece W in the storage space SP1 (S19 to S21).

[0050] <First conveying process> In this case, first, the first transfer step is carried out (S19). In the first conveying step, the work W in the storage space SP1 of the first conveying device 40 is conveyed to the standby position PA of the molding device 50 through the operation control of the first conveying device 40.

[0051] <Forming process> After the first conveying step, a molding step is carried out (S20). In the molding process, the workpiece W at the standby position PA is moved to the processing position PB through the operation control of the input device 52. Then, the resin material 13 is molded in the magnet accommodating hole 15 of the rotor core 11 through the operation control of the molding machine 51. Then, the workpiece W at the processing position PB is returned to the standby position PA through the operation control of the input device 52.

[0052] <Second conveying process> After the molding step, a second transfer step is carried out (S21). In the second conveying step, the workpiece W at the standby position PA of the molding device 50 is conveyed to the empty space SP2 of the second conveying device 60 through the operation control of the second conveying device 60.

[0053] In this embodiment, when at least one of the front-end and rear-end processes is stopped due to some abnormality, molding of the resin material 13 is performed by the molding device 50 using the workpiece W in the storage space SP1 every time a predetermined time T has elapsed since the previous molding was performed.

[0054] If the predetermined time T has not elapsed since the previous molding was performed (S18: NO), the process is terminated without executing the processes of S19 to S21. That is, in this case, the manufacturing device 20 is in a standby state until the predetermined time T elapses. Then, when the predetermined time T elapses (S18: YES), the molding device 50 uses the workpiece W in the storage space SP1 to mold the resin material 13 (S19 to S21). Also, when at least one of the three devices 40, 50, 60 does not operate normally (S17: NO), that is, when at least one of the first conveying process, the molding process, and the second conveying process is stopped, the process is terminated without executing the processes of S18 to S21.

[0055] The operation of this embodiment will be described with reference to FIGS. FIG. 7 shows an example of the operating state of the manufacturing apparatus 20 when the operation of the pre-processing apparatus 30 and the post-processing apparatus 70 stops due to some abnormality while the workpiece W is present inside the forming apparatus 50.

[0056] 7(a), when the operation of the front-end process device 30 and the back-end process device 70 stops, the workpiece W is present inside the forming device 50. In this case, since the forming device 50 and the second conveying device 60 are operating normally, the forming process and the second conveying process for the workpiece W inside the forming device 50 continue to be performed even after the operation of the front-end process device 30 and the back-end process device 70 stops.

[0057] 7(b), the workpiece W in the forming device 50 is transported to the empty space SP2 of the second conveying device 60 after the forming by the forming device 50 is completed. As a result, the empty space SP2 of the second conveying device 60 becomes a space capable of storing two workpieces W.

[0058] Thereafter, when a predetermined time T has elapsed since the previous molding execution, molding is executed by the molding device 50 using one of the two workpieces W stored in the storage space SP1. As a result, as shown in Fig. 7(c), the number of workpieces W stored in the storage space SP1 is reduced by one to one, and the number of workpieces W stored in the empty space SP2 is increased by one to two.

[0059] Furthermore, after a predetermined time T has elapsed since the previous molding execution, molding is executed by the molding device 50 using the one workpiece W remaining in the storage space SP1. As a result, as shown in Fig. 7(d), the number of workpieces W in the storage space SP1 becomes "0", and the number of workpieces W stored in the empty space SP2 increases by one to three, i.e., the empty space becomes "0".

[0060] In this embodiment, when the operation of the upstream process device 30 or the downstream process device 70 is stopped while the workpiece W is present inside the molding device 50, the molding machine 51 continues to mold the resin material 13 using the workpiece W stored in the storage space SP1.

[0061] FIG. 8 shows an example of the operating state of the manufacturing apparatus 20 when the operation of the pre-processing apparatus 30 and the post-processing apparatus 70 stops due to some abnormality while the workpiece W is not present inside the forming apparatus 50.

[0062] As shown in FIG. 8(a), when the front-end process device 30 and the back-end process device 70 are stopped operating, no workpiece W is present inside the forming device 50. In this case, when a predetermined time T has elapsed since the previous molding execution, molding is executed by the molding device 50 using one of the two workpieces W stored in the storage space SP1. As a result, as shown in Fig. 8(b), the number of workpieces W stored in the storage space SP1 is reduced by one, leaving only one workpiece W, and one workpiece W is stored in the empty space SP2.

