Stator magnet assembly device, stator magnet assembly method, and stator manufacturing device

Abstract

To provide a stator magnet assembly device, a stator magnet assembly method, and a stator manufacturing method by which a magnet can be efficiently assembled to a stator core.SOLUTION: A stator magnet assembly device for assembling a magnet to a stator core includes: a holding mechanism that includes a holding member formed of a magnetic material, the holding member having a holding lower surface for holding an upper surface of a magnet by attracting the upper surface with a magnetic force; a movement mechanism for moving the holding member so that the magnet held by the holding member is located in a prescribed position to face a magnet mounting surface of the stator core with a gap disposed therebetween in an up-down direction; and a separation mechanism for separating the magnet held in the prescribed position from the holding lower surface toward the magnet mounting surface.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to a stator magnet assembling device, a stator magnet assembling method, and a method for manufacturing a stator.

Background Art

[0002] Conventionally, a stator incorporated in a magnetic gear electric machine is known. For example, the stator disclosed in Patent Document 1 includes a stator core extending in the circumferential direction. A plurality of magnets (stator magnets) are arranged in the circumferential direction on a plurality of teeth provided on the stator core.

Prior Art Literature

Patent Literature

[0003]

Patent Literature 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] It is preferable that the assembly of the stator magnet to the stator core is performed efficiently.

[0005] An object of the present disclosure is to provide a stator magnet assembling device, a stator magnet assembling method, and a method for manufacturing a stator capable of efficiently assembling a magnet to a stator core.

Means for Solving the Problems

[0006] A stator magnet assembling device according to at least one embodiment of the present disclosure is a stator magnet assembling device for assembling a magnet to a stator core, a holding mechanism including a holding member formed of a magnetic material, the holding member having a holding lower surface for attracting and holding the upper surface of the magnet by magnetic force, A moving mechanism for moving the holding member so that the magnet held by the holding member is disposed at a predetermined position facing the magnet mounting surface of the stator core with a gap therebetween in the vertical direction, and a separating mechanism for separating the magnet held at the predetermined position from the holding lower surface toward the magnet mounting surface.

[0007] A stator magnet assembling method according to at least one embodiment of the present disclosure is a stator magnet assembling method for assembling a magnet to a stator core, comprising: a holding step of attracting and holding the magnet to a holding lower surface of a holding member formed of a magnetic material; a moving step of moving the holding member so that the held magnet is disposed at a predetermined position facing the magnet mounting surface of the stator core with a gap therebetween in the vertical direction; and a separating step of separating the magnet held by the holding member from the holding lower surface toward the magnet mounting surface.

[0008] A method for manufacturing a stator according to at least one embodiment of the present disclosure is a method for manufacturing a stator in which a plurality of the magnets are assembled to the stator core over the entire circumferential length of the stator core by repeating the above-described stator magnet assembling method, wherein the plurality of magnets include a first radially magnetized magnet magnetized on the outer side in the radial direction of the stator core, a second radially magnetized magnet magnetized on the inner side in the radial direction, a first circumferentially magnetized magnet magnetized on one side in the circumferential direction of the stator core, a second circumferentially magnetized magnet magnetized on the other side in the circumferential direction, and the method for manufacturing the stator includes a radially magnet arrangement step of alternately arranging the first radially magnetized magnet and the second radially magnetized magnet at intervals in the circumferential direction of the stator core. After the radial magnet arrangement step, there is a circumferential magnet arrangement step of arranging the first circumferential magnet and the second circumferential magnet at intervals in the circumferential direction, wherein the first circumferential magnet is arranged on the one side in the circumferential direction of the first radial magnet and on the other side in the circumferential direction of the second radial magnet, and the second circumferential magnet is arranged on the other side of the first radial magnet and on the one side in the circumferential direction of the second radial magnet, and a circumferential magnet arrangement step, and is provided with.

Effect of the Invention

[0009] According to the present disclosure, a stator magnet assembling device, a stator magnet assembling method, and a stator manufacturing method that can be efficiently assembled to a stator core can be provided.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9A

Figure 9B

Figure 9C

Figure 9D

Figure 9E

Figure 10A

Figure 10B

Figure 11

Figure 12A

Figure 12B

Figure 12C

Figure 13

Figure 14

Figure 15

Mode for Carrying Out the Invention

[0011] Hereinafter, some embodiments of the present disclosure will be described with reference to the accompanying drawings. However, the dimensions, materials, shapes, relative arrangements, etc. of the components described as embodiments or shown in the drawings are not intended to limit the scope of the present disclosure, but are merely illustrative examples. For example, expressions representing relative or absolute arrangements such as "in a certain direction", "along a certain direction", "parallel", "orthogonal", "center", "concentric", or "coaxial" not only strictly represent such arrangements, but also represent states of relative displacement with tolerances or angles and distances that provide the same function. For example, expressions indicating that things such as "identical", "equal", and "homogeneous" are in an equal state shall represent not only a strictly equal state, but also a state in which there are tolerances or differences to the extent that the same function can be obtained. For example, expressions representing shapes such as a rectangular shape or a cylindrical shape shall represent not only shapes such as a rectangular shape or a cylindrical shape in a geometrically strict sense, but also shapes including concavo-convex portions, chamfered portions, etc. within the range where the same effect can be obtained. On the other hand, the expressions "comprising", "including", or "having" for one component are not exclusive expressions excluding the existence of other components. Note that the same reference numerals may be given to the same configurations and the description thereof may be omitted.

[0012] <Basic Configuration of Magnetic Gear Electric Machine 10> Referring to FIG. 1, a magnetic gear electric machine 10 including a stator 20 will be outlined. The magnetic gear electric machine 10 includes a rotating shaft 18 connected to an external device 9. In FIG. 1, for the convenience of simplifying the drawing, the rotating shaft 18 is depicted as a single solid shaft member, but the present disclosure is not limited thereto. The rotating shaft 18 may be realized by a plurality of shaft members, and the plurality of shaft members may include shaft members formed in a cylindrical shape.

[0013] In the following description, the "axial direction" is the axial direction of the axis S of the rotating shaft 18, the "circumferential direction" is the circumferential direction with respect to the axis S, and the "radial direction" is the radial direction with respect to the axis S. The "inner side in the radial direction" indicates the side in the direction approaching the axis S, and the "outer side in the radial direction" indicates the side in the direction away from the axis S. Note that the axis S is the center of the stator 20. Also, the axial direction in this example is a horizontal direction, and the radial direction is a concept including the vertical direction.

[0014] The magnetic gear electric machine 10 includes a housing 17 that rotatably supports a rotating shaft 18, and a stator 20 fixed to the housing 17. The stator 20 includes a stator core 24, a plurality of stator coils 27 disposed in the stator core 24, and a plurality of magnets (stator magnets) 5 disposed on the inner peripheral surface of the stator core 24. The stator coils 27 are electrically connected to the power system 16.

[0015] The magnetic gear electric machine 10 further includes a pole piece rotor 30. The pole piece rotor 30 includes an annular body 35 extending along the axis S inside the stator 20 in the radial direction, and a pair of connecting members 31 connecting the annular body 35 and the rotating shaft 18. The annular body 35 includes a plurality of pole pieces 36 and a plurality of non-magnetic bodies (not shown) alternately arranged along the circumferential direction. Each connecting member 31 is fixed to the rotating shaft 18, and the pole piece rotor 30 is configured to rotate integrally with the rotating shaft 18.

[0016] The magnetic gear electric machine 10 further includes a magnet rotor 40 connected to the rotating shaft 18 between the pair of connecting members 31. The magnet rotor 40 includes a plurality of inner magnets 41 arranged in the circumferential direction inside the annular body 35 in the radial direction, and a rotor core 42 that supports the inner magnets 41. The rotor core 42 is connected to the rotating shaft 18 via a bearing, and the magnet rotor 40 is configured to rotate relative to the rotating shaft 18.

[0017] The magnetic gear electric machine 10 according to an embodiment is a magnetic gear motor that receives power supply from the power system 16 and drives an external device 9, and its operating principle is as follows. The magnet rotor 40 rotates due to the rotating magnetic field generated by energization in the stator coil 27. The relative positional relationship between the annular body 35 with respect to the plurality of inner magnets 41 and the plurality of magnets 5 changes in the circumferential direction, and the magnetic flux between the magnet rotor 40 and the stator 20 is modulated by the plurality of pole pieces 36, causing the pole piece rotor 30 to rotate. Torque is transmitted from the rotating shaft 18 that rotates together with the pole piece rotor 30 to the external device 9, and the external device 9 is driven.

[0018] The magnetic gear electric machine 10 according to another embodiment is a magnetic gear generator that obtains power from an external device 9 and supplies power to the power system 16, and its operating principle is as follows. When the external device 9 drives the rotating shaft 18, the pole piece rotor 30 rotates together with the rotating shaft 18. The relative positional relationship between the annular body 35 and the plurality of inner magnets 41 and the plurality of magnets 5 changes in the circumferential direction, and the magnet rotor 40 rotates. Due to electromagnetic induction occurring with the rotation of the pole piece rotor 30 and the magnet rotor 40, an electric current is generated in the stator coil 27, and power is supplied to the power system 16.

