Manufacturing method of motor, and air conditioner having motor

Abstract

To simplify weight adjustment of a rotor and suppress an increase in the cost of a motor.SOLUTION: In a manufacturing method of a motor, molds 81 and 82 are prepared. A resin material 67 including a magnetic body 68 is injected into a mold to mold a test plastic magnet 63A. A test rotor 52A is manufactured by fixing the test plastic magnet 63A and a test shaft 61A with a test resin mold 64A. An imbalance in a weight of the test rotor 52A is measured, and a portion of the test plastic magnet 63A where weight adjustment is required is specified. The shape of a portion of each of the molds 81 and 82 corresponding to the portion is deformed. The resin material 67 including the magnetic body 68 is injected into the molds 81 and 82 whose shapes have been deformed to manufacture a product plastic magnet 63B. A product rotor 52B is manufactured by fixing a product shaft 61B having the same shape as the test shaft and the product plastic magnet 63B with a product resin mold 64B having the same material as the test resin mold 64A.SELECTED DRAWING: Figure 21

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a motor, a motor manufactured by the manufacturing method, and an air conditioning apparatus having a motor. [Background technology]

[0002] The indoor unit of an air conditioner disclosed in Patent Document 1 (JP 2005-069580 A) has an indoor fan motor that rotates a crossflow fan. The rotor of the indoor fan motor has a plastic magnet. The plastic magnet is made of, for example, a resin material mixed with magnetic powder, and the magnetic powder forms eight magnetic poles on the outer edge of the rotor. Summary of the Invention [Problem to be solved by the invention]

[0003] The weight balance of the rotor's plastic magnet is affected by the flow of resin injected into the mold during the production of the plastic magnet. If there is an imbalance in the distribution of resin, the manufactured plastic magnet will need to have its weight adjusted. Weight adjustment requires labor and equipment for measurement and processing, which can increase the cost of the motor. Therefore, a method is needed to easily adjust the weight of plastic magnets. [Means for solving the problem]

[0004] The manufacturing method of the first aspect is for manufacturing a product rotor. In the manufacturing method, a mold is prepared. A resin material containing a magnetic substance is injected into the mold to form a circular test plastic magnet. A test rotor is manufactured by fixing the test plastic magnet and a test shaft in the test resin mold. The weight imbalance of the test rotor is measured. Based on the measured imbalance, areas of the test plastic magnet that require weight adjustment are identified. The shape of the part of the mold that corresponds to the area that requires weight adjustment is deformed. A resin material containing a magnetic substance is injected into the mold after the shape has been deformed to form a product plastic magnet. The product rotor is manufactured by fixing a product shaft that has the same shape as the test shaft and the product plastic magnet in a product resin mold made of the same material as the test resin mold.

[0005] According to this manufacturing method, the weight imbalance measured on the test rotor is eliminated in the production rotor by adjusting the weight of the production plastic magnet using the deformed mold, thereby enabling the motor to perform smooth rotational operation.

[0006] The manufacturing method of the second aspect is the manufacturing method of the first aspect, in which the mold has a plurality of mold convex portions and a plurality of mold concave portions. In molding the test plastic magnet, a plurality of test magnet concave portions corresponding to the plurality of mold convex portions and a plurality of test magnet convex portions corresponding to the plurality of mold concave portions are formed on the end face of the test plastic magnet. In particular, the location requiring weight adjustment is one of the plurality of test magnet concave portions to be filled. The shape of that portion of the mold is deformed by cutting one of the mold convex portions corresponding to the one to be filled.

[0007] This manufacturing method eliminates the weight imbalance measured on the test rotor by eliminating the magnet recesses that may have been formed in the finished plastic, allowing the motor to rotate smoothly.

[0008] The manufacturing method of the third aspect is the manufacturing method of the second aspect, wherein, in molding the product plastic magnet, a plurality of product magnet recesses corresponding to the plurality of mold protrusions and a plurality of product magnet protrusions corresponding to the plurality of mold recesses are formed on the end face of the product plastic magnet. When manufacturing the product rotor, the product resin mold covers the plurality of product magnet recesses and the plurality of product magnet protrusions of the product plastic magnet.

[0009] According to this manufacturing method, the resin mold covers the magnet recesses and magnet protrusions, thereby reducing the risk of the magnet recesses and magnet protrusions being subjected to air resistance.

[0010] A manufacturing method according to a fourth aspect is the manufacturing method according to the third aspect, in which, when manufacturing the finished rotor, a metal disk is attached to the finished shaft, thereby fixing the metal disk to the finished resin mold.

[0011] According to this manufacturing method, the rotor has a metal disk, and therefore the resin mold can firmly fix the shaft and the metal disk.

[0012] The manufacturing method of the fifth aspect is a manufacturing method of any one of the first aspect to the fourth aspect, in which the multiple test magnet recesses and multiple test magnet protrusions of the test plastic magnet are arranged axially symmetrically with respect to the axis of the test plastic magnet.

