Rotor manufacturing apparatus and rotor manufacturing method

Abstract

The present invention provides a rotor manufacturing apparatus and a rotor manufacturing method that can improve productivity. [Solution] The manufacturing apparatus includes a movable mold 70 and a fixed mold for clamping a rotor core 11 containing magnets 20 in a slot 14, a filling pot 91 for introducing resin material 30 into the slot 14, a cal plate 90 positioned between the movable mold 70 and the rotor core 11, and a plunger 80 configured to extend and retract relative to the opposing surface 70a of the movable mold 70 facing the cal plate 90, and for pushing the resin material 30 in the filling pot 91 toward the slot 14. The plunger 80 has a first expanding portion 81 and a first contracting portion 82 that protrudes from the first expanding portion 81 and constitutes the tip of the plunger 80, and is narrower than the first expanding portion 81. When the plunger 80 pushes out the resin material 30 in the filling pot 91, the plunger 80 moves to a position where at least the first expanding portion 81 is on the same plane as the opposing surface 70a.

Description

Technical Field

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

Background Art

[0002] Patent Document 1 discloses a manufacturing apparatus for a rotor (referred to as a core part in Patent Document 1), which is a rotor of a rotating electrical machine. The rotor includes an iron core body, a permanent magnet inserted into a magnet insertion hole of the iron core body, and a resin filling material filled in the magnet insertion hole.

[0003] The manufacturing apparatus described in Patent Document 1 includes a lower mold, an upper mold having a housing hole, an auxiliary plate having a resin flow path, and an extrusion part for extruding molten resin into the magnet insertion hole. The lower mold supports a jig on which the iron core body is placed from below. The auxiliary plate is placed on the upper surface of the iron core body. The upper mold sandwiches the jig, the iron core body, and the auxiliary plate together with the lower mold. The extrusion part fills the resin into the magnet insertion hole through the resin flow path of the auxiliary plate by extruding the resin in the housing hole of the upper mold.

[0004] After the resin is solidified, after the pressing part retreats from the housing hole, when the upper mold rises or the lower mold descends, the upper mold and the auxiliary plate are separated from each other.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] In the manufacturing apparatus described in Patent Document 1, the extrusion section does not protrude from the containment hole when the resin is extruded, so the solidified resin remains inside the containment hole. Therefore, when the upper mold and the auxiliary plate are separated, there is a risk that some of the resin will break and remain inside the containment hole. In this case, it is necessary to remove the resin material from the containment hole.

[0007] On the other hand, if the resin channel is made deeper and the extrusion section is moved into the resin channel to avoid the aforementioned problems, the depth of the region where resin exists within the resin channel may become partially larger. In this case, the fluidity of the resin extruded by the extrusion section may decrease, potentially resulting in insufficient resin filling the magnet insertion hole.

[0008] Based on the above, there is room for improvement in increasing the productivity of the rotor. [Means for solving the problem]

[0009] A rotor manufacturing apparatus for solving the above problems manufactures a rotor comprising: a cylindrical rotor core having a slot penetrating in the axial direction; magnets housed in the slots; and a resin material filled in the slots to fix the magnets to the rotor core. The rotor manufacturing apparatus comprises: a first mold and a second mold that clamp the rotor core, in which the magnets housed in the slots, in the axial direction; a filling pot for introducing the resin material into the slots, and a cal plate disposed between the first mold and the rotor core; and a plunger disposed in a housing hole formed in the first mold and configured to retract in and out relative to an opposing surface of the first mold facing the cal plate, and for pushing the resin material in the filling pot toward the slots. The plunger has an enlarged portion and a reduced portion that protrudes from the enlarged portion and constitutes the tip of the plunger, and whose width is reduced compared to the enlarged portion. When the plunger pushes the resin material in the filling pot, the plunger moves to a position where at least the enlarged portion is on the same plane as the opposing surface.

[0010] According to the above configuration, when the plunger pushes out the resin material from the filling pot, the plunger moves to a position where at least the enlarged portion is on the same plane as the opposing surface of the first mold. Therefore, it is possible to prevent the resin material from entering the containment hole. Consequently, it is possible to prevent solidified resin material from remaining in the containment hole.