[0063] Furthermore, after a predetermined time T has elapsed since the previous molding execution, molding is executed by the molding device 50 using the one workpiece W remaining in the storage space SP1. As a result, as shown in Fig. 8(c), the number of workpieces W in the storage space SP1 becomes "0", and the number of workpieces W stored in the empty space SP2 increases by one to two.

[0064] In this embodiment, when the operation of the upstream process device 30 or the downstream process device 70 is stopped while there is no workpiece W inside the molding device 50, the molding machine 51 continues molding the resin material 13 by utilizing the workpiece W stored in the storage space SP1.

[0065] <Action and effect> According to this embodiment, the following advantageous effects can be obtained. (1) According to this embodiment, when the pre-process, the first conveying process, the molding process, the second conveying process, and the post-process are normally performed, each process is repeatedly performed, so that the molding machine 51 can be operated intermittently and continuously. Moreover, even if the pre-process or the post-process is stopped due to some abnormality, as long as the first conveying process, the molding process, and the second conveying process can be performed, the molding of the resin material 13 can be performed by the molding machine 51 as follows. That is, by using the workpiece W stored in the storage space SP1 of the first conveying device 40 and the empty space SP2 set in the second conveying device 60, the molding of the resin material 13 can be continuously performed by the molding machine 51. Thus, according to this embodiment, even if the pre-process or the post-process is stopped, the decrease in the operating rate of the molding machine 51 due to the stoppage can be suppressed, so that the decrease in the productivity of the rotor 10 can be suppressed.

[0066] Moreover, when the preceding or following process is stopped, molding is performed by the molding machine 51 when a predetermined time T has elapsed since the previous molding was performed, in other words, before the resin material prepared in advance in the molding machine 51 becomes unusable. According to this embodiment, such molding by the molding machine 51 can be performed twice by using the two workpieces W stored in the storage space SP1.

[0067] Therefore, even if the upstream process or the downstream process is stopped due to some abnormality, during the period during which molding is performed twice by the molding machine 51 thereafter (hereinafter, the specific period), the resin material in the molding machine 51 is prevented from deteriorating to the extent that it becomes unusable. More specifically, the specific period includes the period from when the upstream process or the downstream process is stopped until molding is performed twice by the molding machine 51, and the period until a predetermined time T has elapsed after molding is performed the second time by the molding machine 51. The maximum time period is the predetermined time T multiplied by "3" (=T×3).

[0068] Therefore, if the operation stop period of the upstream process equipment 30 and the downstream process equipment 70 is shorter than the above-mentioned specific period, there is no need to perform a purging operation when the manufacturing apparatus 20 using the upstream process equipment 30 and the downstream process equipment 70 resumes manufacturing of the rotor 10. In this case, since the purging operation does not have to be performed, it is possible to suppress a decrease in the operating rate of the molding machine 51. As a result, it is possible to suppress a decrease in the operating rate of the manufacturing apparatus 20 including the molding machine 51, and therefore a decrease in the productivity of the rotor 10 can be suppressed.

[0069] (2) The storage space SP1 is set as a space for storing a predetermined number of works W (in this embodiment, two), and the free space SP2 is set as a space for storing a number of works W obtained by adding "1" to the predetermined number (in this embodiment, three).

[0070] In this embodiment, after the molding by the molding device 50 is completed, the workpiece W is discharged to the second conveying device 60 without being retained in the molding device 50. Therefore, if the free space SP2 is set without considering the workpiece W in the molding device 50, the free space SP2 may be insufficient in the second conveying process when the preceding or following process is stopped, making it impossible to discharge the workpiece W in the molding device 50. In this case, even though the workpiece W is stored in the storage space SP1, it becomes impossible to perform molding of the resin material 13 by the molding machine 51 using the workpiece W.

[0071] In this regard, according to the present embodiment, in order to prevent a shortage of the free space SP2, the number of workpieces W that can be stored in the free space SP2 can be determined according to the number of workpieces W that can be stored in the storage space SP1 during normal operation of each process. Therefore, even if the workpieces W after molding are discharged without being retained in the molding device 50, the molding machine 51 can continue molding the resin material 13 by utilizing the workpieces W in the storage space SP1 and the free space SP2 of the second conveying device 60.

[0072] (3) In the first conveying process when each process is executed normally, the work W accumulated in the storage space SP1 is conveyed to the waiting position PA of the molding device 50, provided that a number of work W equal to a predetermined number plus "1" (in this embodiment, three) has accumulated in the first conveying device 40.