[0013] According to this manufacturing method, the test plastic magnet has a plurality of magnet recesses and magnet protrusions arranged axially symmetrically, which is convenient for measuring the weight imbalance in the test rotor.

[0014] A manufacturing method according to a sixth aspect is the manufacturing method according to any one of the first aspect to the fifth aspect, wherein the plurality of mold recesses are provided with injection gates for injecting a resin material.

[0015] According to this manufacturing method, the injection gate is provided in a mold cavity that is not subject to cutting, and therefore the presence of the injection gate does not interfere with cutting of the mold.

[0016] The manufacturing method of the seventh aspect is the manufacturing method of the sixth aspect, in which the number of injection gates is the same as the number of magnetic poles of the finished plastic magnet, or half the number of magnetic poles.

[0017] This manufacturing method allows the number of magnetic poles to match the number of injection gates, making it possible to adjust the weight of the plastic magnet based on the arrangement of the magnetic poles.

[0018] The manufacturing method according to an eighth aspect is the manufacturing method according to the third aspect, wherein the shape of the plurality of product magnet protrusions of the product plastic magnet includes one of a rectangle, a trapezoid, a cylinder, and a cone.

[0019] According to this manufacturing method, the shape of the magnet protrusions is a rectangle, trapezoid, cylinder, or cone, so that the disappearance of the magnet protrusions is easily visible.

[0020] A manufacturing method according to a ninth aspect is the manufacturing method according to any one of the first to eighth aspects, in which the specific gravity of the product resin mold is lighter than the specific gravity of the product plastic magnet.

[0021] According to this manufacturing method, the specific gravity of the resin mold is lighter than that of the plastic magnet, so the resin mold can be expected to be durable, in other words, less likely to break.

[0022] A motor according to a tenth aspect includes a product rotor and a stator. The product rotor is the product rotor according to any one of the first to ninth aspects.

[0023] This configuration eliminates the weight imbalance measured on the test rotor in the production rotor, thereby allowing the motor to rotate smoothly.

[0024] A motor according to an eleventh aspect is the motor according to the tenth aspect, in which the product rotor is an outer rotor having an outer diameter larger than that of the stator.

[0025] According to this manufacturing method, the rotor is an outer rotor and has a large outer diameter, which makes it possible to reduce vibrations of the outer rotor, which tends to require better weight balance.

[0026] An air conditioner according to a twelfth aspect includes a motor and a crossflow fan. The motor is manufactured by the manufacturing method according to the tenth aspect. The crossflow fan is fixed to a product rotor of the motor.

[0027] According to this manufacturing method, the motor has a rotor with a well-balanced weight, which reduces abnormal noise and vibrations in the air conditioner.

[0028] A motor according to a thirteenth aspect comprises a product rotor. The product rotor has a product shaft, a product plastic magnet, and a product resin mold. The product plastic magnet is annular. The product resin mold fixes the product shaft and the product plastic magnet. The shape of the product plastic magnet is not axially symmetrical with respect to the axis of the product plastic magnet.

[0029] A motor according to a fourteenth aspect is the motor according to the thirteenth aspect, wherein a plurality of product magnet recesses and a plurality of product magnet protrusions are formed on the end face of the product plastic magnet. A product resin mold covers the plurality of product magnet recesses and the plurality of product magnet protrusions. Of the plurality of central angles formed by two adjacent product magnet recesses at the axis of the product plastic magnet, all but one central angle are the same.

[0030] With this configuration, some of the magnet recesses in the finished rotor are not axially symmetrical, which allows for correction of the rotor's weight balance. [Brief explanation of the drawings]

