Apparatus and method for manufacturing laminated core

Abstract

To provide a manufacturing apparatus and a manufacturing method which can efficiently manufacture a laminated core.SOLUTION: A manufacturing apparatus 1 includes: an upper plate 2 provided with a plunger 21; a lower plate 3 arranged below the upper plate 2; and a tray 4 which is provided with a laminated core body 61 and is mounted on the lower plate 3. The tray 4 includes a cylindrical part 41 which is inserted into a shaft hole 611 of the laminated core body 61, and a flange part 42 which is brought into contact with the lower plate 3 from above, and is brought into contact with an outer peripheral part 612 of the laminated core body 61 from below. The cylindrical part 41 has a resin arrangement hole 411 where a resin tablet 5 is arranged and a plunger 21 for pressing the resin tablet 5 is inserted. The flange part 42 has a plurality of resin flow channel grooves 421 which radially extend from the resin arrangement hole 411 on the lower surface facing the lower plate 3, and a plurality of gates 422 which extend upward from the plurality of resin flow channel grooves 421 and communicate with the plurality of magnet insertion holes 613.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a manufacturing apparatus and method for manufacturing a laminated core used in a rotor of an electric motor. [Background technology]

[0002] A laminated core used in the rotor of an electric motor includes a laminated core body having a plurality of magnet insertion holes spaced apart in the circumferential direction, and magnet pieces fixed with resin to each of the magnet insertion holes. A technique for manufacturing such a laminated core is disclosed in, for example, Patent Document 1.

[0003] In the technology disclosed in Patent Document 1, a laminated core body with magnet pieces inserted into the magnet insertion holes is placed between an upper mold and a lower mold, and resin is filled into the magnet insertion holes from a resin reservoir provided in the upper mold through a resin flow path formed in a guide member. The resin filled into the magnet insertion holes is thermally cured, fixing the magnet pieces in the magnet insertion holes. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 5985707 Summary of the Invention [Problem to be solved by the invention]

[0005] In the technology disclosed in Patent Document 1, when resin is filled into the magnet insertion holes, molten resin flows into the upper die and guide member. In this case, wear may occur on each of the upper die and guide member due to the flow of molten resin. This increases the frequency of maintenance for each of the upper die and guide member. Furthermore, after the resin filled into the magnet insertion holes hardens, hardened resin remains on each of the upper die and guide member. In this case, it is necessary to remove the hardened resin from each of the upper die and guide member. As such, the increased frequency of maintenance for each of the upper die and guide member and the need to remove the hardened resin pose a problem of reduced manufacturing efficiency of laminated cores.

[0006] An object of the present invention is to provide a manufacturing apparatus and a manufacturing method that can efficiently manufacture a laminated core. [Means for solving the problem]

[0007] According to one aspect of the present invention, a laminated core manufacturing apparatus is provided for manufacturing a laminated core including a laminated core body having a central axial hole and a plurality of magnet insertion holes spaced circumferentially around the axial hole on an outer periphery surrounding the axial hole, and magnet pieces inserted into each of the magnet insertion holes and fixed with resin. The manufacturing apparatus includes an upper plate equipped with a plunger movable in the vertical direction, a lower plate disposed below the upper plate, and a tray placed on the lower plate on which the laminated core body with the magnet pieces inserted into the magnet insertion holes is mounted. The upper plate contacts the laminated core body mounted on the tray on the lower plate from above. The tray has a hole extending in the vertical direction, and has a resin placement hole in which a resin tablet, which is a molded body of the resin, is placed and into which the plunger that presses the resin tablet is inserted, and includes a cylindrical portion that is inserted into the axial hole of the laminated core body, and a flange portion that protrudes radially outward from the lower end of the cylindrical portion and contacts the lower plate from above and the outer periphery of the laminated core body from below, and has a plurality of resin flow path grooves that extend radially from the resin placement hole on the lower surface facing the lower plate, and a plurality of gates that extend upward from the tips of the plurality of resin flow path grooves and communicate with each of the plurality of magnet insertion holes.

[0008] According to this laminated core manufacturing apparatus, a laminated core body is mounted on a tray including a cylindrical portion with a resin placement hole and a flange portion with multiple resin flow grooves and multiple gates. The tray with the laminated core body mounted is placed on a lower plate, and a resin tablet is placed in the resin placement hole of the tray. With the upper plate in contact with the laminated core body from above, a plunger presses the resin tablet in the resin placement hole, allowing the resin extruded from the resin placement hole to be filled into each magnet insertion hole through the tray's resin flow grooves and gates. In this manufacturing apparatus, the tray is provided with a resin placement hole in which a resin tablet is placed, and resin flow grooves and gates connecting the resin placement hole to each magnet insertion hole. In this case, only the tray is subject to maintenance related to wear caused by the resin flowing into each magnet insertion hole. Furthermore, after filling each magnet insertion hole with resin, only the tray retains the resin. Therefore, maintenance and removal of residual resin are required only on the tray. This allows efficient maintenance and removal of residual resin, making it possible to efficiently manufacture laminated cores.