[0073] According to this configuration, when the workpieces W are transported from the storage space SP1 to the standby position PA, one workpiece W that has arrived at and accumulated in a space other than the storage space SP1 (specifically, the transport section 41A) can be replenished in the storage space SP1. This makes it possible to reliably maintain a state in which two workpieces W are accumulated in the storage space SP1 during normal operation of each of the devices 30, 40, 50, 60, 70. Therefore, even if the preceding or succeeding process is stopped, the molding machine 51 can perform molding of the resin material 13 twice by using the two workpieces W accumulated in the storage space SP1 of the first transport device 40.

[0074] <Example of change> The above embodiment can be modified as follows: The above embodiment and the following modifications can be combined with each other to the extent that no technical contradiction occurs.

[0075] The condition for transporting the workpiece W from the storage space SP1 to the standby position PA during normal operation of each device 30, 40, 50, 60, 70 can be changed arbitrarily as long as it is a condition that allows two workpieces W to be maintained in the storage space SP1. For example, the above condition can be "the workpiece W after molding has been discharged from the standby position PA to the second transport device 60."

[0076] The lift unit 46C of the transport unit 41C can be omitted. In this case, the transport units 41A to 41C and the molding device 50 may be disposed so that the electric roller conveyors 43A to 43C and the standby position PA of the molding device 50 are aligned in a straight line in a side view.

[0077] The lift unit 66D of the transport unit 61D can be omitted. In this case, the molding device 50 and the transport units 61D-61G may be arranged so that the standby position PA of the molding device 50 and the electric roller conveyors 63D-63G are aligned in a straight line in a side view.

[0078] Instead of using the electric roller conveyors 43A-43C, 63D-63G, any type of conveying device may be used as the conveying device for conveying the workpieces W. Any type of conveying device may be used as the conveying device as long as it can send the workpieces W downstream at a predetermined timing.

[0079] The specified number is not limited to "two", but can be "one" or any natural number greater than or equal to three. The manufacturing apparatus may be constructed so that the workpiece W after molding by the molding device 50 can be held at the standby position PA of the molding device 50.

[0080] In such a manufacturing apparatus, the number of workpieces W stored in advance in the storage space SP1 in preparation for the stoppage of the upstream or downstream process is the same as the number of workpieces W discharged from the molding device 50 into the empty space SP2 when molding is performed by the molding machine 51 when the upstream or downstream process is stopped.

[0081] Therefore, in the above manufacturing apparatus, the number of workpieces W stored in the storage space SP1 during normal operation of each of the devices 30, 40, 50, 60, 70 may be set to be the same (a predetermined number) as the number of workpieces W that can be stored in the empty space SP2. By adopting such a configuration, the number of workpieces W stored in the storage space SP1 and the number of workpieces W that can be stored in the empty space SP2 can be set without excess or deficiency, so that the configuration of the apparatus for manufacturing the rotor 10 can be simplified.

[0082] The operation of the above-mentioned manufacturing apparatus will be described below with reference to Fig. 9. Note that the same components as those in the above-mentioned embodiment or the corresponding components are given the same reference numerals, and duplicated descriptions will be omitted.

[0083] FIG. 9 shows an example of the operating state of the manufacturing apparatus when the operation of the front-end process equipment 30 and the back-end process equipment 70 stops due to some abnormality. As shown in Figure 9(a), in the manufacturing apparatus of this example, the number of works W stored in the storage space SP1 during normal operation of each device 30, 40, 50, 60, and 70 and the number of works W that can be stored in the free space SP2 are set to "two."

[0084] In this example, the workpiece W is present inside the forming apparatus 50 when the operation of the front-end process apparatus 30 and the rear-end process apparatus 70 stops. In this case, since the forming apparatus 50 is in a normal operating state, the forming process for the workpiece W inside the forming apparatus 50 continues even after the operation of the front-end process apparatus 30 and the rear-end process apparatus 70 stops. Therefore, as shown in Fig. 9(b) , after forming is completed, the workpiece W inside the forming apparatus 50 moves to and remains at the standby position PA of the forming apparatus 50.

[0085] Thereafter, when a predetermined time T has elapsed since the previous molding execution, molding is executed by the molding device 50 using one of the two workpieces W stored in the storage space SP1. As a result, as shown in FIG. 9(c), the number of workpieces W stored in the storage space SP1 is reduced by one, leaving only one workpiece W. After molding is completed, the workpiece W remains in the standby position PA. One workpiece W is stored in the vacant space SP2.