[0031] [Figure 1] 1 is a schematic diagram showing the appearance of an air conditioning apparatus 100 according to an embodiment of the present disclosure. [Figure 2] 1 is a schematic diagram showing the configuration of an air conditioning device 100. FIG. [Figure 3] 2 is a cross-sectional view of the indoor fan 24 and the indoor fan motor 241. FIG. [Figure 4] FIG. 2 is a cross-sectional view of a rotor 52. [Figure 5] FIG. [Figure 6] FIG. 2 is a perspective view of a disk 62 that constitutes the rotor 52. [Figure 7] FIG. 2 is a perspective view of a plastic magnet 63 that constitutes the rotor 52. [Figure 8] FIG. 2 is a schematic diagram showing a first step in manufacturing a test rotor 52A. [Figure 9] 10 is a schematic diagram showing a second step of manufacturing the test rotor 52A. FIG. [Figure 10] FIG. 10 is a schematic diagram showing a third step of manufacturing the test rotor 52A. [Figure 11] FIG. 10 is a schematic diagram showing a fourth step in manufacturing the test rotor 52A. [Figure 12] FIG. 10 is a schematic diagram showing a fifth step in manufacturing the test rotor 52A. [Figure 13] FIG. 10 is a plan view of a test plastic magnet 63A. [Figure 14] FIG. 10 is a schematic diagram showing a sixth step of manufacturing the test rotor 52A. [Figure 15] FIG. 10 is a schematic diagram showing a seventh step of manufacturing the test rotor 52A. [Figure 16] FIG. 10 is a schematic diagram showing an eighth step of manufacturing the test rotor 52A. [Figure 17] FIG. 10 is a schematic diagram showing a ninth step of manufacturing the test rotor 52A. [Figure 18] FIG. 10 is a schematic diagram showing a tenth step of manufacturing the test rotor 52A. [Figure 19] FIG. 10 is a schematic diagram showing a first step in manufacturing a finished rotor 52B. [Figure 20] 10 is a schematic diagram showing a second step for manufacturing the finished rotor 52B. FIG. [Figure 21] 10 is a schematic diagram showing a third step for manufacturing the finished rotor 52B. FIG. [Figure 22] 10 is a schematic diagram showing a fourth step for manufacturing the finished rotor 52B. FIG. [Figure 23] 10 is a schematic diagram showing a fifth step for manufacturing the finished rotor 52B. FIG. [Figure 24] 10 is a schematic diagram showing a sixth step for manufacturing the finished rotor 52B. FIG. [Figure 25] 10 is a schematic diagram showing a seventh step for manufacturing the finished rotor 52B. FIG. [Figure 26] FIG. 10 is a plan view of the product plastic magnet 63B. [Figure 27] FIG. 10 is a plan view of the product plastic magnet 63B. [Figure 28] 10 is a schematic diagram showing an eighth step of manufacturing the finished rotor 52B. FIG. [Figure 29] FIG. 10 is a schematic diagram showing a ninth step for manufacturing the finished rotor 52B. [Figure 30] FIG. 10 is a schematic diagram showing a tenth step of manufacturing the finished rotor 52B. DETAILED DESCRIPTION OF THE INVENTION

[0032] <Embodiment> (1) Overall structure 1 shows the exterior of an air conditioning apparatus 100 according to an embodiment of the present disclosure. The air conditioning apparatus 100 has an outdoor unit 10 that functions as a heat source, an indoor unit 20 that provides conditioned air to a user, and a connecting pipe 30 that connects the outdoor unit 10 and the indoor unit 20.

[0033] (2) Detailed configuration 2 shows the configuration of the air conditioner 100. The air conditioner 100 has a refrigerant circuit RC through which a refrigerant R circulates.

[0034] (2-1) Outdoor unit 10 The outdoor unit 10 is a device for obtaining hot heat or cold heat from outdoor air, which is a heat source. The outdoor unit 10 has components related to the refrigerant circuit RC, such as a compressor 11, a four-way switching valve 12, an outdoor heat exchanger 13, an outdoor fan 14, an outdoor expansion valve 15, an accumulator 16, a liquid shut-off valve 17, and a gas shut-off valve 18. The outdoor unit 10 also has an outdoor unit control unit 19 as a component related to the electrical system.

[0035] The compressor 11 has a compressor motor 111, a suction pipe 11a, and a discharge pipe 11b. The compressor 11 compresses the low-pressure gaseous refrigerant R sucked through the suction pipe 11a by the power of the compressor motor 111, and discharges the high-pressure gaseous refrigerant R from the discharge pipe 11b.

[0036] The four-way switching valve 12 switches the connection of the refrigerant circuit RC depending on whether the operation is cooling or heating. During cooling operation, the four-way switching valve 12 forms the connection shown by the solid line in Figure 2. During heating operation, the four-way switching valve 12 forms the connection shown by the dashed line in Figure 2.

[0037] The outdoor heat exchanger 13 takes in cold or hot heat from the outdoor air into the refrigerant R. The outdoor heat exchanger 13 functions as a condenser or a heat radiator during cooling operation, and as an evaporator or a heat absorber during heating operation.

[0038] The outdoor fan 14 moves the outdoor air so that the outdoor air passes through the outdoor heat exchanger 13, thereby promoting heat exchange between the outdoor air and the refrigerant R. The outdoor fan 14 is driven by the power of an outdoor fan motor 141.

[0039] The outdoor expansion valve 15 is a device for reducing the pressure of the refrigerant R. The outdoor expansion valve 15 is a valve whose opening is adjusted by, for example, electrical control.

[0040] The accumulator 16 separates and stores the liquid refrigerant component from the circulating refrigerant R, and allows the gas refrigerant component to pass through.

[0041] The liquid shutoff valve 17 and the gas shutoff valve 18 are valves that are manually opened and closed by an installer of the outdoor unit 10. The liquid shutoff valve 17 opens and closes the flow path of the refrigerant R in a liquid state or a two-phase gas-liquid state. The gas shutoff valve 18 opens and closes the flow path of the refrigerant R in a gas state.

[0042] The outdoor unit control unit 19 acquires signals from various sensors (not shown) and further controls the compressor motor 111, the outdoor fan motor 141, the outdoor expansion valve 15, and the like.