[0019] In FIG. 1, a structure in which the rotating shaft 18 rotates together with the pole piece rotor 30 is illustrated, but the present disclosure is not limited thereto. For example, a structure in which the rotating shaft 18 rotates together with the magnet rotor 40 may be adopted. In this case, the pole piece rotor 30 is connected to the rotating shaft 18 via a bearing.

[0020] <Basic Configuration of Stator 20> FIG. 2 is a schematic diagram of a stator 20 according to an embodiment of the present disclosure. The stator core 24 of the stator 20 is formed of a soft magnetic material. The stator core 24 includes a base 23 extending in the circumferential direction and a plurality of teeth 25 protruding radially inward from the base 23. The plurality of teeth 25 are arranged at intervals in the circumferential direction, and the plurality of stator coils 27 described above are arranged on the plurality of teeth 25. Each tooth 25 has a tip portion 252, and an intervening member 209 is arranged in an opening formed between two adjacent tip portions 252. The intervening member 209, which may be formed of, for example, a resin member, is held by the two tip portions 252.

[0021] The stator 20 further includes a plurality of protrusions 6 that protrude radially inwardly of the plurality of teeth 25. The protrusions 6 illustrated in FIG. 2 include a protrusion 7 that protrudes radially inwardly from the tip 252 of the tooth 25 and a protrusion 8 that protrudes radially inwardly from the intervening member 209. The protrusion 7 is integrally formed of the same soft magnetic material as the tip 252, and the protrusion 8 is integrally formed of the same resin member as the intervening member 209. The protrusions 7 and 8 have the same shape as each other. Note that the intervening member 209 is not an essential component of the stator 20, and the protrusions 6 may not include the protrusion 8. In this case, the plurality of protrusions 6 are constituted only by the plurality of protrusions 7. In the following description, the term "protrusion 6" may be used when referring to the protrusions 7 and 8 without distinguishing them.

[0022] The stator 20 further includes a plurality of magnets 5 that are alternately arranged with the plurality of protrusions 6 in the circumferential direction. The plurality of magnets 5 are arranged radially inwardly of the plurality of teeth 25, and each magnet 5 is sandwiched between two protrusions 6 that are adjacent to each other in the circumferential direction among the plurality of protrusions 6. Note that an adhesive may be interposed between the magnet 5 and the tooth 25, and in this case, the protrusions 6 may not be arranged. Also, an adhesive may be interposed between two adjacent magnets 5 in the circumferential direction.

[0023] The arrangement of the plurality of magnets 5 is a Halbach array. The Halbach array in this example enhances the magnetic flux caused by the magnets 5 radially inwardly rather than radially outwardly with respect to the plurality of magnets 5. The Halbach array is realized by arranging a group of magnets 5 composed of four magnets 5 magnetized in different directions in the circumferential direction. The four magnets 5 constituting this group of magnets 5 are surrounded by a two-dot chain line J in FIG. 2 as an example. Note that each magnet 5 extending in the axial direction is constituted by a plurality of permanent magnets (not shown) laminated in the axial direction. In this specification, for convenience of explanation, each such magnet 5 extending in the axial direction is counted as one.

[0024] The four magnets 5 that make up the magnet group include a first radially magnetized magnet 1 magnetized on the outer side in the radial direction, a second radially magnetized magnet 2 magnetized on the inner side in the radial direction, a first circumferentially magnetized magnet 3 magnetized on one side in the circumferential direction, and a second circumferentially magnetized magnet 4 magnetized on the other side in the circumferential direction. The first circumferentially magnetized magnet 3 is located on one side in the circumferential direction relative to the first radially magnetized magnet 1, and the second circumferentially magnetized magnet 4 is located on the other side in the circumferential direction relative to the first radially magnetized magnet 1. The magnetization directions of these four magnets 5 are indicated by thick arrows in each magnet 5, and the end of each magnet 5 on the side where the arrow points is the N pole.

[0025] In the following description, when referring to the first radially magnetized magnet 1, the second radially magnetized magnet 2, the first circumferentially magnetized magnet 3, and the second circumferentially magnetized magnet 4 without distinction, they may be referred to as "magnet 5".

[0026] <Stator Magnet Assembly Device 50A According to the First Embodiment> An overview of the stator magnet assembly device 50 used in the manufacture of the stator 20 is provided. The stator magnet assembly device 50 is configured to assemble the magnet 5 to the stator core 24. FIG. 3 is a schematic diagram showing the stator magnet assembly device 50A (50) according to the first embodiment. The stator 20 is formed in a cylindrical shape centered on the axis S, but only a part of it is shown in the figure. Also, in the figure, for the convenience of simplifying the drawing, the illustration of a plurality of teeth 25 is omitted.

[0027] In the following description, among the inner peripheral surfaces of the stator core 24 (in other words, the inner peripheral surfaces of each of the plurality of teeth 25), the surface located below the axis S (see FIG. 1) of the stator 20 may be referred to as the "magnet mounting surface 29".

[0028] As illustrated in FIG. 3, the stator magnet assembling device 50A (50) includes a holding mechanism 55A (55) for holding the magnet 5, a separating mechanism 70A (70) for separating the magnet 5 from the holding mechanism 55A, and a moving mechanism 60A (70) for moving the holding mechanism 55A together with the separating mechanism 70A. In FIG. 3, the holding mechanism 55A, the separating mechanism 70A, and the moving mechanism 60A are all illustrated as the first embodiment. The holding mechanism 55B, the separating mechanism 70B, and the moving mechanism 60B according to the second embodiment will be described later.

[0029] As shown in FIG. 5, the holding mechanism 55A includes a holding member 53 formed of a magnetic material. The holding lower surface 54 of the holding member 53 is configured to attract and hold the upper surface 5a of the magnet 5 by magnetic force. More specifically, when the magnet 5 approaches the holding member 53, the holding member 53 is magnetized by the magnet 5. Due to the magnetic attractive force generated between the magnet 5 and the holding member 53, the magnet 5 is attracted to the holding lower surface 54. The holding lower surface 54 may directly contact the upper surface 5a (not shown), or may indirectly contact the upper surface 5a via other members such as a spacer 66 described later. Note that the upper surface 5a is an end surface on the inner side in the radial direction of the magnet 5.

[0030] The holding member 53 is an axially extending plate formed in an L shape. More specifically, the holding member 53 has a horizontally extending horizontal plate 531 and a vertically standing vertical plate 532 erected upward from an end of the horizontal plate 531. The holding lower surface 54 is the lower surface of the horizontal plate 531. Note that the holding member 53 may be a columnar body extending in the axial direction (not shown), and the holding lower surface 54 may be the lower surface of the columnar body.

[0031] The separating mechanism 70A illustrated in FIG. 5 is configured to separate the magnet 5 held by the holding lower surface 54 downward. As means for separating the magnet 5, several means can be adopted as described later. The details will be described later. The separating mechanism 70A is attached to the holding member 53.

[0032] As shown in FIG. 3, the moving mechanism 60A movably supports the holding mechanism 55A. Accordingly, the holding mechanism 55A moves together with the separating mechanism 70A. By moving the holding member 53 of the holding mechanism 60A, the magnet 5 held by the holding member 53 reaches a predetermined position.

[0033] Here, the predetermined position is a position where the magnet 5 faces the magnet mounting surface 29 with a gap in the vertical direction (see FIG. 9C). The magnet 5 at the predetermined position faces the magnet mounting surface 29 with a gap across the entire axial length of the magnet 5. The magnet 5 at the predetermined position is held on the holding lower surface 54 by the magnetic attractive force between the holding member 53 and the magnet 5. Note that the magnet 5 at the predetermined position may receive a magnetic attractive force from the stator core 24 formed of a soft magnetic material. However, when the magnet 5 is disposed at the predetermined position, the attractive force caused by the holding member 53 is greater than the attractive force caused by the stator core 24.

[0034] The magnet 5 held by the holding member 53 is separated from the holding lower surface 54 toward the magnet mounting surface 29 by the separating mechanism 70A at the predetermined position. The separating mechanism 70A may separate the magnet 5 that directly contacts the holding lower surface 54 from the holding lower surface 54, or may separate the magnet 5 that indirectly contacts the holding lower surface 54 via the spacer 66 from the holding lower surface 54 together with the spacer 66. If the magnet 5 at the predetermined position approaches the magnet mounting surface 29 further, the magnetic attractive force between the magnet 5 and the stator core 24 increases, and the magnet 5 is attracted to and contacts the magnet mounting surface 29.

[0035] According to the above configuration, after the moving mechanism 60A moves the holding member 53 so that the magnet 5 is disposed at the predetermined position, the separating mechanism 70A moves the magnet 5 downward from the holding lower surface 54 toward the magnet mounting surface 29, so that the magnet 5 is attracted by the stator core 24 and mounted on the magnet mounting surface 29. Since the magnet 5 can be mounted on the magnet mounting surface 29 without any trouble, a stator magnet assembling device 50A (50) that can efficiently assemble the magnet 5 to the stator core 24 is realized.