[0009] In the laminated core manufacturing apparatus, the resin placement hole extends along the central axis of the cylindrical portion, and the plurality of resin flow grooves extend from the resin placement hole by approximately the same length.

[0010] In this embodiment, the resin placement hole in which the resin tablet is placed is located on the central axis of the cylindrical portion, and the resin flow grooves extending radially from the resin placement hole are approximately the same length. In this case, the filling time required for the resin extruded from the resin placement hole by the plunger pressing the resin tablet through the resin flow grooves and gates to fill each magnet insertion hole can be approximately the same for each magnet insertion hole. In other words, resin can be filled into multiple magnet insertion holes approximately simultaneously.

[0011] In the above-described laminated core manufacturing apparatus, the tray may be a transfer tray that is transferred to the lower plate with the laminated core body attached thereto.

[0012] In this embodiment, the tray with the laminated core body attached thereto can be placed on the lower plate by transporting the tray relative to the lower plate.

[0013] In the laminated core manufacturing apparatus, the resin may be a thermosetting resin, and the upper plate and the lower plate may have a heating section capable of raising the temperature to a temperature at which the thermosetting resin is thermally cured.

[0014] Thermosetting resin temporarily enters a molten state with fluidity at the thermosetting temperature, but retains its hardened state after a predetermined polymerization reaction. Using these properties of thermosetting resin, the manufacturing device fills each magnet insertion hole of the laminated core body with molten resin and thermally hardens the filled resin within each magnet insertion hole to secure the magnet pieces. The heating unit on the upper plate heats the plunger attached to the upper plate, the laminated core body in contact with the upper plate, and the tray from above to the thermosetting temperature. The heating unit on the lower plate also heats the tray placed on the lower plate from below to the thermosetting temperature. This maintains the resin flow path from the resin placement hole of the tray through the resin flow grooves and gates to the magnet insertion holes of the laminated core body at the thermosetting temperature. Therefore, the resin extruded from the resin placement hole by the plunger pressing the resin tablet can be filled into each magnet insertion hole in a molten state through the resin flow grooves and gates. Furthermore, the filled resin can be thermally hardened within each magnet insertion hole.

[0015] A method for manufacturing a laminated core according to another aspect of the present invention is a method for manufacturing a laminated core including a laminated core body having a central axial hole and a plurality of magnet insertion holes spaced circumferentially around the axial hole on an outer periphery surrounding the axial hole, and magnet pieces inserted into each of the magnet insertion holes and fixed with resin. This manufacturing method includes the steps of: preparing a tray having a cylindrical portion having a resin placement hole extending in the vertical direction and a flange portion protruding radially outward from the lower end of the cylindrical portion, the flange portion having a plurality of resin flow grooves extending radially from the resin placement hole and a plurality of gates extending upward from the tips of the resin flow grooves; attaching the laminated core body to the tray by inserting the cylindrical portion into the axial hole and contacting the flange portion with the outer periphery from below, and then inserting the magnet pieces into the plurality of magnet insertion holes; and a plunger equipped with a plunger movable in the vertical direction. The method includes the steps of placing the tray with the laminated core body attached on a lower plate positioned below the upper plate, and placing a resin tablet, which is a molded body of the resin, in the resin placement hole; and, with the plunger inserted into the resin placement hole, bringing the upper plate into contact with the laminated core body attached to the tray on the lower plate from above, and then lowering the plunger to press the resin tablet, thereby filling the resin extruded from the resin placement hole into the multiple magnet insertion holes through the multiple resin flow grooves and the multiple gates.

[0016] According to this manufacturing method for a laminated core, a laminated core body is mounted on a tray including a cylindrical portion with a resin disposition hole and a flange portion with a resin flow channel groove and a gate. The tray with the laminated core body mounted thereon is placed on a lower plate, and a resin tablet is placed in the resin disposition hole of the tray. A plunger is then inserted into the resin disposition hole. This positions the center of the resin disposition hole on the central axis of the plunger, allowing the tray to be accurately positioned relative to the plunger. Next, the upper plate is brought into contact with the laminated core body mounted on the tray on the lower plate from above, and then the plunger is lowered to press against the resin tablet in the resin disposition hole. This allows the resin extruded from the resin disposition hole to be filled into the magnet insertion hole through the resin flow channel groove and gate of the tray.