[0086] Furthermore, after a predetermined time T has elapsed since the previous molding execution, molding is executed by the molding device 50 using the one workpiece W remaining in the storage space SP1. As a result, as shown in Fig. 9(d), the number of workpieces W in the storage space SP1 becomes "0", and the number of workpieces W stored in the empty space SP2 increases by one to two, that is, the empty space becomes "0". After molding is completed, the workpiece W remains in the standby position PA.

[0087] In the example shown in Figure 9, even if the operation of the upstream process device 30 or the downstream process device 70 is stopped, the molding machine 51 continues to operate intermittently by utilizing the two workpieces W stored in the storage space SP1 and the empty space SP2 set up in the second conveying device 60.

[0088] As long as the number A of workpieces W that can be stored in the free space SP2 is equal to or greater than the number B of workpieces W that can be stored in the storage space SP1 in advance, the numbers A and B of workpieces W can be changed arbitrarily. For example, the number A of workpieces W that can be stored in the free space SP2 may be set to "four," and the number B of workpieces W that can be stored in the storage space SP1 in advance may be set to "two."

[0089] In the processing of S17 of the operation control process (FIG. 6), “when the operation of at least one of the upstream process device 30 and the downstream process device 70 is stopped” may be changed to “when the operation of at least one of the upstream process device 30 and the downstream process device 70 is stopped upon completion of the manufacture of the rotor 10.”

[0090] The rotor manufacturing method and rotor manufacturing apparatus according to the above-described embodiment can also be applied to a manufacturing apparatus that employs a molding machine that uses a thermosetting resin material. <Additional Notes> The above embodiment includes the configurations described in the following supplementary notes.

[0091] [Appendix 1] A manufacturing method of a rotor including a rotor core having magnet accommodating holes, magnets accommodated in the magnet accommodating holes, and a resin material filled in the magnet accommodating holes to fix the magnets to the rotor core, the manufacturing method including the steps of: a pre-process of forming a workpiece with the magnet accommodated in the magnet accommodating hole; a first conveying process of conveying the workpiece to a molding device including a molding machine by a first conveying device after the pre-process; a molding process of molding the resin material in the magnet accommodating hole by the molding device after the first conveying process; a second conveying process of conveying the workpiece from the molding device to a post-process device by a second conveying device after the molding process; and a second conveying process of conveying the workpiece to a post-process device by the post-process device after the second conveying process. and a subsequent process for performing post-processing on the workpieces, wherein when each process for manufacturing the rotor is normally performed, the process is performed so that a predetermined number of the workpieces are stored in the storage space of the first conveying device and an available space for storing more than the predetermined number of the workpieces is set in the second conveying device, and when at least one of the previous process and the subsequent process is stopped, the first conveying process conveys the workpieces stored in the storage space to the molding device, the molding process molds the resin material of the transported workpieces by the molding device, and the second conveying process conveys the workpieces after molding to the available space.

[0092] [Appendix 2] The method for manufacturing a rotor described in [Appendix 1], wherein the free space is set to a number of spaces for storing the workpieces that is the predetermined number plus "1". [Appendix 3] The method for manufacturing a rotor described in [Appendix 1], wherein the free space is set as a space in which the predetermined number of the workpieces can accumulate.

[0093] [Appendix 4] A method for manufacturing a rotor described in any one of [Appendix 1] to [Appendix 3], in which in the first conveying step when each of the steps is performed normally, the workpieces accumulated in the storage space of the first conveying device are conveyed to the molding device on the condition that the number of the workpieces accumulated in the first conveying device is the predetermined number plus "1."

[0094] [Appendix 5] The method for producing a rotor according to any one of [Appendix 1] to [Appendix 4], wherein in the molding step, the resin material is molded using a thermoplastic resin material. [Appendix 6] A manufacturing apparatus for manufacturing a rotor including a rotor core having magnet accommodating holes, magnets accommodated in the magnet accommodating holes, and a resin material filled in the magnet accommodating holes to fix the magnets to the rotor core, the manufacturing apparatus comprising: a front-end process device for forming a workpiece with the magnet accommodated in the magnet accommodating hole; a molding device including a molding machine and molding the resin material in the magnet accommodating hole in the workpiece using the molding machine; a back-end process device for performing post-processing on the workpiece in which the resin material has been molded; a first conveying device for transporting the workpiece from the front-end process device to the molding device; a second conveying device for transporting the workpiece from the molding device to the back-end process device; and a control unit for controlling the operation of each device constituting the manufacturing apparatus, a control unit that controls the operation of each of the devices so that, when each of the devices is operating normally, a predetermined number of the workpieces are accumulated in the first conveying device and free space for accumulating more than the predetermined number of the workpieces is set in the second conveying device, and when the operation of at least one of the front-end process device and the back-end process device stops, controls the operation of the molding device, the first conveying device, and the second conveying device so that the workpieces accumulated in the first conveying device are transported to the molding device, the molding device molds the transported workpieces with the resin material, and the workpieces after molding are discharged into the free space of the second conveying device. [Explanation of symbols]