[0036] Hereinafter, the moving mechanism 60A (60), the separating mechanism 70A (70), and the holding mechanism 55A (55) according to the first embodiment will be described in detail in order.

[0037] <Moving mechanism 60A according to the first embodiment> Referring to FIGS. 3 and 4, the moving mechanism 60A (60) according to the first embodiment will be described in detail. Note that in FIG. 4, the illustration of the holding mechanism 55A is omitted.

[0038] The moving mechanism 60A includes a pair of struts 64 arranged at intervals in the axial direction, an axial guide 65A (65) supported by the pair of struts 64, and a slider 69 attached to the axial guide 65A. The axial guide 65A extends axially so as to pass inside the stator 20 and is located, for example, below the axis S (see FIG. 4) of the stator 20. The slider 69 is configured to move along the axial guide 65A.

[0039] The holding member 53 of the holding mechanism 55A is connected to the slider 69. Therefore, the holding member 53 supported by the axial guide 65A can move axially together with the separating mechanism 70A.

[0040] As shown in FIG. 4, the axial guide 65A (65) has a first guide portion 61 disposed within the axial range of the stator core 24 and a second guide portion 62 disposed at a position axially away from one side of the axial range of the stator core 24. The first guide portion 61 and the second guide portion 62 are integrally formed of the same material, and the slider 69 (see FIG. 3) is adapted to move linearly between the first guide portion 61 and the second guide portion 62. Also, the axial length (dimension L2) of the second guide portion 62 is equal to or greater than the axial length (dimension L1) of the first guide portion 61.

[0041] Returning to FIG. 3, the moving mechanism 60A may further include a vertical moving mechanism 67 for moving the holding member 53 in the vertical direction. The vertical moving mechanism 67 includes a base 161 connected to the slider 69, a vertical rail 162 installed on the base 161 and extending in the vertical direction, and a movable support 163 connected to the vertical rail 162 via a bearing. The movable support 163 is movable along the vertical rail 162, and thus is relatively movable in the vertical direction with respect to the slider 69. The holding member 53 is fixed to the movable support 163 by a fastening member (not shown). Therefore, the holding member 53 is movable in the axial direction together with the slider 69 and is movable in the vertical direction together with the movable support 163.

[0042] The attachment of the magnet 5 to the holding lower surface 54 (see FIG. 5) is performed, for example, as follows. First, the magnet 5 is attached to the holding lower surface 54 while the holding member 53 is supported by the second guide portion 62 (see FIG. 3). At this time, the holding member 53 is located, for example, at the upper end of the movable range in the vertical direction (however, the present disclosure is not limited to the holding member 53 being located at the upper end of the movable range, and the holding member 53 may be located such that the magnet 5 is located above the magnet mounting surface 29). After attaching the magnet 5, the holding member 53 moves toward the other side in the axial direction, and the magnet 5 moves to directly above the magnet mounting surface 29. Thereafter, the holding member 53 moves downward, and the magnet 5 reaches a predetermined position.

[0043] In this example, by manually pushing the holding member 53 by an operator, the holding member 53 moves in each of the axial direction and the vertical direction. However, the present disclosure is not limited thereto, and the moving mechanism 60A may further include at least one drive source (not shown). The drive source is realized by a motor, a solenoid, an air cylinder, a hydraulic cylinder, or a combination thereof.

[0044] According to the configuration in which the moving mechanism 60A includes the axial guide 65A, the magnet 5 can be attached to the holding member 53 at a position axially separated from a predetermined position. Thereafter, the holding member 53 can move stably in the axial direction so that the magnet 5 is disposed at the predetermined position. Therefore, the attachment operation of the magnet 5 to the magnet mounting surface 29 can be easily performed. Note that either one of the pair of columns 64 of the moving mechanism 60A may not be provided. In this case, the axial guide 65A is cantilevered by a single column 64. Even in this case, it is possible to obtain the above-described technical advantages.

[0045] According to the configuration in which the axial length of the second guide portion 62 is equal to or greater than the axial length of the first guide portion 61, the magnet 5 can be attached to the holding lower surface 54 while the holding member 53 is supported by the second guide portion 62. Since the magnet 5 is attached at a position separated from one side within the axial range of the stator core 24, the magnetic attractive force between the magnet 5 and the stator core 24 does not inhibit the attachment of the magnet 5. Therefore, the attachment operation of the magnet 5 can be easily performed.

[0046] According to the configuration in which the moving mechanism 60A includes the vertical moving mechanism 67, the magnet 5 can be attached to the holding lower surface 54 at a position separated from above the magnet mounting surface 29. Since the magnetic attractive force between the magnet 5 and the stator core 24 does not inhibit the attachment of the magnet 5, the attachment operation of the magnet 5 can be easily performed. Note that the moving mechanism 60A may not include the vertical moving mechanism 67. In this case, the holding member 53 is directly attached to the slider 69 (see FIGS. 9A to 9E).

[0047] <Separation mechanism 70A according to the first embodiment> Referring to FIGS. 5 and 6, the separation mechanism 70A (70) according to the first embodiment will be described in detail. The separation mechanism 70A includes a biasing unit 80 for separating the magnet 5 held by the holding member 53 from the holding lower surface 54 toward the magnet mounting surface 29.

[0048] The biasing unit 80 has a biasing rod 82 with the vertical direction as the axial direction. The biasing rod 82 is inserted into a holding hole 57 of the holding member 53. Here, the holding hole 57 is a through-hole that penetrates the holding member 53 in the vertical direction, and in this example, it opens at the holding lower surface 54 which is the lower surface of the horizontal plate 531. In this example, the biasing rod 82 is inserted into each of a plurality of holding holes 57 arranged with a gap in the axial direction. The biasing rod 82 is configured to be displaced in the vertical direction.

[0049] More specifically, the holding hole 57 is a threaded hole having an inner peripheral surface 58 formed with a female thread, and the biasing rod 82 has a threaded shaft portion 83 that engages with the female thread of the inner peripheral surface 58. The threaded shaft portion 83 may be the shaft portion of a screw 37 such as a wing screw. By the operator rotating the screw 37, the biasing rod 82 is displaced downward. When the lower end portion of the threaded shaft portion 83 protrudes downward from the holding hole 57, it abuts directly or indirectly against the magnet 5. When the screw 37 is further rotated, the threaded shaft portion 83 biases the magnet 5 downward, and the magnet 5 is separated from the holding lower surface 54 toward the magnet mounting surface 29. The magnet 5 separated from the magnet mounting surface 29 is mounted on the magnet mounting surface 29 by the magnetic attractive force received from the stator 20.

[0050] According to the configuration in which the separation mechanism 70A includes the biasing unit 80, even when the magnet 5 receives a magnetic repulsive force from the magnet mounting surface 29 side when the separation mechanism 70A separates the magnet 5 from the holding lower surface 54 toward the magnet mounting surface 29, the magnet 5 can be displaced to the magnet mounting surface 29. More specifically, when each magnet 5 is sequentially mounted on the magnet mounting surface 29 such that the arrangement of the magnets 5 becomes a Halbach array, the magnet 5 held by the holding member 53 may receive a repulsive force from the magnet 5 already mounted on the magnet mounting surface 29 (further details will be described later with reference to FIG. 15). In this regard, according to this configuration, since the biasing unit 80 can displace the magnet 5 at a predetermined position toward the magnet mounting surface 29, it is possible to suppress the above-mentioned repulsive force from hindering the mounting operation. Therefore, the mounting operation of the magnet 5 can be performed accurately and easily. Note that the biasing unit 80 may include an injection unit that injects air against the magnet 5 instead of the biasing rod 82. Even in this case, since the injected air biases the magnet 5 at a predetermined position toward the magnet mounting surface 29, the above-described technical advantages can be obtained.

[0051] According to the configuration in which the biasing unit 80 has a biasing rod 82 configured to be displaced in the vertical direction, the biasing rod 82 biases the magnet 5 downward, so that the magnet 5 can be reliably displaced toward the magnet mounting surface 29. Note that the biasing rod 82 may not include the threaded shaft portion 83. For example, even when the biasing rod 82 is the shaft portion of an air cylinder or a solenoid, the biasing rod 82 can bias the magnet 5 downward, so that the above-described technical advantages can be obtained.

[0052] According to the configuration in which the biasing rod 82 has a threaded shaft portion 83 that engages with the inner peripheral surface 58 of the holding hole 57, when the operator rotates the screw 37, the rotating biasing rod 82 gradually displaces downward together with the magnet 5. Since the speed of the magnet 5 approaching the magnet mounting surface 29 from a predetermined position can be reduced, the impact force generated between the two when the magnet 5 reaches the magnet mounting surface 29 due to the magnetic attractive force can be reduced. Therefore, the magnet 5 can be properly mounted on the magnet mounting surface 29. Note that an actuator such as a motor may rotate the biasing rod 82 instead of the operator. Even in this case, the above-described technical advantages can be obtained.