[0017] In the laminated core manufacturing method described above, the resin is a thermosetting resin, and the manufacturing method further includes the steps of raising the plunger until the resin filled in the magnet insertion holes is thermally cured and then exits the resin placement holes, releasing the upper plate from contact with the laminated core body, and then separating the laminated core body from the tray.

[0018] When a tray is placed on the lower plate and the upper plate is in contact with the laminated core body attached to the tray, the resin filled in the magnet insertion holes of the laminated core body contacts the upper plate, and the resin in the resin flow channel grooves of the tray contacts the lower plate. In this case, the contact area of ​​the resin with the upper and lower plates is larger on the lower plate than on the upper plate. Therefore, when the resin filled in the magnet insertion holes is thermally cured and the upper plate is released from contact with the laminated core body, the tray with the laminated core body attached remains placed on the lower plate, and the resin hardened in the magnet insertion holes is separated from the upper plate. This prevents hardened resin from remaining on the upper plate.

[0019] Furthermore, after the upper plate is released from contact with the laminated core body, the laminated core body is separated from the tray. When the laminated core body is separated from the tray, the resin that has hardened in the magnet insertion holes breaks at the gate of the tray. In this case, the hardened resin remains in the resin flow channel groove and gate of the tray, so the hardened resin can be removed from the tray. [Effects of the Invention]

[0020] As described above, according to the present invention, it is possible to provide a manufacturing apparatus and a manufacturing method that can efficiently manufacture a laminated core. [Brief explanation of the drawings]

[0021] [Figure 1] 1 is a diagram illustrating a schematic diagram of a laminated core manufacturing apparatus according to an embodiment of the present invention. [Figure 2] FIG. 2 is a plan view of a laminated core manufactured by the manufacturing apparatus. [Figure 3] FIG. 10 is a top view of the tray with the laminated core body attached. [Figure 4] FIG. [Figure 5] 10 is a flowchart showing a method for manufacturing a laminated core. [Figure 6] 3A to 3C are diagrams schematically showing the processes of steps S1 and S2 in the manufacturing method of the laminated core. [Figure 7] 5A to 5C are diagrams schematically showing the processes of steps S3 and S4 in the manufacturing method of the laminated core. [Figure 8] 10A and 10B are diagrams schematically showing the processes of steps S5 and S6 in the manufacturing method of the laminated iron core. [Figure 9] 10A and 10B are diagrams schematically showing the processes of steps S7 and S8 in the manufacturing method of the laminated core. [Figure 10] 10 is a diagram schematically showing the processing of steps S9 and S10 in the manufacturing method of the laminated iron core. FIG. [Figure 11] FIG. 10 is a diagram schematically showing a laminated core manufacturing apparatus according to a modified embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0022] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A laminated core manufacturing apparatus and method according to an embodiment of the present invention will now be described with reference to the accompanying drawings.

[0023] [About laminated core manufacturing equipment] 1 is a diagram that schematically shows a laminated core manufacturing apparatus 1 according to an embodiment of the present invention. The manufacturing apparatus 1 is an apparatus that manufactures a laminated core 6 used in the rotor of an electric motor.

[0024] The laminated core 6 manufactured by the manufacturing apparatus 1 has a laminated structure in which multiple annular steel plates with insulating coatings are stacked. The laminated core 6 will be described with reference to FIG. 2 . The laminated core 6 includes a laminated core body 61 having an annular shape and magnet pieces 62. The laminated core body 61 has a central axial hole 611 and multiple magnet insertion holes 613 equally spaced circumferentially on an outer periphery 612 surrounding the axial hole 611. In the example shown in FIG. 2 , the laminated core body 61 has eight magnet insertion holes 613 equally spaced circumferentially on the outer periphery 612. The laminated core body 61 also has rotation positioning keys 614 that protrude radially inward from the edge of the axial hole 611. The magnet pieces 62 are made of permanent magnets and are fixed in place by resin 51 while inserted into each of the multiple magnet insertion holes 613.