[0011] Furthermore, with the above configuration, the plunger moves to a position where the expanding portion is on the same plane as the opposing surface of the first type, thereby positioning the contracting portion within the filling pot. This makes it possible to suppress the partial increase in the depth of the region where the resin material is present within the filling pot compared to the case where the plunger does not have a contracting portion. Therefore, a decrease in the fluidity of the resin material can be suppressed.

[0012] Based on the above, it is possible to improve the productivity of the rotor. A rotor manufacturing method to solve the above problem is a rotor manufacturing method comprising a cylindrical rotor core having a slot penetrating in the axial direction, a magnet housed in the slot, and a resin material filled in the slot to fix the magnet to the rotor core, wherein a calplate having a filling pot for introducing the resin material into the slot is placed on one end face in the axial direction of the rotor core in which the magnet is housed in the slot, and the rotor core and the calplate are clamped together in the axial direction by a first mold and a second mold. The process includes a mold clamping step and a filling step of filling the slots with resin material by pushing out the resin material in the filling pot using a plunger that is positioned in a receiving hole formed in the first mold and is configured to be able to move in and out relative to an opposing surface of the first mold facing the Calplate, wherein the plunger has an expanded portion and a reduced portion that protrudes from the expanded portion and constitutes the tip of the plunger, and is narrower than the expanded portion, and in the filling step, the plunger is moved to a position where at least the expanded portion is on the same plane as the opposing surface.

[0013] According to the above configuration, the same effects as those of the manufacturing apparatus of the rotor can be achieved.

Brief Description of the Drawings

[0014] [Figure 1] FIG. 1 is a perspective view of a rotor in one embodiment. [Figure 2] FIG. 2 is a cross-sectional view of the rotor of FIG. 1. [Figure 3] FIG. 3 is a cross-sectional view of a manufacturing apparatus of a rotor in one embodiment. [Figure 4] FIG. 4 is a cross-sectional view showing the plunger and the cal plate of FIG. 3. [Figure 5] FIG. 5 is a cross-sectional view showing a support step and a transfer step in a manufacturing method of a rotor. [Figure 6] FIG. 6 is a cross-sectional view showing a mold clamping step in a manufacturing method of a rotor. [Figure 7] FIG. 7 is a cross-sectional view showing a filling step in a manufacturing method of a rotor. [Figure 8] FIG. 8 is a cross-sectional view showing a separation step in a manufacturing method of a rotor. [Figure 9] FIG. 9 is a cross-sectional view showing a mold opening step in a manufacturing method of a rotor. [Figure 10] FIG. 10 is a cross-sectional view showing a manufacturing apparatus of a rotor of a modified example.

Embodiments for Carrying Out the Invention

[0015] Hereinafter, referring to FIGS. 1 to 9, an embodiment of a manufacturing apparatus of a rotor and a manufacturing method of a rotor will be described. First, the rotor 10 manufactured by the manufacturing apparatus of the rotor of the present embodiment (hereinafter referred to as the manufacturing apparatus 40) will be described.

[0016] (Configuration of Rotor 10) As shown in FIGS. 1 and 2, the rotor 10 includes a rotor core 11, a plurality of magnets 20, and a plurality of resin materials 30. The rotor 10 is used, for example, in a magnet-embedded type motor.

[0017] The rotor core 11 has a substantially cylindrical shape. The rotor core 11 is formed, for example, by laminating a plurality of core pieces 12 punched out from electromagnetic steel sheets. Hereinafter, the axial direction of the rotor core 11 is simply referred to as the axial direction. Also, the radial direction of the rotor core 11 is simply referred to as the radial direction. Also, the circumferential direction of the rotor core 11 is simply referred to as the circumferential direction.

[0018] The rotor core 11 has a first end face 11a and a second end face 11b that are located on opposite sides in the axial direction. The rotor core 11 has a central hole 13 and a plurality of slots 14. A shaft (not shown) is inserted into the central hole 13. The plurality of slots 14 are formed at intervals in the circumferential direction on the outer peripheral portion of the rotor core 11. The central hole 13 and the slots 14 penetrate the rotor core with respect to the axial direction. That is, both the central hole 13 and the slots 14 open to the first end face 11a and the second end face 11b.