[0053] <Holding mechanism 55A according to the first embodiment> Referring to FIG. 6, the holding mechanism 55A(55) according to the first embodiment will be described in detail. The holding mechanism 55A further includes a pair of holding protrusions 51 that are arranged at intervals in a direction orthogonal to the axial direction along the holding lower surface 54. Each holding protrusion 51 protrudes downward from the holding lower surface 54. Also, each holding protrusion 51 is separate from the holding member 53 and is formed of a non-magnetic material. Each holding protrusion 51 is fixed to the holding lower surface 54 by, for example, a fastening member. Further, each holding protrusion 51 extends in the axial direction. The axial length of the holding protrusion 51 may be equal to or greater than the axial length of the magnet 5. An inner surface 51a is formed on each holding protrusion 51. The pair of inner surfaces 51a face each other in a direction orthogonal to the axial direction. Each holding protrusion 51 is shorter than the magnet 5 in the vertical direction.

[0054] Furthermore, the holding mechanism 55A includes a spacer 66 interposed between the upper surface 5a of the magnet 5 and the holding lower surface 54. The spacer 66 is a plate that extends in the axial direction between the pair of holding protrusions 51 and has a thickness in the vertical direction. The spacer 66 in this example abuts against each inner surface 51a. The spacer 66 is formed of a non-magnetic material having excellent lubricity and wear resistance.

[0055] Furthermore, the spacer 66 in this example has a flat lower surface 661 and a recess 662 formed in the lower surface 661. The recess 662 extends in the axial direction. The upper end portion of the magnet 5 is fitted into the recess 662, and the bottom surface 662a formed in the recess 662 is in direct contact with the upper surface 5a of the magnet 5. Note that, although this is merely an example, the vertical dimension (i.e., the depth dimension) of the recess 662 is 1 / 2 or less, and more specifically 1 / 4 or less, of the vertical dimension of the magnet 5.

[0056] The spacer 66 is attached to the holding lower surface 54 as follows. The operator inserts the spacer 66 between the pair of holding protrusions 51 and brings it into contact with the holding lower surface 54. At this time, the holding hole 57 is blocked from below by the spacer 66. While pressing the spacer 66 against the holding lower surface 54, the operator inserts the magnet 5 between the pair of holding protrusions 51 and fits it into the recess 662. Due to the attractive force between the magnet 5 and the holding member 53, the spacer 66 is attached to the holding lower surface 54 together with the magnet 5. Thereafter, when the above-described biasing rod 82 protrudes downward from the holding hole 57 and biases the spacer 66 downward, the spacer 66 and the magnet 5 can be displaced downward along the pair of holding protrusions 51 and separated from the holding lower surface 54.

[0057] According to the configuration in which the holding mechanism 55A includes the pair of holding protrusions 51, when the magnet 5 is attached to the holding lower surface 54 and when the magnet 5 is separated from the holding lower surface 54 together with the spacer 66, the pair of holding protrusions 51 can guide the displacement of the magnet 5 in the vertical direction. Therefore, the mounting operation of the magnet 5 is facilitated. Note that the recess 662 into which the magnet 5 fits may not be formed on the lower surface 661 of the spacer 66. Even in this case, it is possible to obtain the above-described technical advantages.

[0058] According to the configuration in which the holding mechanism 55A includes the spacer 66, the biasing unit 80 can bias the magnet 5 toward the magnet mounting surface 29 via the spacer 66. Thereby, it is possible to suppress the concentration of the biasing force on a specific part of the magnet 5, and the magnet 5 can be separated from the holding lower surface 54 in a posture substantially parallel to the axial direction. Further, since the spacer 66 is in contact with the pair of inner surfaces 51a, it is possible to suppress the spacer 66 from tilting with respect to the axial direction and the circumferential direction. Therefore, the magnet 5 can be placed in a posture that is even more substantially parallel to the axial direction and the circumferential direction. Further, the vertical distance from the holding lower surface 54 to the magnet 5 when the holding member 53 holds the magnet 5 is optimized through adjustment of the thickness of the spacer 66. Thereby, the magnetic attractive force between the holding lower surface 54 and the magnet 5 can be optimized, and the transfer of the magnet 5 from the holding lower surface 54 to the magnet mounting surface 29 can be made smooth.

[0059] <Rotary support mechanism 90> As shown in FIGS. 3 and 7, the stator magnet assembling device 50A (50) may further include a rotation support mechanism 90 configured to rotate the stator 20. By rotating the stator 20 in the circumferential direction, the relative position of the stator core 24 with respect to the holding member 53 is changed.

[0060] As illustrated in FIG. 3, the rotation support mechanism 90 includes a pair of support wall portions 94 arranged with a space therebetween in the axial direction, a plurality of support shafts 95 supported by each of the pair of support wall portions 94, a rotating body 96 supported by each of the plurality of support shafts 95, a stator support 92 that supports the stator core 24, and a pin 98 extending in the axial direction.

[0061] The pair of support wall portions 94 are wall portions extending in a direction orthogonal to the axial direction, and are arranged between the pair of support columns 64 described above. Each support shaft 95 extends in the axial direction and supports the rotating body 96 via a bearing. Accordingly, each rotating body 96 is rotatable about each support shaft 95. The rotating body 96 is a roller as an example. In the example of FIG. 7, a plurality of rotating bodies 96 are arranged on each support wall portion 94. However, the present disclosure is not limited thereto, and the number of rotating bodies 96 arranged between the pair of support wall portions 94 may be one.

[0062] The stator support 92 in this example is a pair of rings that sandwich the stator core 24 in the axial direction. Each ring extends in the circumferential direction. Each ring is supported by a plurality of rotating bodies 96, whereby the stator support 92 rotates in the circumferential direction together with the stator core 24. The stator support 92 has a plurality of insertion holes 93 arranged with a space therebetween along the circumferential direction. Each insertion hole 93 is open in the axial direction. The pin 98 is inserted into one of the plurality of insertion holes 93 and a hole 94a formed in the support wall portion 94.

[0063] The assembly of the magnet 5 using the rotation support mechanism 90 is performed as follows. The operator removes the pin 98 and rotates the stator support 92 together with the stator core 24 in the circumferential direction. At this time, in conjunction with the rotation of the stator support 92, all of the plurality of rotating bodies 96 rotate. When a desired portion of the magnet mounting surface 29 reaches directly below the axis S (see FIG. 4), the operator stops the rotation of the stator support 92 and inserts the pin 98 into the hole 94a and the insertion hole 93. The stator core 24 is fixed, and the operator can mount the magnet 5 on the magnet mounting surface 29.

[0064] According to the configuration in which the stator magnet assembly device 50A includes the rotation support mechanism 90, the relative position of the stator core 24 with respect to the holding member 53 is changed by the rotation of the stator core 24. Thereby, a desired magnet mounting surface 29 can be disposed directly below the magnet 5 held by the holding member 53. Therefore, the mounting operation of the magnet 5 can be accurately performed.

[0065] The rotation support mechanism 90 is not limited to the above-described embodiment. The stator support 92 may be a single ring instead of a pair of rings. Gear teeth continuously extending along the circumferential direction may be formed on the outer peripheral surface of the single ring. In this case, the rotating body 96 is a gear (pinion) that meshes with the gear teeth instead of a roller, and the lower portion of the rotating body 96 meshes with a rack linearly extending along a horizontal direction. If the rack is linearly moved by power applied from a drive source such as a motor, the stator support 92 can rotate together with the stator core 24. In this case, if the rotation support mechanism 90 includes a stopper for stopping the rack at a predetermined position, all of the above-described insertion hole 93, hole 94a, and pin 98 are unnecessary. Alternatively, the rack may be stopped using the holding torque of the motor. In this case, a stopper is unnecessary. Also in this embodiment, since the relative position of the stator core 24 with respect to the holding member 53 is changed by the rotation of the stator core 24, the above-described technical advantages can be obtained.

[0066] <Method for Assembling Stator Magnet (First Embodiment)> Referring to FIGS. 8 and 9A to 9D, a method of assembling the magnet 5 (stator magnet) according to the first embodiment will be described. In this assembling method, the stator magnet assembling device 50A according to the first embodiment is used. Hereinafter, an assembling method in an embodiment where the moving mechanism 60A does not include the vertical moving mechanism 67 (see FIG. 3) will be exemplified. Hereinafter, "step" may be abbreviated as "S".

[0067] First, a holding step (S11) is executed to attract and hold the magnet 5 on the holding lower surface 54. For example, as shown in FIGS. 9A and 9B, the operator moves the holding member 53 to the second guide portion 62 and attaches the magnet 5 to the holding lower surface 54 via the spacer 66. Thereby, the magnet 5 is held by the holding lower surface 54 at a position separated from one axial side within the axial range of the stator core 24.

[0068] Next, a rotation step (S13) is executed to rotate the stator core 24 to a predetermined rotational position and stop it. S13 is executed using the rotation support mechanism 90. By rotating the stator core 24 (arrow A in FIG. 9B), a desired portion of the magnet mounting surface 29 comes to be located directly below the axis S.

[0069] Next, an adhesion step (S15) is executed to apply an adhesive to at least one of the lower surface 5b of the magnet 5 and the magnet mounting surface 29 located directly below the axis S. The application of the adhesive is executed by an operator, an industrial robot, or a combination thereof. Note that the lower surface 5b is a surface opposite to the upper surface 5a of the magnet 5.