[0025] Returning to FIG. 1 , the manufacturing apparatus 1 manufactures the laminated core 6 by filling each magnet insertion hole 613 of the laminated core body 61 with resin 51 and fixing magnet pieces 62 in each magnet insertion hole 613 with the resin 51. The resin 51 is a thermosetting resin such as phenolic resin, epoxy resin, unsaturated polyester resin, or polyurethane. The thermosetting resin 51 temporarily becomes fluid and molten at a thermosetting temperature of, for example, about 170°C, but retains the hardened state after hardening due to a polymerization reaction for a predetermined period of time. The manufacturing apparatus 1 fills each magnet insertion hole 613 of the laminated core body 61 with the molten resin 51 and fixes the magnet pieces 62 in each magnet insertion hole 613 by thermally hardening the filled resin 51 in each magnet insertion hole 613.

[0026] The manufacturing apparatus 1 comprises an upper frame 1A and a lower frame 1B arranged opposite each other in the vertical direction, a lifting plate 1C, guide posts 1D, and a lifting unit 1E. The upper frame 1A forms the upper surface of the manufacturing apparatus 1, and the lower frame 1B forms the lower surface of the manufacturing apparatus 1. The upper frame 1A and the lower frame 1B are connected by multiple guide posts 1D extending in the vertical direction. The lifting plate 1C has a flat plate shape and is supported by the multiple guide posts 1D so that it can move in the vertical direction. The lifting plate 1C is supported by the multiple guide posts 1D in a horizontal position. The lifting unit 1E is installed on the lower frame 1B below the lifting plate 1C. The lifting unit 1E moves the lifting plate 1C in the vertical direction along the guide posts 1D by driving a servo motor or the like.

[0027] Furthermore, the manufacturing apparatus 1 includes an upper plate 2 equipped with a plunger 21 , a lower plate 3 disposed below the upper plate 2 , and a tray 4 placed on the lower plate 3 .

[0028] The upper plate 2 has a flat plate shape and is suspended horizontally from the upper frame 1A so as to be located between the upper frame 1A and the lifting plate 1C. The upper plate 2 has a heating unit 2A that can raise the temperature of the resin 51, which is made of a thermosetting resin. The upper plate 2 is heated by the heating unit 2A to the thermosetting temperature, for example, about 170°C.

[0029] The plunger 21 has, for example, a cylindrical shape and is mounted on the upper plate 2 in a vertically extending position so as to be vertically movable. In this embodiment, one plunger 21 is mounted on the upper plate 2. The plunger 21 is connected to the push rod 22 via a holder 23. The plunger 21 moves vertically as the push rod 22 is moved vertically by a driving device (not shown) such as a servo motor. The plunger 21 also has a chamfered portion 211 on its lower tip.

[0030] The lower plate 3 has a flat shape and is fixed to the upper surface of the lift-up plate 1C in a horizontal position. The lower plate 3 moves up and down relative to the upper plate 2 as the lift-up plate 1C moves up and down. The lower plate 3 has a heating unit 3A that can heat the resin 51, which is made of a thermosetting resin, to a thermosetting temperature of, for example, about 170°C by the heating unit 3A. The lower plate 3 also has a tray guide 31 on its upper surface that guides the placement of the tray 4.

[0031] The tray 4 is fitted with a laminated core body 61 with magnet pieces 62 inserted into each magnet insertion hole 613. With the laminated core body 61 fitted, the tray 4 is placed on the lower plate 3 using the tray guide 31 as a guide. In this embodiment, the tray 4 is a transport tray that is transported to the lower plate 3 with the laminated core body 61 fitted. In this case, by transporting the tray 4 relative to the lower plate 3, the tray 4 with the laminated core body 61 fitted can be placed on the lower plate 3.

[0032] The tray 4 will be described in detail with reference to FIGS. 3 and 4 in addition to FIG. 1. The tray 4 includes a cylindrical portion 41 having a cylindrical shape and a flat flange portion 42 that protrudes radially outward from the lower end of the cylindrical portion 41. In the tray 4, the cylindrical portion 41 and the flange portion 42 may be integral or separate. In this embodiment, the cylindrical portion 41 and the flange portion 42 are provided separately and independently from each other. In this case, the flange portion 42 is detachably attached to the cylindrical portion 41 using a fastener such as a bolt.