[0043] (2-2) Indoor unit 20 The indoor unit 20 is a device for providing a user with hot or cold heat in the form of conditioned air. The indoor unit 20 has an indoor heat exchanger 23 and an indoor fan 24 as components related to the refrigerant circuit RC. Furthermore, the indoor unit 20 has an indoor unit control unit 29 as a component related to the electrical system.

[0044] The indoor heat exchanger 23 transfers the cold or hot heat of the refrigerant R to the indoor air. The indoor heat exchanger 23 functions as an evaporator or a heat absorber during cooling operation. The outdoor heat exchanger 13 functions as a condenser or a radiator during heating operation.

[0045] The indoor fan 24 moves the indoor air so that the indoor air passes through the indoor heat exchanger 23, thereby promoting heat exchange between the indoor air and the refrigerant R. The indoor fan 24 is driven by the power of an indoor fan motor 241.

[0046] The indoor unit control unit 29 acquires signals from various sensors (not shown). Furthermore, the indoor unit control unit 29 controls the indoor fan motor 241 and the like. In addition, the indoor unit control unit 29 transmits and receives data, commands, status, and other signals to and from the outdoor unit control unit 19 via communication.

[0047] (2-3) Connecting pipe 30 Arranged within the connecting pipe 30 are liquid refrigerant piping 31, gas refrigerant piping 32, and electrical communication lines 35. The liquid refrigerant piping 31 allows refrigerant R in a liquid state or a two-phase gas-liquid state to move between the outdoor unit 10 and the indoor unit 20. The liquid refrigerant piping 31 allows refrigerant R in a gas state to move between the outdoor unit 10 and the indoor unit 20. The electrical communication lines 35 allow signal transmission between the outdoor unit control unit 19 and the indoor unit control unit 29, thereby constituting the air conditioner control unit 9.

[0048] (3) Detailed configuration of the indoor fan 24 and the indoor fan motor 241 FIG. 3 shows the indoor fan 24 and the indoor fan motor 241.

[0049] (3-1) Indoor fan 24 The indoor fan 24 is a cross-flow fan and is fixed to a rotor 52 of an indoor fan motor 241.

[0050] (3-2) Indoor fan motor 241 The indoor fan motor 241 includes a stator 51 , a rotor 52 , and a bearing 53 .

[0051] (3-2-1) Stator 51 The stator 51 has an iron core 71 and a coil 72. When a current flows through the coil 72, the coil 72 generates a magnetic field.

[0052] (3-2-2) Rotor 52 4 rotates by interacting with the magnetic field generated by the coil 72 of the stator 51. The rotor 52 is an outer rotor and has a larger outer diameter than the stator 51, and furthermore, has a larger inner diameter than the outer diameter of the stator 51. The rotor 52 has a shaft 61, a disk 62, a plastic magnet 63, and a resin mold 64.

[0053] (3-2-2-1) Shaft 61 5, the shaft 61 defines an axis 631 of the rotor 52. The rotor 52 rotates around the axis 631.

[0054] (3-2-2-2) Disk 62 5 is for firmly fixing the shaft 61 to the resin mold 64. The disk 62 is made of metal. The entire disk 62 is disposed inside the resin mold 64.

[0055] 6, the disk 62 has a center hole 621 and a plurality of through holes 622. The center hole 621 is for fixing the shaft 61 to the disk 62 with the shaft 61 passing through it. The inner diameter of the center hole 621 does not have a clearance with respect to the outer diameter of the shaft 61. The shaft 61 and the disk 62 are fixed by press-fitting the shaft 61 into the center hole 621.

[0056] The plurality of through holes 622 are for allowing a resin material to pass through when forming the resin mold 64. The plurality of through holes 622 are formed separately from the center hole 621.

[0057] (3-2-2-3) Plastic Magnet 63 7 interacts with the magnetic field generated by the coil 72 to generate a rotational force for the rotor 52. The plastic magnet 63 has a ring shape centered on the axis 631 of the rotor 52. In other words, the axis 631 of the rotor 52 is the same as the axis 631 of the plastic magnet 63. The plastic magnet 63 has a first end face 632 and a second end face 633 that are spaced apart in the direction in which the axis 631 extends. At least the first end face 632 has a magnet protrusion 636 and a magnet recess 635.

[0058] The plastic magnet 63 is made of a resin material containing a magnetic substance, such as rare earth magnet powder or ferrite magnet powder, and the resin material is, for example, a thermosetting resin or a thermoplastic resin.

[0059] Examples of thermosetting resins include epoxy resins, bismaleimide resins, phenolic resins, urea resins, melamine resins, alkyd resins, unsaturated polyester resins, DAP resins, and polyurethane resins.