[0070] Next, a moving step (S17) is executed to move the holding member 53 so that the magnet 5 held by the holding member 53 is disposed at a predetermined position. The holding member 53 moves along the second guide portion 62 and the first guide portion 61. By the holding member 53 moving along the axial direction, the magnet 5 reaches a predetermined position (see FIG. 9C). At this time, the holding member 53 is supported by the first guide portion 61 over the entire axial length of the holding member 53.

[0071] Next, a separation step (S19) is executed to separate the magnet 5 held by the holding member 53 from the holding lower surface 54 toward the magnet mounting surface 29. S19 is executed by the biasing unit 80 of the separation mechanism 70A described above. More specifically, the magnet 5 held by the holding member 53 is biased toward the magnet mounting surface 29 so as to move away from the holding lower surface 54 (see FIG. 9D). More specifically, the operator uses the biasing rod 82 inserted through the holding hole 57 to bias the magnet 5 and the spacer 66 toward the magnet mounting surface 29 so that the magnet 5 moves away from the holding lower surface 54 together with the spacer 66.

[0072] The magnet 5 displaced downward from the predetermined position is attracted to the magnet mounting surface 29 by the attractive force received from the stator core 24. As a result, the magnet 5 is mounted on the magnet mounting surface 29 (see FIG. 9E), and the spacer 66 is removed. This assembling method is completed.

[0073] Note that the moving mechanism 60A may include the aforementioned vertical moving mechanism 67 (see FIG. 1). In this case, after moving the holding member 53 to the position supported by the first guide portion 61 in S17, the holding member 53 is moved downward so that the magnet 5 is disposed at the predetermined position. Note that the order of S11, S13, and S15 may be any combination. Furthermore, these three steps may be executed simultaneously.

[0074] According to the configuration in which the bonding step (S15) is executed, after the magnet 5 is mounted on the magnet mounting surface 29 by executing the separation step (S19), it is possible to suppress the magnet 5 from lifting off the magnet mounting surface 29 due to the influence of other magnets 5.

[0075] <Modification Example of the Separation Mechanism 70A (70)> FIG. 10A is a schematic diagram showing a separation mechanism 70A according to a first modification. The separation mechanism 70A may further include an electromagnet 72 disposed on the holding member 53. The electromagnet 72 is disposed, for example, on the upper surface of the horizontal plate 531. The electromagnet 72 has an energized coil (not shown) extending spirally along the vertical direction. When a current flows through the energized coil, the electromagnet 72 is turned on, and when the energization stops, the electromagnet 72 is turned off.

[0076] Examples of the use of the electromagnet 72 are as follows. When the electromagnet 72 is turned on, the magnet 5 can be attracted to the holding lower surface 54 by the magnetic field generated in the energized coil. If the electromagnet 72 changes to the off state after the magnet 5 reaches a predetermined position, the magnetic force due to the electromagnet 72 disappears, and the magnet 5 can be easily displaced downward from the holding lower surface 54.

[0077] By changing the winding direction of the energized coil, a magnetic force directed downward can be applied to the magnet 5 by the magnetic field generated when the electromagnet 72 is turned on. In this case, if the electromagnet 72 is switched from the off state to the on state after the magnet 5 reaches a predetermined position, the magnet 5 will move away from the holding lower surface 54 and displace toward the magnet mounting surface 29. Therefore, in the separation step (S19), the electromagnet 72 may be switched from the on state to the off state, or may be switched from the off state to the on state.

[0078] According to the above configuration, by switching the state of the electromagnet 72, the separation mechanism 70A can separate the magnet 5 from the holding lower surface 54.

[0079] As described above, the magnet 5 according to an embodiment of the present disclosure includes the first radial magnet 1, the second radial magnet 2, the first circumferential magnet 3, and the second circumferential magnet 4. When a specific magnet 5 out of these four types of magnets 5 is mounted on the magnet mounting surface 29, it is also possible to use the electromagnet 72.

[0080] FIG. 10B is a schematic diagram showing the separation mechanism 70A according to the second modification. The separation mechanism 70A may further include a mounting magnet 74 detachably attached to the holding member 53. The mounting magnet 74 is, for example, a permanent magnet disposed on the upper surface of the horizontal plate 531. By the mounting magnet 74 attracting the magnet 5, the magnet 5 is more strongly attracted to the holding lower surface 54. In this case, in the separation step (S19), the mounting magnet 74 will be removed.

[0081] According to the above configuration, when the mounting magnet 74 is removed from the holding member 53, the separation mechanism 70A can separate the magnet 5 from the holding lower surface 54. Note that the present disclosure is not limited to the mounting magnet 74 being detached upward from the holding member 53. The mounting magnet 74 may be detached from the holding member 53 while sliding in the axial direction or the circumferential direction with respect to the horizontal plate 531.

[0082] As described above, the magnet 5 according to an embodiment of the present disclosure includes the first radial magnet 1, the second radial magnet 2, the first circumferential magnet 3, and the second circumferential magnet 4. According to these four types of magnets 5, a plurality of types of mounting magnets 74 may be selectively used.

[0083] <Stator Magnet Assembly Device 50B According to the Second Embodiment> With reference to FIGS. 8, 11, and 12A to 12C, the stator magnet assembly device 50B (50) according to the second embodiment will be described. Among the components of the stator magnet assembly device 50B, those that are the same as those in the first embodiment are given the same reference numerals in the drawings, and the description thereof may be omitted or simplified below.

[0084] As illustrated in FIG. 11, the stator magnet assembly device 50B (50) includes a holding mechanism 55B (55), a moving mechanism 60B (60), and a separation mechanism 70B (70).

[0085] The holding mechanism 55B includes a rod-shaped jig 45 having a longitudinal direction. The rod-shaped jig 45 has the above-described holding member 53 formed on the first side in the longitudinal direction and a non-magnetic member 44 made of a non-magnetic material formed on the second side in the longitudinal direction. The holding member 53 and the non-magnetic member 44 are connected to each other and extend continuously and linearly in the longitudinal direction. The rod-shaped jig 45 may be detachable from the axial guide 65B (65) described later. The first side in the longitudinal direction of the rod-shaped jig 45 is the side in the direction indicated by arrow Q1, and the second side in the longitudinal direction is the side in the direction indicated by arrow Q2.

[0086] The axial guide 65B (65) of the moving mechanism 60B includes a third guide portion 63 disposed on the other axial side with respect to the axial range of the stator core 24. The third guide portion 63 is integrally formed of the same material as the first guide portion 61. When the rod-shaped jig 45 is attached to the axial guide 65B, the longitudinal direction of the rod-shaped jig 45 becomes parallel to the axial direction, and the second side in the longitudinal direction becomes one axial side. The attached rod-shaped jig 45 can move along the axial guide 65B.

[0087] The separation mechanism 70B includes a protruding portion 49 fixed to the end face 24a of the stator core 24 on the other axial side. The protruding portion 49 protrudes toward the axis S side (i.e., the center side of the stator 20) from the magnet mounting surface 29 located directly below the axis S.

[0088] The usage method of the stator magnet assembling device 50B is as shown in the flowchart of FIG. 8. For the sake of avoiding duplication of explanation, only the steps different from those of the first embodiment will be described below.

[0089] In the holding step (S11), the rod-shaped jig 45 is attached to the axial guide 65B, and the magnet 5 is attached to the holding member 53 (see FIG. 11). At this time, the holding member 53 is supported by the second guide portion 62.

[0090] In the moving step (S17), the operator moves the bar-shaped jig 45 along the axial guide 65B so that the magnet 5 is disposed at a predetermined position. When the magnet end face 5c of the magnet 5 on the other axial side abuts against the protruding portion 49, S17 ends (see Fig. 12A).

[0091] In the separating step (S19), with the magnet end face 5c remaining in contact with the protruding portion 49, the operator further moves the bar-shaped jig 45 to the other axial side. The magnet 5 in contact with the protruding portion 49 remains stationary. The bar-shaped jig 45 moves toward the other axial side while sliding with respect to the magnet 5. The end of the magnet 5 on one axial side comes into contact with the non-magnetic member 44 instead of the holding member 53 (see Fig. 12B). As a result, the end of the magnet 5 is displaced to the magnet mounting surface 29 by the magnetic attraction force received from the magnet mounting surface 29. Even after the magnet 5 assumes a posture inclined with respect to the axial direction, the bar-shaped jig 45 continues to move. Eventually, the end of the magnet 5 on the other axial side receives a stronger attraction force from the magnet mounting surface 29 than the attraction force received from the holding member 53 and moves from the holding member 53 to the magnet mounting surface 29. Thereby, the magnet 5 is mounted on the magnet mounting surface 29 (see Fig. 12C).

[0092] According to the above configuration, the magnet 5 can be mounted on the magnet mounting surface 29 simply by moving the bar-shaped jig 45 toward the other axial side, so that the magnet 5 can be efficiently assembled to the stator core 24.