[0033] The cylindrical portion 41 has a resin disposition hole 411 extending in the vertical direction, and is inserted into the axial hole 611 of the laminated core body 61. The resin disposition hole 411 is a hole that is circular when viewed in the vertical direction and penetrates the cylindrical portion 41 from top to bottom. A resin tablet 5, which is a molded body of resin 51, is placed in the resin disposition hole 411, and a plunger 21 that presses the resin tablet 5 is inserted from above. The cylindrical portion 41 has a first chamfered portion 412 that is chamfered on the upper hole edge of the resin disposition hole 411. This improves the ease of inserting the plunger 21 into the resin disposition hole 411 from above. The cylindrical portion 41 also has a second chamfered portion 413 that is chamfered on its upper end. This improves the ease of inserting the cylindrical portion 41 into the axial hole 611 of the laminated core body 61. Furthermore, the cylindrical portion 41 has on its outer circumferential surface a key groove 414 with which the rotation positioning key 614 of the laminated core body 61 can be engaged. The cylindrical portion 41 is inserted into the axial hole 611 of the laminated core body 61 with the rotation positioning key 614 engaged with the key groove 414.

[0034] The flange portion 42 contacts the lower plate 3 from above when the tray 4 is placed on the lower plate 3. Furthermore, the flange portion 42 contacts the outer peripheral portion 612 from below when the cylindrical portion 41 is inserted into the axial hole 611 of the laminated core body 61. The flange portion 42 has multiple resin flow grooves 421 and multiple gates 422. Each resin flow groove 421 is a groove that opens downward and is formed on the lower surface of the flange portion 42 facing the lower plate 3, and has a shape that extends radially from the lower end of the resin placement hole 411. Each resin flow groove 421 forms a flow path between the flange portion 421 and the lower plate 3, through which the fluid, molten resin 51 flows. Each gate 422 extends upward from the end of the resin flow groove 421 opposite the resin placement hole 411 and communicates with each magnet insertion hole 613. Each gate 422 forms a flow path that guides the resin 51 in each resin flow groove 421 to each magnet insertion hole 613. Each gate 422 communicates with the radially inner region of each magnet insertion hole 613 .

[0035] The laminated core body 61 is mounted on the tray 4 with the cylindrical portion 41 inserted into the axial hole 611 and the flange portion 42 in contact with the outer periphery 612 from below.

[0036] In the manufacturing apparatus 1 described above, the laminated core body 61 is mounted on a tray 4 including a cylindrical portion 41 having a resin disposing hole 411 and a flange portion 42 having a plurality of resin flow path grooves 421 and a plurality of gates 422. The tray 4 with the laminated core body 61 mounted thereon is placed on the lower plate 3, and a resin tablet 5 is placed in the resin disposing hole 411 of the tray 4.

[0037] As the lift-up plate 1C moves upward, the lower plate 3 also moves upward, causing the upper plate 2 to come into contact from above with the laminated core body 61 attached to the tray 4 on the lower plate 3. With the upper plate 2 in contact with the laminated core body 61 from above, the plunger 21 moves downward and presses the resin tablets 5 in the resin disposition holes 411 from above. This allows the resin 51 extruded from the resin disposition holes 411 to be filled into each magnet insertion hole 613 through the resin flow channel grooves 421 and gates 422 of the tray 4. At this time, each gate 422 is connected to a radially inner region of each magnet insertion hole 613. In this case, the resin 51 is filled into each magnet insertion hole 613 from the radially inner region, allowing the magnet pieces 62 to be fixed in the radially outer region of each magnet insertion hole 613.

[0038] As described above, the thermosetting resin 51 temporarily becomes fluid and molten at the thermosetting temperature. However, after hardening due to a polymerization reaction over a predetermined period of time, it retains its hardened state. By utilizing these properties of thermosetting resin, the manufacturing apparatus 1 fills each magnet insertion hole 613 of the laminated core body 61 with the molten resin 51 and thermally hardens the filled resin 51 in each magnet insertion hole 613 to fix the magnet pieces 62. During this process, the heating unit 2A of the upper plate 2 can heat the plunger 21 attached to the upper plate 2, the laminated core body 61 in contact with the upper plate 2, and the tray 4 from above to the thermosetting temperature. Furthermore, the heating unit 3A of the lower plate 3 can heat the tray 4 placed on the lower plate 3 from below to the thermosetting temperature. This allows the resin flow path from the resin placement hole 411 of the tray 4, via each resin flow groove 421 and each gate 422, to each magnet insertion hole 613 of the laminated core body 61 to be maintained at the thermosetting temperature. Therefore, the resin 51 extruded from the resin placement hole 411 by pressing the resin tablet 5 with the plunger 21 can be filled in a fluid, molten state into each magnet insertion hole 613 through each resin flow channel groove 421 and each gate 422. Furthermore, the filled resin 51 can be thermally cured in each magnet insertion hole 613 to fix the magnet pieces 62 in each magnet insertion hole 613.

[0039] The upper plate 2 may be formed with a groove for releasing gases and the like generated by the polymerization reaction when the resin 51 is thermally cured to the outside.