[0060] Examples of thermoplastic resins include vinyl polymers (polyethylene, polypropylene, polyvinyl chloride, polystyrene, ABS resin, AS resin, polymethacrylic acid, polymethacrylic acid ester, polyacrylic acid, polyacrylic acid ester, polyvinylidene chloride, etc.), polyamides (Nylon 6 (registered trademark), Nylon 66 (registered trademark), aromatic polyamides, etc.), polyesters (polyethylene terephthalate, polybutylene terephthalate, etc.), fluororesins (PTFE, FEP, PFA, etc.), polyacetal, polycarbonate, modified polyphenylene ether, polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyetherimide, polyetheretherketone, polyetherketone, liquid crystalline polyester, and copolymers (random, block, graft, or alternating copolymers, etc.) in which the skeletons of these resins are arbitrarily combined.

[0061] (3-2-2-4) Resin mold 64 5 secures at least the disk 62 and the plastic magnet 63 to each other. The resin mold 64 is made of a thermosetting resin or a thermoplastic resin. The resin mold 64 contacts the first end surface 632 of the plastic magnet 63. The specific gravity of the resin mold 64 is lighter than that of the plastic magnet 63.

[0062] (3-2-3) Bearing 53 3 is for rotatably supporting the shaft 61. The bearing 53 is installed in the stator 51. The bearing 53 is, for example, a sliding bearing or a rolling bearing.

[0063] (4) Manufacturing method of rotor 52 The manufacturing of the rotor 52 includes a molding process for the plastic magnets 63. As mentioned above, the plastic magnets 63 are formed from a resin material containing magnetic material. This resin material has fluidity during the molding stage. Between the time the resin material starts to be injected into the cavity of the mold and the time the cavity is completely filled, the resin material has already begun to solidify at the bottom of the cavity. This tends to result in uneven density of the plastic magnets 63. In addition, variations in mold dimensions and the viscosity of the resin material passing through the injection passage can sometimes cause uneven filling of the resin material. This results in weight unevenness in the plastic magnets 63.

[0064] The degree of weight imbalance in the plastic magnet 63 is reproducible. In other words, when a large number of plastic magnets 63 are molded, they may all have the same degree of weight imbalance. To eliminate such weight imbalance, the rotor manufacturing method includes a first step of manufacturing a test rotor 52A, a second step of measuring the weight imbalance of the test rotor 52A, and a third step of manufacturing a weight-adjusted product rotor 52B. In the first step, a mold is used to mold the test plastic magnet 63A, which is then used to manufacture the test rotor 52A. In the second step, measurements are taken of the test rotor 52A to verify the performance of the mold. In the third step, a mold is modified based on the measurement results to mold the product plastic magnet 63B, which is then used to manufacture the product rotor 52B. Each step is described in detail below.

[0065] (4-1) First Phase: Manufacturing of Test Rotor 52A The first to tenth steps of manufacturing the test rotor 52A will be described.

[0066] (4-1-1) Fixing the test disc 62A In a first step, as shown in FIG. 8, the test shaft 61A is press-fitted into the central hole 621 of the test disc 62A, thereby fixing the test shaft 61A and the test disc 62A to each other.

[0067] (4-1-2) Molding of test plastic magnet 63A In the second step, as shown in FIG. 9, a first mold 81 and a second mold 82 are prepared for manufacturing the test plastic magnet 63A. This figure shows a schematic cross section of the first mold 81 and the second mold 82. The second mold 82 is provided with a resin inlet 83 and multiple injection gates 84. The resin inlet 83 is for introducing resin material from outside the second mold 82. The injection gate 84 is for injecting the resin material into a cavity 85 (FIG. 10) formed by the first mold 81 and the second mold 82. The resin inlet 83 and the injection gate 84 are connected by a passage called a runner. The second mold 82 has multiple mold protrusions 821 and multiple mold recesses 822 formed in areas corresponding to the circumference of the test plastic magnet 63A. Each of the multiple mold protrusions 821 is formed to protrude toward the cavity 85 formed by the first mold 81 and the second mold 82. Each of the plurality of mold recesses 822 is formed between two adjacent mold protrusions 821. Each of the plurality of injection gates 84 is provided in one of the plurality of mold recesses 822.

[0068] A mark generating portion 86 is provided at a specific location on the first mold 81 or the second mold 82. For example, as shown in Fig. 9, the mark generating portion 86 may be provided as a protrusion at the bottom of the second mold 82, and may be used to imprint an inscription on the test plastic magnet 63A. Furthermore, the mark generating portion 86 is not limited to imprinting a simple figure, and may also be used to inscribe letters indicating an identification number of the cavity 85 or the like on the test plastic magnet 63A.

[0069] In the third step, as shown in FIG. 10, the prepared first mold 81 and second mold 82 are combined to form a cavity 85.

[0070] In the fourth step, as shown in FIG. 11 , a resin material 67 for forming a test plastic magnet 63A is injected through a resin inlet 83. The resin material 67 is injected through an injection gate 84 into a cavity 85. A plurality of magnets 89 are installed in one or both of a first mold 81 and a second mold 82. Each magnet 89 is installed at a position corresponding to one of the injection gates 84. A magnetic substance 68 is mixed into the resin material 67. The resin material 67 is solidified while being exposed to a magnetic field generated by the magnets 89. Before the resin material 67 is completely solidified, the magnetic substance 68 is aligned or magnetized by the action of the magnetic field.