[0093] <Method for manufacturing stator> With reference to Figs. 13 to 15, a method for manufacturing the stator 20 will be described. In the method for manufacturing the stator 20, a plurality of magnets 5 are assembled to the stator core 24 over the entire circumferential length of the stator core 24 by repeating the method for assembling the stator magnet (S11 to S19) illustrated in Fig. 8. As a result, a plurality of magnets 5 are arranged in a Halbach array in the stator core 24.

[0094] The manufacturing method of the stator 20 includes a radial magnet arranging step (S21) of alternately arranging the first radial magnet 1 and the second radial magnet 2 at intervals in the circumferential direction of the stator core 24, and a circumferential magnet arranging step (S23) of arranging the first circumferential magnet 3 and the second circumferential magnet 4 at intervals in the circumferential direction after S21.

[0095] In S21, through S11 to S19 shown in FIG. 8, either one of the first radial magnet 1 or the second radial magnet 2 is arranged. By repeatedly executing S11 to S19, a plurality of first radial magnets 1 and a plurality of second radial magnets 2 are sequentially assembled to the stator core 24 (see FIG. 14).

[0096] S23 is the same as S21. That is, through S11 to S19 shown in FIG. 8, either one of the first circumferential magnet 3 or the second circumferential magnet 4 is arranged. By repeatedly executing S11 to S19, a plurality of first circumferential magnets 3 and a plurality of second circumferential magnets 4 are sequentially assembled to the stator core 24 (see FIG. 15). The operator arranges the first circumferential magnet 3 on one circumferential side with respect to the first radial magnet 1 and on the other circumferential side with respect to the second radial magnet 2, and arranges the second circumferential magnet 4 on the other circumferential side with respect to the first radial magnet 1 and on one circumferential side with respect to the second radial magnet 2.

[0097] When assembling the first circumferential magnet 3 and the second circumferential magnet 4, the first radial magnet 1 and the second radial magnet 2 are already assembled to the stator core 24. Therefore, due to the influence of the magnetic fields caused by each of the first radial magnet 1 and the second radial magnet 2, the first radial magnet 1 and the second circumferential magnet 4 are each attached to the stator core 24 while receiving magnetic repulsive forces. Thus, in the separation step (S19) shown in FIG. 8, it is preferable to use the biasing unit 80 (see FIG. 9D) to bias the first circumferential magnet 3 and the second circumferential magnet 4 toward the magnet mounting surface 29. Thereby, the first circumferential magnet 3 and the second circumferential magnet 4 can reach the magnet mounting surface 29 while resisting the repulsive force.

[0098] In addition, even after the first circumferential magnet 3 and the second circumferential magnet 4 are mounted on the magnet mounting surface 29, due to the influence of the magnetic field caused by the first radial magnet 1 and the second radial magnet 2, they may be urged inward in the radial direction and float from the magnet mounting surface 29. In this regard, by performing the adhesion step (S15), the first circumferential magnet 3 and the second circumferential magnet 4 are adhered to the magnet mounting surface 29, so that the lifting of the first circumferential magnet 3 and the second circumferential magnet 4 can be suppressed.

[0099] <Summary> The content described in several of the above-described embodiments can be understood as follows, for example.

[0100] 1) The stator magnet assembling device (50) according to at least one embodiment of the present disclosure is a stator magnet assembling device for assembling a magnet (5) to a stator core (24), a holding mechanism including a holding member (53) formed of a magnetic material, the holding member having a holding lower surface (54) for attracting and holding the upper surface (5a) of the magnet by magnetic force, a holding mechanism (55); a moving mechanism (60) for moving the holding member so that the magnet held by the holding member is disposed at a predetermined position facing the magnet mounting surface (29) of the stator core with a gap in the vertical direction; a separating mechanism (70) for separating the magnet held at the predetermined position from the holding lower surface toward the magnet mounting surface; and is provided with.

[0101] According to the configuration of 1) above, after the moving mechanism moves the holding member so that the magnet is disposed at a predetermined position, the separating mechanism separates the magnet from the holding lower surface toward the magnet mounting surface, so that the magnet is attracted to the stator core and mounted on the magnet mounting surface. Since the magnet can be mounted on the magnet mounting surface without any delay, a stator magnet assembling device capable of efficiently assembling the magnet to the stator core is realized.

[0102] 2) In some embodiments, it is the stator magnet assembling device described in 1) above, The moving mechanism further includes an axial guide (65) that extends in the axial direction of the stator core and movably supports the holding member.

[0103] According to the configuration of 2) above, the magnet can be attached to the holding member at a position axially separated from the predetermined position. Thereafter, the holding member can move stably in the axial direction so that the magnet is disposed at the predetermined position. Therefore, the attachment work of the magnet to the magnet mounting surface can be easily performed.

[0104] 3) In some embodiments, there is provided a stator magnet assembling device according to 2) above, wherein the axial guide includes a first guide portion (61) disposed within the axial range of the stator core, and a second guide portion (62) disposed at a position separated from one side of the axial range of the stator core, and the axial length of the second guide portion is equal to or greater than the axial length of the first guide portion.

[0105] According to the configuration of 3) above, the magnet can be attached to the holding lower surface while the holding member is supported by the second guide portion. Since the magnet is attached at a position separated from one side of the axial range of the stator core, the magnetic attractive force between the magnet and the stator core does not inhibit the attachment of the magnet. Therefore, the attachment work of the magnet can be easily performed.

[0106] 4) In some embodiments, there is provided a stator magnet assembling device according to 2) or 3) above, wherein the moving mechanism includes a vertical movement mechanism (60) for moving the holding member in the vertical direction.

[0107] According to the configuration of 4) above, the magnet can be attached to the holding lower surface at a position separated from above the magnet mounting surface. Since the magnetic attractive force between the magnet and the stator core does not inhibit the attachment of the magnet, the attachment work of the magnet can be easily performed.

[0108] 5) In some embodiments, there is provided a stator magnet assembling device according to any one of 1) to 4) above, wherein the holding mechanism is a pair of holding protrusions formed of a non-magnetic material and protruding downward from the holding lower surface, and the pair of holding protrusions (51) are arranged at intervals along the holding lower surface in a direction orthogonal to the axial direction of the stator core.

[0109] According to the configuration of 5) above, when the magnet is attached to the holding lower surface and when the magnet is separated from the holding lower surface, the pair of holding protrusions can guide the displacement of the magnet in the vertical direction. Therefore, the magnet mounting operation is facilitated.

[0110] 6) In some embodiments, there is provided a stator magnet assembling device according to any one of 1) to 5) above, wherein the separation mechanism includes a biasing unit (80) for biasing the magnet held by the holding member so as to be separated from the holding lower surface toward the magnet mounting surface.

[0111] According to the configuration of 6) above, when the separation mechanism separates the magnet from the holding lower surface toward the magnet mounting surface, even when the magnet receives a magnetic repulsive force from the magnet mounting surface side, the magnet can be displaced toward the magnet mounting surface by the biasing unit. Therefore, the magnet mounting operation can be performed accurately and easily.

[0112] 7) In some embodiments, there is provided a stator magnet assembling device according to 6) above, wherein the holding member has a holding hole (57) opening on the holding lower surface, the biasing unit has a biasing rod (82) inserted through the holding hole, and the biasing rod is configured to be displaced vertically.

[0113] According to the configuration of 7) above, by the biasing rod biasing the magnet downward, the magnet can be reliably displaced toward the magnet mounting surface side.

[0114] 8) In some embodiments, the stator magnet assembling device described in 7) above, the holding hole is a threaded hole having an inner peripheral surface (58) formed with a female thread, the biasing rod has a threaded shaft portion (83) that engages with the inner peripheral surface.

[0115] According to the configuration of 8) above, by rotating the biasing rod, the biasing rod gradually displaces downward together with the magnet. Since the speed of the magnet approaching the magnet mounting surface can be reduced, the collision force generated between the two when the magnet reaches the magnet mounting surface can be reduced. Therefore, the magnet can be more properly mounted on the magnet mounting surface.

[0116] 9) In some embodiments, the stator magnet assembling device described in any one of 6) to 8) above, the holding mechanism further includes a spacer interposed between the magnet and the holding lower surface, the spacer (66) extending in the axial direction of the stator core and formed of a non-magnetic material.

[0117] According to the configuration of 9) above, the biasing unit can bias the magnet toward the magnet mounting surface via the spacer. Thereby, it is possible to suppress the biasing force from concentrating on a specific part of the magnet, and the magnet can be separated from the holding lower surface in a posture substantially parallel to the axial direction. Further, the distance from the holding lower surface to the magnet when the holding member holds the magnet is optimized through adjustment of the thickness of the spacer. Thereby, the magnetic attraction force between the holding lower surface and the magnet can be optimized, and the transfer of the magnet from the holding lower surface to the magnet mounting surface can be made smooth. Furthermore, in an embodiment where the spacer abuts against the inner surface of each of the pair of holding protrusions, it is possible to suppress the spacer displaced toward the magnet mounting surface from tilting with respect to the axial direction and the circumferential direction, and the magnet can be made in a posture more substantially parallel to the axial direction and the circumferential direction.