[0040] In the manufacturing apparatus 1 according to this embodiment, as shown in FIGS. 3 and 4 , the resin disposition hole 411 in the tray 4 extends along the central axis of the cylindrical portion 41. The multiple resin flow grooves 421 extend from the resin disposition hole 411 at approximately the same length. In this case, the resin disposition hole 411 in which the resin tablet 5 is disposed is positioned on the central axis of the cylindrical portion 41, and the resin flow grooves 421 extending radially from the resin disposition hole 411 have approximately the same length. In this case, the filling time required for the resin 51 extruded from the resin disposition hole 411 by the plunger 21 pressing the resin tablet 5 to pass through the resin flow grooves 421 and the gates 422 and fill each magnet insertion hole 613 can be made approximately the same for each magnet insertion hole 613. In other words, the resin 51 can be filled into multiple magnet insertion holes 613 at approximately the same time. Furthermore, the resin 51 filled into each magnet insertion hole 613 can be cured approximately simultaneously, thereby fixing the magnet pieces 62 in each magnet insertion hole 613.

[0041] In the manufacturing apparatus 1, after the resin 51 filled in each magnet insertion hole 613 has thermally hardened, the lower plate 3 moves downward in conjunction with the downward movement of the lifting plate 1C, causing the upper plate 2 to release contact with the laminated core body 61 mounted on the tray 4 on the lower plate 3.

[0042] When the tray 4 is placed on the lower plate 3 and the upper plate 2 is in contact with the laminated core body 61 attached to the tray 4, the resin 51 filled in each magnet insertion hole 613 of the laminated core body 61 contacts the upper plate 2, and the resin 51 in each resin flow channel 421 of the tray 4 contacts the lower plate 3. In this case, the contact area of ​​the resin 51 with the upper plate 2 and the lower plate 3 is larger on the lower plate 3 than on the upper plate 2. Therefore, when the resin 51 filled in each magnet insertion hole 613 is thermally cured and the upper plate 2 is released from contact with the laminated core body 61, the tray 4 with the laminated core body 61 attached remains placed on the lower plate 3, and the resin 51 hardened in each magnet insertion hole 613 is separated from the upper plate 2. This makes it possible to prevent hardened resin 51 from remaining on the upper plate 2.

[0043] Furthermore, after the upper plate 2 is released from contact with the laminated core body 61, the laminated core body 61 is separated from the tray 4. When the laminated core body 61 is separated from the tray 4, the resin 51 hardened in each magnet insertion hole 613 is broken at the gates 422 of the tray 4. In this case, the hardened resin 51 remains in each resin flow path groove 421 and each gate 422 of the tray 4, so the hardened resin 51 can be removed from the tray 4. At this time, because the cylindrical portion 41 and the flange portion 42 are provided separately and independently from each other in the tray 4, the flange portion 42 can be removed from the cylindrical portion 41. This allows the hardened resin 51 remaining in each resin flow path groove 421 and each gate 422 formed in the flange portion 42 to be removed efficiently.

[0044] Furthermore, the flange 42 may have a laminated structure in which a plate body in which each resin flow path groove 421 is formed and a plate body in which each gate 422 is formed are laminated together. In this case, each resin flow path groove 421 and each gate 422 can be separated to remove the cured resin 51.

[0045] Furthermore, each resin flow path groove 421 that opens downward in the flange portion 42 may have a groove shape in which the groove width increases downward. In this case, the cured resin 51 remaining in each resin flow path groove 421 can be efficiently removed.

[0046] In the manufacturing apparatus 1 configured as described above, the tray 4 is provided with the resin placement hole 411 in which the resin tablet 5 is placed, and the resin flow grooves 421 and gates 422 that connect the resin placement hole 411 and each magnet insertion hole 613. In this case, the tray 4 is the only object that requires maintenance to prevent wear caused by the resin 51 filling each magnet insertion hole 613 flowing. Furthermore, after the resin 51 is filled into each magnet insertion hole 613, the resin 51 remains only on the tray 4. Therefore, maintenance and the work of removing residual resin need only be performed on the tray 4. This allows the maintenance and the work of removing residual resin to be performed efficiently, making it possible to efficiently manufacture the laminated core 6.

[0047] The cylindrical portion 41 of the tray 4 may have a structure in which the central portion in which the resin disposing hole 411 is formed is detachable. In this case, the ease of maintenance of the central portion in which the resin disposing hole 411, in which the plunger 21 slides, is improved.