[0095] W…Work PA…Standby position PB…Processing position SP1: Storage space SP2: Free space 10...Rotor 11...Rotor core 11a...first end surface 11b…Second end surface 12...Magnet 13...Resin material 14...Center hole 15...Magnet receiving hole 16...Pallet material 17…Gate plate 20,90…Manufacturing equipment 30…Front-process equipment 40...First conveying device 41A, 41B, 41C...Transportation section 43A, 43B, 43C...Electric roller conveyor 44A, 44B, 44C...Stopper members 45A, 45B, 45C...Work sensor 46C…Lift section 50…Forming equipment 51...Molding machine 52...Insertion device 54…Guide section 55...Operation control unit 60...Second conveying device 61D, 61E, 61F, 61G...Transport section 63D, 63E, 63F, 63G...Electric roller conveyor 64D, 64E, 64F, 64G...Stopper parts 65D, 65E, 65F, 65G...Work sensor 66D…Lift section 70…Post-process equipment 80...Electronic control device

Claims

1. A manufacturing method of a rotor including a rotor core having magnet accommodating holes, magnets accommodated in the magnet accommodating holes, and a resin material filled in the magnet accommodating holes to fix the magnets to the rotor core, comprising: a front-end process for forming a workpiece in a state in which the magnet is accommodated in the magnet accommodating hole; a first conveying step of conveying the work to a molding device including a molding machine by a first conveying device after the previous step; a molding step of molding the resin material into the magnet accommodating hole by the molding device after the first conveying step; a second conveying step of conveying the workpiece from the forming device to a post-processing device by a second conveying device after the forming step; A post-processing step of performing a post-processing on the work by the post-processing device after the second conveying step, When each process for manufacturing the rotor is normally performed, the process is performed so that a predetermined number of the workpieces are stored in a storage space of the first transport device and a free space for storing the predetermined number or more of the workpieces is set in the second transport device. When at least one of the upstream process and the downstream process is stopped, the first transport process transports the workpiece stored in the storage space to the molding device, the molding process performs molding of the resin material on the transported workpiece by the molding device, and the second transport process transports the workpiece after molding to the vacant space. A method for manufacturing a rotor.

2. As the free space, a space in which the work pieces can be accumulated is set to a number obtained by adding "1" to the predetermined number. A method for manufacturing the rotor according to claim 1 .

3. As the free space, a space in which the predetermined number of the works can be accumulated is set. A method for manufacturing the rotor according to claim 1 .

4. In the first conveying step during normal execution of each step, the workpieces stored in the storage space of the first conveying device are conveyed to the molding device on the condition that the number of the workpieces stored in the storage space of the first conveying device is equal to or greater than the predetermined number. A method for manufacturing a rotor according to any one of claims 1 to 3.

5. In the molding step, the resin material is molded using a thermoplastic resin material. A method for manufacturing a rotor according to any one of claims 1 to 3.

6. A manufacturing apparatus for manufacturing a rotor including a rotor core having magnet accommodating holes, magnets accommodated in the magnet accommodating holes, and a resin material filled in the magnet accommodating holes to fix the magnets to the rotor core, comprising: a front-end process device for forming a workpiece in a state in which the magnet is accommodated in the magnet accommodating hole; a molding device including a molding machine and configured to mold the resin material into the magnet accommodating hole in the workpiece by the molding machine; a post-processing device that performs post-processing on the workpiece on which the resin material has been molded; a first conveying device that conveys the work from the upstream process device to the forming device; A second conveying device that conveys the work from the forming device to the post-processing device; A control unit for controlling the operation of each device constituting the manufacturing apparatus, The control unit is When each of the devices is operating normally, the operation of each of the devices is controlled so that a predetermined number of the workpieces is accumulated in the first conveying device and an empty space for accumulating the predetermined number or more of the workpieces is set in the second conveying device; and When at least one of the upstream process device and the downstream process device stops operating, the operation of the molding device, the first conveying device, and the second conveying device is controlled so that the workpieces accumulated in the first conveying device are transported to the molding device, the molding device performs molding of the resin material on the transported workpieces, and the workpieces after molding are discharged into the empty space of the second conveying device. Rotor manufacturing equipment.

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