[0118] 10) In some embodiments, the stator magnet assembling device described in any one of 1) to 9) above, the separating mechanism further includes an electromagnet disposed on the holding member.

[0119] According to the configuration of 10) above, by switching the state of the electromagnet, the separation mechanism can separate the magnet from the holding lower surface.

[0120] 11) In some embodiments, it is a stator magnet assembling device according to any one of 1) to 10) above, The separation mechanism further includes a mounting magnet (74) detachably attached to the holding member.

[0121] According to the configuration of 11) above, by removing the mounting magnet from the holding member, the separation mechanism can separate the magnet from the holding lower surface.

[0122] 12) In some embodiments, it is a stator magnet assembling device according to any one of 2) to 4) above, The holding mechanism further includes a rod-shaped jig (45) having a longitudinal direction, The rod-shaped jig, The holding member formed on the first side in the longitudinal direction, And a non-magnetic member (44) made of a non-magnetic material formed on the second side in the longitudinal direction, And has, The axial guide is configured to movably support the rod-shaped jig such that the longitudinal direction is parallel to the axial direction and the second side is one side of the axial direction. The separation mechanism includes a protruding portion that protrudes toward the center side of the stator core and is configured to abut against a magnet end surface (5c) on the other side of the magnet at the predetermined position.

[0123] According to the configuration of 12) above, the bar-shaped jig can be installed on the axial guide, and the magnet can be attached to the holding member. When the bar-shaped jig is moved to the other side in the axial direction, the magnet end face abuts against the protruding portion. The bar-shaped jig continues to move to the other side, and the magnet in contact with the protruding portion maintains a stationary state. As a result, the end of the magnet on one side in the axial direction abuts against a non-magnetic member instead of the holding member, and is displaced to the magnet mounting surface by the magnetic attractive force received from the magnet mounting surface. After that, the bar-shaped jig continues to move. Eventually, the end of the magnet on the other side in the axial direction receives a stronger attractive force from the magnet mounting surface than the attractive force received from the holding member, and moves from the holding member to the magnet mounting surface. Thereby, the magnet is attached to the magnet mounting surface. In this way, since the magnet can be attached to the magnet mounting surface only by moving the bar-shaped jig toward the other side in the axial direction, the magnet can be efficiently assembled to the stator core.

[0124] 13) In some embodiments, it is a stator magnet assembling device according to any one of 1) to 12) above, further comprising a rotation support mechanism (90) configured to change the relative position of the stator core with respect to the holding member by rotating the stator core.

[0125] According to the configuration of 13) above, the relative position of the stator core with respect to the holding member is changed by the rotation of the stator core. Thereby, a desired magnet mounting surface can be arranged directly below the magnet held by the holding member. Therefore, the magnet mounting operation can be performed accurately.

[0126] 14) A stator magnet assembling method according to at least one embodiment of the present disclosure is a stator magnet assembling method for assembling a magnet (5) to a stator core (24), a holding step (S11) of attracting and holding the magnet to the holding lower surface (54) of a holding member (53) formed of a magnetic material; a moving step (S17) of moving the holding member so that the held magnet is disposed at a predetermined position facing the magnet mounting surface (29) of the stator core with a gap in the vertical direction. A separating step (S19) of separating the magnet held by the holding member away from the holding lower surface toward the magnet mounting surface; is provided.

[0127] According to the configuration of 14) above, the same technical advantages as those of 1) above can be obtained.

[0128] 15) In some embodiments, there is provided a stator magnet assembling method according to 14) above, further comprising an adhering step (S15) of applying an adhesive to at least one of the lower surface (5b) of the magnet and the magnet mounting surface before the separating step.

[0129] According to the configuration of 15) above, after the magnet is mounted on the magnet mounting surface by executing the separating step, it is possible to suppress the magnet from lifting off the magnet mounting surface due to the magnetic force of other magnets.

[0130] 16) In some embodiments, there is provided a stator magnet assembling method according to 14) or 15) above, wherein in the holding step, the magnet is held on the holding lower surface at a position away from one side within the axial range of the stator core, and in the moving step, the holding member holding the magnet is moved along the axial direction of the stator core.

[0131] According to the configuration of 16) above, the same technical advantages as those of 3) above can be obtained.

[0132] 17) In some embodiments, there is provided a stator magnet assembling method according to 16) above, wherein in the moving step, after the holding member is moved in the axial direction, the holding member is moved downward so that the magnet is disposed at the predetermined position.

[0133] According to the configuration of 17) above, the same technical advantages as those of 4) above can be obtained.

[0134] 18) In some embodiments, it is a method for assembling a stator magnet according to any one of 14) to 17) above, In the separation step, the magnet held by the holding member is biased toward the magnet mounting surface so as to be separated from the holding lower surface.

[0135] According to the configuration of 18) above, the same technical advantages as those of 6) above can be obtained.

[0136] 19) In some embodiments, it is a method for assembling a stator magnet according to 18) above, The holding member has a holding hole (57) that opens on the holding lower surface, In the separation step, the magnet is biased toward the magnet mounting surface so as to be separated from the holding lower surface by using a biasing rod (82) that is inserted into the holding hole and is displaceable in the vertical direction.

[0137] According to the configuration of 19) above, the same technical advantages as those of 7) above can be obtained.

[0138] 20) In some embodiments, it is a method for assembling a stator magnet according to any one of 14) to 19) above, In the separation step, the electromagnet (72) disposed on the holding member is turned on or off.

[0139] According to the configuration of 20) above, the same technical advantages as those of 10) above can be obtained.

[0140] 21) In some embodiments, it is a method for assembling a stator magnet according to any one of 14) to 20) above, In the separation step, the mounting magnet (74) attached to the holding member is removed.

[0141] According to the configuration of 21) above, the same technical advantages as those of 11) above can be obtained.

[0142] 22) In some embodiments, it is a method for assembling a stator magnet according to 14) above, In the holding step, a bar-shaped jig having a longitudinal direction, wherein the holding member is formed on a first side in the longitudinal direction, and a non-magnetic member made of a non-magnetic material is formed on a second side in the longitudinal direction, the magnet is held by the holding member of the bar-shaped jig (45), In the moving step, an axial guide (65) that supports the bar-shaped jig so that the longitudinal direction is parallel to the axial direction of the stator core and the second side is on one side in the axial direction of the stator core is used, and the bar-shaped jig is moved along the axial guide so that the magnet is disposed at the predetermined position, In the separating step, a protruding portion (49) protruding toward the center side of the stator core is brought into contact with a magnet end face (5c) on the other side in the axial direction of the magnet that has moved with the execution of the moving step, and the bar-shaped jig is further moved to the other side along the axial guide.

[0143] According to the configuration of 22) above, the same technical advantages as those of 12) above can be obtained.

[0144] 23) In some embodiments, a stator magnet assembling method according to any one of 14) to 22) above, further includes a rotating step (S13) of rotating the stator core to a predetermined rotational position and stopping it before the execution of the moving step.

[0145] According to the configuration of 23) above, the same technical advantages as those of 13) above can be obtained.

[0146] 24) A method for manufacturing a stator according to at least one embodiment of the present disclosure is a method for manufacturing a stator in which a plurality of the magnets are assembled to the stator core over the entire circumferential length of the stator core by repeating the stator magnet assembling method described in 14) above, the plurality of magnets are A first radially magnetized magnet (1) magnetized on the outer side in the radial direction of the stator core, A second radially magnetized magnet (2) magnetized on the inner side in the radial direction, A first circumferentially magnetized magnet (3) magnetized on one side in the circumferential direction of the stator core, A second circumferentially magnetized magnet (4) magnetized on the other side in the circumferential direction, comprising, The method for manufacturing the stator is A radial magnet arranging step (S21) of arranging the first radially magnetized magnet and the second radially magnetized magnet alternately with a space therebetween in the circumferential direction of the stator core, After the radial magnet arranging step, a circumferential magnet arranging step of arranging the first circumferentially magnetized magnet and the second circumferentially magnetized magnet with a space therebetween in the circumferential direction, wherein the first circumferentially magnetized magnet is arranged on the one side in the circumferential direction of the first radially magnetized magnet and on the other side in the circumferential direction of the second radially magnetized magnet, and the second circumferentially magnetized magnet is arranged on the other side of the first radially magnetized magnet and on the one side in the circumferential direction of the second radially magnetized magnet (S23) and comprising.

[0147] According to the configuration of 24) above, the same technical advantages as in 1) above can be obtained.

[0148] 25) In some embodiments, it is the method for manufacturing the stator described in 24) above, In the separation step, the first circumferentially magnetized magnet or the second circumferentially magnetized magnet held by the holding member is biased toward the magnet mounting surface so as to be away from the holding lower surface.

[0149] According to the configuration of 25) above, even when the first circumferentially magnetized magnet or the second circumferentially magnetized magnet receives a magnetic repulsive force from the first radially magnetized magnet and the second radially magnetized magnet during the execution of the circumferential magnet arranging step, these circumferential magnets can be mounted on the magnet mounting surface.