[0048] [About the manufacturing method of laminated cores] The manufacturing method of the laminated core 6 can be carried out using the above-described manufacturing apparatus 1. The manufacturing method of the laminated core 6 will be described with reference to the flowchart of Fig. 5 and Figs. 6 to 10 which show schematic diagrams of the processing of each step. In the manufacturing method using the manufacturing apparatus 1, the laminated core 6 is manufactured by performing each processing step from step S1 to step S10.

[0049] In step S1, a tray 4 is prepared, which includes a cylindrical portion 41 having a resin placement hole 411 and a flange portion 42 having a plurality of resin flow path grooves 421 and a plurality of gates 422. In step S2, the cylindrical portion 41 is inserted into the axial hole 611, and the flange portion 42 is brought into contact with the outer circumferential portion 612 from below, thereby mounting the laminated core body 61 on the tray 4. Thereafter, magnet pieces 62 are inserted into the plurality of magnet insertion holes 613.

[0050] Next, in step S3, the tray 4 on which the laminated core body 61 is mounted is placed on the lower plate 3. In step S4, the resin tablet 5, which is a molded body of the resin 51, is placed in the resin placement hole 411.

[0051] Next, in step S5, the lower plate 3 is moved upward in conjunction with the upward movement of the lift-up plate 1C, and is stopped just before the upper plate 2 comes into contact with the laminated core body 61. In this state, the plunger 21 is lowered and inserted from above into the resin disposing hole 411. This positions the center of the resin disposing hole 411 on the central axis of the plunger 21, allowing the tray 4 to be positioned with precision relative to the plunger 21.

[0052] Next, in step S6, the lower plate 3 is moved upward in conjunction with the upward movement of the lift-up plate 1C, so that the upper plate 2 comes into contact with the laminated core body 61 mounted on the tray 4 on the lower plate 3 from above.

[0053] Next, in step S7, the plunger 21 inserted from above into the resin disposition hole 411 is lowered to press the resin tablet 5. This allows the resin 51 extruded from the resin disposition hole 411 to be filled, in a fluid, molten state, into each of the magnet insertion holes 613 through the resin flow channel grooves 421 and gates 422 of the tray 4. Furthermore, the filled resin 51 is thermally cured in each of the magnet insertion holes 613, thereby fixing the magnet pieces 62 in each of the magnet insertion holes 613.

[0054] After the resin 51 filled in each magnet insertion hole 613 has thermally hardened, in step S8, the plunger 21 is raised until it comes out of the resin arrangement hole 411. Then, in step S9, the lower plate 3 is moved downward in conjunction with the downward movement of the lift-up plate 1C, thereby releasing the upper plate 2 from contact with the laminated core body 61 attached to the tray 4 on the lower plate 3. In this case, the tray 4 with the laminated core body 61 attached remains placed on the lower plate 3, and the hardened resin 51 in each magnet insertion hole 613 is separated from the upper plate 2. This makes it possible to prevent hardened resin 51 from remaining on the upper plate 2.

[0055] The tray 4 with the laminated core body 61 attached is moved from the lower plate 3 to another work table. Then, in step S10, the laminated core body 61 is separated from the tray 4. This allows the laminated core 6 to be obtained, with the magnet pieces 62 fixed in each magnet insertion hole 613 of the laminated core body 61.

[0056] When the laminated core body 61 is separated from the tray 4, the resin 51 hardened in each magnet insertion hole 613 breaks at the gates 422 of the tray 4. In this case, the hardened resin 51 remains in each resin flow path groove 421 and each gate 422 of the tray 4, so the hardened resin 51 can be removed from the tray 4. At this time, by removing the flange portion 42 from the cylindrical portion 41, the hardened resin 51 remaining in each resin flow path groove 421 and each gate 422 formed in the flange portion 42 can be efficiently removed.

[0057] [Modified embodiment] Although the embodiment of the present invention has been described above, the present invention is not limited to this and may take the following modified embodiments, for example.

[0058] In the above embodiment, the manufacturing apparatus 1 is described as including a tray 4 in which one plunger 21 is mounted on the upper plate 2 and a resin disposition hole 411 is formed along the central axis of the cylindrical portion 41, but is not limited to such a configuration. As shown in Fig. 11, the manufacturing apparatus 1 may have a structure in which a plurality of plungers 21 are mounted on the upper plate 2 and the tray 4 has a cylindrical portion 41 in which a plurality of resin disposition holes 411, the same number as the plungers 21, are formed.