[0071] In the fifth step, as shown in FIG. 12, the first mold 81 and the second mold 82 are removed. The solidified resin material 67 forms the test plastic magnet 63A. A plurality of test magnet recesses 635A and a plurality of test magnet protrusions 636A are formed on the first end surface 632 of the test plastic magnet 63A. Each test magnet recess 635A corresponds to one of the plurality of mold protrusions 821. Each test magnet protrusion 636A corresponds to one of the plurality of mold recesses 822. The mold recesses 822 are shaped so that the test magnet protrusions 636A are rectangular, trapezoidal, cylindrical, or conical. A reference position mark 639 is formed on the second end surface 633 of the test plastic magnet 63A by the mark generator 86.

[0072] 13, a plurality of test magnet recesses 635A and test magnet protrusions 636A are arranged at equal intervals along the circumference of a first end surface 632 of the test plastic magnet 63A. The plurality of test magnet recesses 635A and the plurality of test magnet protrusions 636A of the test plastic magnet 63A are arranged axially symmetrically with respect to the axis 631 of the test plastic magnet 63A, and a magnetic pole 637 is formed at the location of each test magnet protrusion 636A. The magnetic poles 637 are formed by magnetic material 68 that is aligned or magnetized by the magnetic field of the magnet 89.

[0073] (4-1-3) Molding of test resin mold 64A In the sixth step, as shown in Fig. 14, a third mold 91 for molding the test resin mold 64A is prepared. The third mold 91 has a first recess 911 and a second recess 912. The first recess 911 functions as a jig for supporting the test shaft 61A. The second recess 912 functions as a jig for supporting the test plastic magnet 63A.

[0074] 15, the test disk 62A and the fixed test shaft 61A are placed in the first recess 911. In addition, the test plastic magnet 63A is placed in the second recess 912.

[0075] In an eighth step, as shown in Fig. 16, a fourth mold 92 is fitted into the third mold 91. The fourth mold 92 has a third recess 921. The third recess 921 functions as a jig for supporting the test shaft 61A. A cavity 93 is formed between the third mold 91 and the fourth mold 92 that fit together.

[0076] 17, in a ninth step, a resin material 69 for forming a test resin mold 64A is injected or poured into the cavity 85. The resin material 69 is solidified.

[0077] In the tenth step, as shown in FIG. 18, the third mold 91 and the fourth mold 92 are removed. The solidified resin material 69 forms a test resin mold 64A. The test resin mold 64A secures the test shaft 61A, the test disc 62A, and the test plastic magnet 63A together. This completes the test rotor 52A.

[0078] (4-2) Second Stage: Measurement of weight imbalance of test rotor 52A While rotating the test rotor 52A, the weight imbalance is measured. Based on the results, a location in the test plastic magnet 63A that requires weight adjustment is identified. For example, in the test plastic magnet 63A shown in FIG. 12, the location that requires weight adjustment is identified as one test magnet recess 635x among multiple test magnet recesses 635A that should be filled with resin material 67. At this time, the position of this test magnet recess 635x in the test plastic magnet 63A that should be filled is determined using the reference position mark 639 as a reference. For example, in the example of FIG. 13, the position of the test magnet recess 635x that should be filled is determined to be on the opposite side of the reference position mark 639 with respect to the central axis 631 of the test plastic magnet 63A.

[0079] (4-3) Third Stage: Manufacturing of Product Rotor 52B The first to tenth steps of manufacturing the finished rotor 52B will be described.

[0080] (4-3-1) Fixing the disc 62 A product shaft 61B having the same shape as the test shaft 61A and a product disk 62B having the same shape as the test disk 62A are prepared. In a first step, as shown in Fig. 19, the product shaft 61B is press-fitted into the center hole 621 of the product disk 62B, in the same manner as in manufacturing the test rotor 52A, thereby fixing the product shaft 61B and the product disk 62B to each other.

[0081] (4-3-2) Molding of product plastic magnet 63B In the second step, as shown in Fig. 20, the second mold 82 is deformed at a location corresponding to a portion requiring weight adjustment. For example, of the multiple mold protrusions 821 of the second mold 82, one corresponding to one test magnet recess 635x to be filled with resin material 67 is removed by cutting (dotted line in Fig. 20).

[0082] In the third step, as shown in FIG. 21, a first mold 81 and a second mold 82 that has been subjected to cutting are combined together to form a cavity 85.

[0083] 22, a resin material 67 for forming the product plastic magnet 63B is injected through a resin inlet 83 and solidified. A magnetic substance 68 is mixed into the resin material 67.