[0019] As shown in FIG. 1, the central hole 13 has a substantially circular shape in a plan view. On the inner surface of the central hole 13, two keys 13a that project toward each other in the radial direction are provided. By fitting the two keys 13a into key grooves provided in a shaft (not shown), relative movement between the rotor core 11 and the shaft in the circumferential direction is restricted.

[0020] The cross-sectional shape of the slot 14 perpendicular to the axial direction is a substantially rectangular shape having a long side and a short side. The cross-sectional shape of the slot 14 is the same throughout the axial direction. The magnet 20 is, for example, a permanent magnet. One magnet 20 is housed in each slot 14. The magnet 20 is fixed to the rotor core 11 via a resin material 30 filled in the slot 14.

[0021] The magnet 20 is elongated in the axial direction. The length of the magnet 20 in the axial direction is shorter than the length of the rotor core 11 in the axial direction. The cross-sectional shape of the magnet 20 perpendicular to the axial direction is approximately rectangular.

[0022] One end face of the magnet 20 in the axial direction is located, for example, axially inward from the first end face 11a. The other end face of the magnet 20, opposite to the one end face in the axial direction, is flush with, for example, the second end face 11b.

[0023] The resin material 30 is, for example, a thermosetting resin. The resin material 30 is filled around the entire circumference of the magnet 20, for example, between the inner surface of the slot 14 and the outer surface of the magnet 20. The resin material 30 covers one end face of the magnet 20 in the axial direction and is formed flush with the first end face 11a of the rotor core 11.

[0024] (Overall configuration of manufacturing equipment 40) As shown in Figure 3, the manufacturing apparatus 40 includes a support jig 50, a fixed mold 60, a movable mold 70, a plurality of plungers 80, and a calplate 90. The fixed mold 60 is an example of the "second type". The movable mold 70 is an example of the "first type".

[0025] The support jig 50 supports the rotor core 11 from below. The fixed mold 60 supports the support jig 50 from below. The movable mold 70 is positioned above the fixed mold 60. The movable mold 70 is configured to move up and down relative to the fixed mold 60. The fixed mold 60 and the movable mold 70 are configured to clamp the rotor core 11 in the axial direction. The clamping plate 90 is positioned between the movable mold 70 and the rotor core 11 when the fixed mold 60 and the movable mold 70 are clamped. Each plunger 80 is configured to extend and retract relative to the movable mold 70.

[0026] (Support jig 50) The support jig 50 includes a base plate 51, a post 52, and a spacer 54. The base plate 51 is flat. The post 52 protrudes upward from the center of the base plate 51. The spacer 54 is superimposed on the upper surface of the base plate 51 and supports the second end face 11b of the rotor core 11.

[0027] The base plate 51 has a plurality of through holes 51a that penetrate in the thickness direction. The plurality of through holes 51a are spaced apart from each other so as to surround the post 52. The post 52 is cylindrical. The post 52 passes through the spacer 54. The post 52 is inserted into the central hole 13 of the rotor core 11. The outer circumferential surface of the post 52 is provided with a keyway (not shown) into which the key 13a (see Figure 1) of the rotor core 11 engages. The engagement of the key 13a with the keyway positions the rotor core 11 relative to the support jig 50. Multiple positioning pins 53 are provided on the tip surface of the post 52.

[0028] The spacer 54 is flat. The spacer 54 has a central hole 54a into which the post 52 is inserted. Although not shown in the figure, the spacer 54 is provided to move up and down along the post 52 by a lifting mechanism that moves up and down within the through hole 51a of the base plate 51. When the spacer 54 rises relative to the post 52, the rotor core 11 is removed from the support jig 50.

[0029] (Configuration of the movable type 70) The movable type 70 has a planar opposing surface 70a that faces the calplate 90. The movable type 70 has multiple housing holes 71, each housing a plurality of plungers 80. The housing holes 71 open to the opposing surface 70a and penetrate the movable type 70 in the vertical direction. The cross-section of the housing holes 71 is circular.