[0059] In this case, in the flange portion 42 of the tray 4, a plurality of resin flow path grooves 421 extend radially from the lower ends of the plurality of resin disposition holes 411, and a gate 422 extends upward from the tip of each resin flow path groove 421. In this case, it is preferable that the resin flow path grooves 421 extending from each of the plurality of resin disposition holes 411 have approximately the same length.

[0060] In the manufacturing apparatus 1 according to a modified embodiment of the above configuration, while the upper plate 2 is in contact with the laminated core body 61 from above, each plunger 21 descends and presses the resin tablet 5 in each resin placement hole 411 from above, so that the resin 51 extruded from each resin placement hole 411 can be filled into each magnet insertion hole 613 through each resin flow path groove 421 and each gate 422. [Explanation of symbols]

[0061] 1 Manufacturing equipment 2 Upper plate 2A heating section 21 Plunger 3 Lower plate 3A heating section 4 trays 41 Cylindrical part 411 Resin placement hole 42 Brim 421 Resin flow channel groove Gate 422 5 resin tablets 51 Resin 6 Laminated core 61 Laminated core body 611 Shaft hole 612 Outer periphery 613 Magnet insertion hole 62 Magnet piece

Claims

1. A laminated core manufacturing device including a laminated core body having an axial hole in the center and a plurality of magnet insertion holes provided at intervals in the circumferential direction on an outer periphery surrounding the axial hole, and magnet pieces inserted into each of the plurality of magnet insertion holes and fixed with resin, an upper plate equipped with a plunger that can move up and down; a lower plate disposed below the upper plate; a tray on which the laminated core body having the magnet pieces inserted into the plurality of magnet insertion holes is mounted and which is placed on the lower plate; the upper plate contacts from above the laminated core body attached to the tray on the lower plate, The tray is a cylindrical portion that is inserted into the axial hole of the laminated core body, the cylindrical portion having a resin placement hole that extends in the vertical direction, in which a resin tablet that is a molded body of the resin is placed and into which the plunger that presses the resin tablet is inserted; A laminated core manufacturing device comprising: a flange portion that protrudes radially outward from the lower end of the cylindrical portion, contacts the lower plate from above, and contacts the outer periphery of the laminated core body from below, the flange portion having a plurality of resin flow path grooves extending radially from the resin placement hole on its lower surface facing the lower plate, and a plurality of gates that extend upward from the tips of the plurality of resin flow path grooves and communicate with each of the plurality of magnet insertion holes.

2. the resin disposition hole extends along a central axis of the cylindrical portion, The laminated core manufacturing device according to claim 1 , wherein the plurality of resin flow grooves extend from the resin placement hole at substantially the same length.

3. 2. The laminated core manufacturing device according to claim 1, wherein the tray is a carrier tray that is carried to the lower plate with the laminated core body attached thereto.

4. the resin is a thermosetting resin, 2. The laminated core manufacturing device according to claim 1, wherein the upper plate and the lower plate have heating portions capable of raising the temperature to a temperature at which the thermosetting resin is thermally cured.

5. A method for manufacturing a laminated core including a laminated core body having an axial hole in the center and a plurality of magnet insertion holes provided at intervals in the circumferential direction on an outer periphery surrounding the axial hole, and magnet pieces inserted into each of the plurality of magnet insertion holes and fixed with resin, preparing a tray including a cylindrical portion having a resin placement hole extending in the vertical direction and a flange portion protruding radially outward from a lower end of the cylindrical portion, the flange portion having a plurality of resin flow path grooves extending radially from the resin placement hole and a plurality of gates extending upward from tips of the plurality of resin flow path grooves; a step of inserting the cylindrical portion into the axial hole and bringing the flange portion into contact with the outer circumferential portion from below to mount the laminated core body on the tray, and then inserting the magnet pieces into the plurality of magnet insertion holes; placing the tray with the laminated core body attached on a lower plate disposed below an upper plate equipped with a plunger that can move up and down, and placing a resin tablet, which is a molded body of the resin, in the resin placement hole; A method for manufacturing a laminated core, comprising the steps of: inserting the plunger into the resin placement hole, bringing the upper plate into contact with the laminated core body mounted on the tray on the lower plate from above, and then lowering the plunger to press the resin tablet, thereby filling the resin extruded from the resin placement hole into the multiple magnet insertion holes through the multiple resin flow channel grooves and the multiple gates.

6. the resin is a thermosetting resin, 6. The method for manufacturing a laminated core according to claim 5, further comprising the steps of: raising the plunger until the resin filled in the plurality of magnet insertion holes is thermally hardened and then emerges from the resin placement hole; releasing the upper plate from contact with the laminated core body; and then separating the laminated core body from the tray.

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