[0084] In the fifth step, as shown in FIG. 23, the first mold 81 and the second mold 82 are removed. The solidified resin material 67 forms the product plastic magnet 63B. A plurality of product magnet recesses 635B are formed on the first end surface 632 of the product plastic magnet 63B, but the number of product magnet recesses 635B is one less than the number of test magnet recesses 635A. The shape of the product magnet protrusions 636B is formed to be rectangular, trapezoidal, cylindrical, or conical, depending on the shape of the mold recess 822. A reference position mark 639 is formed on the second end surface 633 of the product plastic magnet 63B.

[0085] 24, multiple product magnet recesses 635B and product magnet protrusions 636B are arranged at equal intervals on the first end surface 632 of the product plastic magnet 63B, except for the areas corresponding to the cutouts of the mold. The number of injection gates 84 that the second mold 82 has is the same as the number of magnetic poles 637 of the product plastic magnet 63B.

[0086] 25, multiple product magnet recesses 635B and multiple product magnet protrusions 636B are formed on the first end surface 632 of the product plastic magnet 63B. Of the multiple central angles θ and φ formed by two adjacent product magnet recesses 635B at the axis 631, all of the central angles θ except for one central angle φ are the same. Because the shape around the central angle φ is different from the other parts, the shape of the product plastic magnet 63B is not axially symmetrical with respect to the axis 631 of the product plastic magnet 63B.

[0087] (4-3-3) Forming of resin mold 64 In a sixth step, as shown in FIG. 26, the aforementioned third mold 91 is prepared to form the product resin mold 64B.

[0088] 27, the product disk 62B and the fixed product shaft 61B are placed in the first recess 911. In addition, the product plastic magnet 63B is placed in the second recess 912.

[0089] In an eighth step, as shown in FIG. 28, a fourth mold 92 is fitted into the third mold 91 to form a cavity 93.

[0090] 29, in a ninth step, a resin material 69 is injected or poured into the cavity 85. The resin material 69 is solidified.

[0091] In the tenth step, as shown in FIG. 30, the third mold 91 and the fourth mold 92 are removed. The solidified resin material 69 forms a product resin mold 64B. The specific gravity of the product resin mold 64B is lighter than the specific gravity of the product plastic magnet 63B. The product resin mold 64B secures the product shaft 61B, the product disc 62B, and the product plastic magnet 63B together. This completes the product rotor 52B.

[0092] (5) Features (5-1) The weight imbalance measured for the test rotor 52A is eliminated for the product rotor 52B by adjusting the weight of the product plastic magnet 63B using a deformed or cut mold. This allows the indoor fan motor 241 to rotate smoothly. Furthermore, abnormal noise and vibration of the air conditioning device 100 can be reduced.

[0093] (5-2) The product resin mold 64B covers the product magnet recessed portion 635B and the product magnet protruding portion 636B, thereby reducing the risk that the product magnet recessed portion 635B and the product magnet protruding portion 636B will be subjected to air resistance.

[0094] (5-3) The product rotor 52B has a product disk 62B. Therefore, the product resin mold 64B can firmly fix the product shaft 61B and the product disk 62B.

[0095] (5-4) In the test plastic magnet 63A, a plurality of magnet recesses 635 and magnet protrusions 636 are arranged axially symmetrically, which is convenient for measuring the weight imbalance in the test rotor 52A.

[0096] (5-5) Injection gate 84 is provided in mold recess 822 that is not the target of cutting. Therefore, the presence of injection gate 84 does not interfere with cutting of second mold 82.

[0097] (5-6) The number of magnetic poles 637 matches the number of injection gates 84. Therefore, the weight of the product plastic magnet 63B can be adjusted based on the arrangement of the magnetic poles 637.

[0098] (5-7) The shape of the product magnet protrusion 636B is a rectangle, trapezoid, cylinder, or cone, so that the missing portion of the product magnet protrusion 636B is easily visible.

[0099] (5-8) The specific gravity of the product resin mold 64B is lighter than the specific gravity of the product plastic magnet 63B, so the product resin mold 64B can be expected to be durable, in other words, less likely to break.

[0100] (5-9) The product rotor 52B is an outer rotor and has a large outer diameter, which can reduce vibrations associated with outer rotors that tend to require better weight balance.

[0101] <Modifications of the embodiment> (6) Variations (6-1) First Modification In the above-described embodiment, the number of injection gates 84 in the second mold 82 is the same as the number of magnetic poles 637 in the product plastic magnet 63B. Alternatively, the number of injection gates 84 in the second mold 82 may be half the number of magnetic poles 637 in the product plastic magnet 63B.

[0102] (6-2) Second Modification In the above-described embodiment, the rotor 52 is an outer rotor and has a larger outer diameter than the stator 51. Alternatively, the rotor 52 may be an interrotor having an outer diameter larger than the inner diameter of the stator 51.