Explanation of reference numerals

[0150] 1: First radially magnetized magnet 2: Second radial magnet 3: First circumferential magnet 4: Second circumferential magnet 5: Magnet 5a: Upper surface 5b: Lower surface 5c: Magnet end face 6 - 8: Protrusion 9: External device 10: Magnetic gear electric machine 16: Power system 17: Housing 18: Rotating shaft 20: Stator 23: Base 24: Stator core 24a: End face 25: Tooth 27: Stator coil 29: Magnet mounting surface 30: Pole piece rotor 31: Connecting member 35: Annular body 36: Pole piece 37: Screw 40: Magnet rotor 41: Inner magnet 42: Rotor core 44: Non - magnetic member 45: Rod - shaped jig 49: Protruding part 50: Stator magnet assembling device 51: Holding protrusion 51a: Inner surface 53: Holding member 54: Holding lower surface 55: Holding mechanism 57: Holding hole 58: Inner circumferential surface 60: Moving mechanism 61: First guide part 62: Second guide part 63: Third guide part 64: Support pillar 65: Axial guide 66: Spacer 67: Vertical moving mechanism 69: Slider 70: Spacing mechanism 72: Electromagnet 74: Mounting magnet 80: Biasing unit 82: Biasing rod 83: Threaded shaft portion 90: Rotational support mechanism 92: Stator support 93: Insertion hole 94: Support wall portion 94a: Hole 95: Support shaft 96: Rotating body 98: Pin 161: Base 162: Vertical rail 163: Movable support 209: Intervening member 252: Tip portion 531: Horizontal plate 532: Vertical plate 661: Bottom surface 662: Concave portion 662a: Bottom surface A, Q1, Q2: Arrow L1, L2: Dimension S: Axis

Claims

1. A stator magnet assembling device for assembling a magnet to a stator core, comprising: a holding mechanism including a holding member formed of a magnetic material, the holding member having a holding lower surface for attracting and holding the upper surface of the magnet by magnetic force; a moving mechanism for moving the holding member so that the magnet held by the holding member is disposed at a predetermined position facing the magnet mounting surface of the stator core with a gap therebetween in the vertical direction; a separating mechanism for separating the magnet held at the predetermined position from the holding lower surface toward the magnet mounting surface; A stator magnet assembling device comprising the above.

2. The moving mechanism further includes an axial guide extending in the axial direction of the stator core and supporting the holding member movably. The stator magnet assembling device according to Claim 1.

3. The axial guide includes: a first guide portion disposed within the axial range of the stator core; a second guide portion disposed at a position separated from one side of the axial range of the stator core; and the axial length of the second guide portion is equal to or greater than the axial length of the first guide portion. The stator magnet assembling device according to Claim 2.

4. The moving mechanism includes a vertical moving mechanism for moving the holding member in the vertical direction. The stator magnet assembling device according to Claim 2 or 3.

5. The holding mechanism further includes a pair of holding protrusions formed of a non-magnetic material and protruding downward from the holding lower surface, the pair of holding protrusions being spaced apart along the holding lower surface in a direction orthogonal to the axial direction of the stator core. The stator magnet assembling device according to any one of Claims 1 to 3.

6. The separating mechanism includes a biasing unit for biasing the magnet held by the holding member to be separated from the holding lower surface toward the magnet mounting surface. The stator magnet assembling device according to any one of Claims 1 to 3.

7. The holding member has a holding hole opening at the holding lower surface, the biasing unit has a biasing rod inserted into the holding hole, and the biasing rod is configured to be displaced vertically. The stator magnet assembling device according to Claim 6.

8. The holding hole is a threaded hole having an inner peripheral surface formed with a female thread, and the biasing rod has a threaded shaft portion screwed onto the inner peripheral surface. The stator magnet assembling device according to Claim 7. ​

9. The holding mechanism further includes a spacer interposed between the magnet and the holding lower surface, the spacer extending in the axial direction of the stator core and formed of a non-magnetic material. The stator magnet assembling device according to claim 6.

10. The separating mechanism further includes an electromagnet disposed on the holding member. The stator magnet assembling device according to any one of claims 1 to 3.

11. The separating mechanism further includes a mounting magnet removably attached to the holding member. The stator magnet assembling device according to any one of claims 1 to 3.

12. The holding mechanism further includes a bar-shaped jig having a longitudinal direction, wherein the bar-shaped jig has the holding member formed on a first side in the longitudinal direction, and a non-magnetic member made of a non-magnetic material formed on a second side in the longitudinal direction, and the axial guide is configured to movably support the bar-shaped jig such that the longitudinal direction is parallel to the axial direction and the second side is on one side in the axial direction. The separating mechanism includes a protruding portion protruding toward the center side of the stator core and configured to contact a magnet end surface on the other side of the magnet at the predetermined position. The stator magnet assembling device according to claim 2 or 3.

13. The device further includes a rotation support mechanism configured to change a relative position of the stator core with respect to the holding member by rotating the stator core. The stator magnet assembling device according to any one of claims 1 to 3.

14. A stator magnet assembling method for assembling a magnet to a stator core, the method including: a holding step of attracting and holding the magnet on a holding lower surface of a holding member formed of a magnetic material; a moving step of moving the holding member so that the held magnet is disposed at a predetermined position where a gap is provided in a vertical direction with respect to a magnet mounting surface of the stator core; a separating step of separating the magnet held by the holding member from the holding lower surface toward the magnet mounting surface. The stator magnet assembling method comprising the above steps.

15. Before the separating step, the method further includes an adhesive application step of applying an adhesive to at least one of a lower surface of the magnet and the magnet mounting surface. The stator magnet assembling method according to claim 14.

16. In the holding step, the magnet is held on the holding lower surface at a position separated from one side within an axial range of the stator core. In the moving step, the holding member that holds the magnet is moved along the axial direction of the stator core. The method for assembling a stator magnet according to claim 14 or 15.

17. In the moving step, after moving the holding member in the axial direction, the holding member is moved downward so that the magnet is disposed at the predetermined position. The method for assembling a stator magnet according to claim 16.

18. In the separating step, the magnet held by the holding member is urged toward the magnet mounting surface so as to be separated from the holding lower surface. The method for assembling a stator magnet according to claim 14 or 15.

19. The holding member has a holding hole that opens at the holding lower surface. In the separating step, an urging rod that is inserted into the holding hole and is displaceable in the vertical direction is used to urge the magnet toward the magnet mounting surface so as to be separated from the holding lower surface. The method for assembling a stator magnet according to claim 18.

20. In the separating step, an electromagnet disposed in the holding member is turned on or off. The method for assembling a stator magnet according to claim 14 or 15.

21. In the separating step, a mounting magnet attached to the holding member is removed. The method for assembling a stator magnet according to claim 14 or 15.

22. In the holding step, a bar-shaped jig having a longitudinal direction, wherein the holding member is formed on a first side in the longitudinal direction, and a non-magnetic member made of a non-magnetic material is formed on a second side in the longitudinal direction, holds the magnet on the holding member. In the moving step, an axial guide that supports the bar-shaped jig such that the longitudinal direction is parallel to the axial direction of the stator core and the second side is one side in the axial direction of the stator core is used, and the bar-shaped jig is moved along the axial guide so that the magnet is disposed at the predetermined position. In the separating step, a protruding portion that protrudes toward the center side of the stator core is brought into contact with a magnet end surface on the other side in the axial direction of the magnet that has moved with the execution of the moving step, and the bar-shaped jig is further moved to the other side along the axial guide. The method for assembling a stator magnet according to claim 14.

23. Before the execution of the moving step, the method further includes a rotating step of rotating the stator core to a predetermined rotational position and stopping it. The method for assembling a stator magnet according to claim 14 or 15.

24. A method for manufacturing a stator in which a plurality of the magnets are assembled to the stator core over the entire circumferential length of the stator core by repeating the method for assembling a stator magnet according to claim 14, wherein the plurality of magnets include a first radially magnetized magnet magnetized on the outer side in the radial direction of the stator core, a second radially magnetized magnet magnetized on the inner side in the radial direction, a first circumferentially magnetized magnet magnetized on one side in the circumferential direction of the stator core, and a second circumferentially magnetized magnet magnetized on the other side in the circumferential direction, and the method for manufacturing the stator includes a radial magnet arrangement step of alternately arranging the first radially magnetized magnet and the second radially magnetized magnet at intervals in the circumferential direction of the stator core, and, after the radial magnet arrangement step, a circumferential magnet arrangement step of arranging the first circumferentially magnetized magnet and the second circumferentially magnetized magnet at intervals in the circumferential direction, wherein the first circumferentially magnetized magnet is arranged on the one side in the circumferential direction of the first radially magnetized magnet and on the other side in the circumferential direction of the second radially magnetized magnet, and the second circumferentially magnetized magnet is arranged on the other side of the first radially magnetized magnet and on the one side in the circumferential direction of the second radially magnetized magnet. A method for manufacturing a stator comprising the steps.

25. In the separation step, the first circumferentially magnetized magnet or the second circumferentially magnetized magnet held by the holding member is biased toward the magnet mounting surface so as to be separated from the holding lower surface. The method for manufacturing a stator according to claim 24.

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