[0103] <Conclusion> Although the embodiments of the present disclosure have been described above, it will be understood that various changes in form and details can be made without departing from the spirit and scope of the present disclosure as defined in the claims. [Explanation of symbols]

[0104] 10: Outdoor unit 20: Indoor unit 24: Indoor fan (cross flow fan) 51: Stator 52: Rotor 52A: Test rotor 52B: Product rotor 61: Shaft 61A: Test shaft 61B: Product shaft 62:Disc 62A: Test disc 62B: Product disc 63: Plastic magnet 63A: Test plastic magnet 63B:Product Plastic Magnet 64: Resin mold 64A: Test resin mold 64B: Product resin mold 67: Resin materials 68:Magnetic material 69: Resin materials 81: First mold (mold) 82: Second mold (mold) 83: Resin inlet 84: Injection gate 85: Cavity 100: Air conditioning equipment 241: Indoor fan motor (motor) 631: Axial center 632: 1st end face (end face) 633: 2nd end face 635: Magnet recess 635A: Test magnet recess 635B: Product magnet recess 635x: Test magnet recess (where weight adjustment is required) 636: Magnet convex part 636A: Test magnet convex part 636B: Convex part of product magnet 637 :Magnetic pole 821: Mold protrusion 822: Mold recess θ: central angle φ: Central angle [Prior art documents] [Patent documents]

[0105] [Patent Document 1] Japanese Patent Application Laid-Open No. 2005-069580

Claims

1. Prepare molds (81, 82); A resin material (67) containing a magnetic substance (68) is injected into the mold to form a circular test plastic magnet (63A). A test rotor (52A) is manufactured by fixing the test plastic magnet and a test shaft (61A) in a test resin mold (64A); measuring a weight imbalance of the test rotor; Identifying a location (635x) in the test plastic magnet that requires weight adjustment based on the measured imbalance; Deforming the shape of a portion of the mold corresponding to the portion requiring weight adjustment; The resin material containing the magnetic material is injected into the mold after the deformation of the shape, thereby forming a product plastic magnet (63B). A product rotor (52B) is manufactured by fixing a product shaft (61B) having the same shape as the test shaft and the product plastic magnet in a product resin mold (64B) made of the same material as the test resin mold. Manufacturing method.

2. The mold has a plurality of mold projections (821) and a plurality of mold recesses (822), During the molding of the test plastic magnet, a plurality of test magnet recesses (635A) corresponding to the plurality of mold protrusions and a plurality of test magnet protrusions (636A) corresponding to the plurality of mold recesses are formed on the end surface (632) of the test plastic magnet, In the identification, the portion (635x) requiring weight adjustment is one (635x) of the plurality of test magnet recesses to be filled, The deformation of the shape of the part of the mold is performed by cutting one mold protrusion corresponding to the one to be filled. The method of claim 1.

3. In molding the product plastic magnet, a plurality of product magnet recesses (635B) corresponding to the plurality of mold protrusions, and a plurality of product magnet protrusions (636B) corresponding to the plurality of mold recesses are formed on the end surface (632) of the product plastic magnet, When manufacturing the product rotor, the product resin mold covers the plurality of product magnet recesses and the plurality of product magnet protrusions of the product plastic magnet. The method of claim 2.

4. When manufacturing the product rotor, a metal disk is attached to the product shaft, thereby fixing the metal disk to the product resin mold. The method of claim 3.

5. The plurality of test magnet recesses and the plurality of test magnet protrusions of the test plastic magnet are arranged axially symmetrically with respect to the axis (631) of the test plastic magnet. The method according to any one of claims 1 to 4.

6. The plurality of mold recesses are provided with injection gates (84) for injecting the resin material. The method according to any one of claims 1 to 4.

7. The number of said injection gates is equal to the number of magnetic poles (637) of said product plastic magnet or is half of said number of said magnetic poles. The method of claim 6.

8. The shape of the plurality of product magnet protrusions of the product plastic magnet includes one of a rectangle, a trapezoid, a cylinder, and a cone. The method of claim 3.

9. The specific gravity of the resin mold product is lighter than the specific gravity of the plastic magnet product. The method according to any one of claims 1 to 4.

10. The product rotor (52) manufactured by the manufacturing method according to any one of claims 1 to 4; A stator (51); A motor (241).

11. The product rotor is an outer rotor having an outer diameter larger than that of the stator. The motor of claim 10.

12. A motor (241) manufactured by the manufacturing method according to claim 10; a cross-flow fan (24) fixed to the product rotor of the motor; Equipped with An air conditioning device (100).

13. A product shaft (61B), A circular plastic magnet (63B); a product resin mold (64B) for fixing the shaft and the product plastic magnet; A motor (241) comprising a product rotor (52B) having The shape of the product plastic magnet is not axially symmetrical with respect to the axis center (631) of the product plastic magnet. Motor (241).

14. A plurality of product magnet recesses (635B) and a plurality of product magnet protrusions (636B) are formed on the end surface (632) of the product plastic magnet, the product resin mold covers the plurality of product magnet recesses and the plurality of product magnet protrusions, Among the plurality of central angles (θ, φ) formed by two adjacent recesses of the product magnet at the axis (631) of the product plastic magnet, all the remaining central angles except for one central angle (φ) are the same.

14. The motor of claim 13.

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