[0030] When clamping the fixed mold 60 and the movable mold 70, clamping force is applied to the movable mold 70. (Configuration of Plunger 80) As shown in Figure 4, the plunger 80 is configured to move up and down within the housing hole 71 of the movable mold 70, thereby being able to move in and out relative to the opposing surface 70a of the movable mold 70. The plunger 80 pressurizes the resin material 30 in the filling pot 91, which will be described later, and fills it into the slot 14.

[0031] The plunger 80 has a first expanding portion 81 and a first shrinking portion 82. The cross-sections of the first expanding portion 81 and the first shrinking portion 82 are circular. The first enlarged portion 81 extends in the vertical direction. The first reduced portion 82 protrudes downward from the lower surface of the first enlarged portion 81. The first reduced portion 82 constitutes the tip of the plunger 80. The first enlarged portion 81 and the first reduced portion 82 are continuous.

[0032] The width, or diameter, of the first enlarged portion 81 is constant in the axial direction. The diameter of the first enlarged portion 81 is approximately the same as the width, or diameter, of the receiving hole 71. The width, or diameter, of the first reduced portion 82 is smaller than that of the first enlarged portion 81. The diameter of the first reduced portion 82 gradually increases in the axial direction toward the first enlarged portion 81. The first reduced portion 82 is frustoconical in shape with a planar tip surface.

[0033] (Composition of Calplate 90) As shown in Figure 3, the Calplate 90 is placed on the first end face 11a of the rotor core 11, which is supported by a support jig 50. The Calplate 90 has multiple filling pots 91 into which resin material 30 is introduced into multiple slots 14.

[0034] As shown in Figure 4, the filling pot 91 has a second enlarged section 92, a second reduced section 93, and a communication hole 94. The cross-sections of the second enlarged section 92, the second reduced section 93, and the communication hole 94 are circular.

[0035] The second enlarged portion 92 opens toward the movable mold 70 on the upper surface of the calplate 90. The width, i.e., diameter, of the second enlarged portion 92 gradually increases toward the movable mold 70 in the axial direction. The diameter of the second enlarged portion 92 is larger than the diameter of the first enlarged portion 81. The diameter of the second enlarged portion 92 is larger than the diameter of the housing hole 71.

[0036] The second reduction section 93 opens to the bottom surface of the second expansion section 92. The second reduction section 93 is narrower than the second expansion section 92. More specifically, the diameter of the second reduction section 93 is smaller than the diameter of the second expansion section 92. The diameter of the second reduction section 93 is constant in the axial direction. The diameter of the second reduction section 93 is larger than the maximum diameter of the first reduction section 82. The diameter of the second reduction section 93 is smaller than the diameter of the first expansion section 81 and the diameter of the housing hole 71. Therefore, when the second reduction section 93 is projected onto the housing hole 71 in the axial direction, the entire second reduction section 93 is located within the housing hole 71. The inner surface of the second reduction section 93, i.e., the bottom surface and inner circumferential surface of the second reduction section 93, is configured to support the cylindrical resin material 30 before melting.

[0037] The communication hole 94 connects the second reduction section 93 and the slot 14. The communication hole 94 opens to the bottom surface of the second reduction section 93 and to the lower surface of the calplate 90. The communication hole 94 opens to the portion of the bottom surface of the second reduction section 93 that faces the plunger 80 in the axial direction.

[0038] The width, or diameter, of the communication hole 94 gradually increases in the axial direction towards the movable mold 70. The inclination angle of the inner circumferential surface of the communication hole 94 with respect to the axial direction is the same as, for example, the inclination angle of the inner circumferential surface of the second enlarged portion 92 with respect to the axial direction.

[0039] As shown in Figure 3, the Calplate 90 has a recess 95 and a plurality of positioning holes 96. The recess 95 opens on the lower surface of the central part of the Calplate 90. Each positioning hole 96 opens on the upper surface of the recess 95 and penetrates the Calplate 90 in the thickness direction.

[0040] The tip of the post 52 is inserted into the recess 95. The positioning pin 53 of the post 52 is inserted into the positioning hole 96. By inserting the positioning pin 53 into the positioning hole 96, the calplate 90 is positioned relative to the support jig 50. This connects the filling pot 91 and the slot 14.

[0041] (Manufacturing method for rotor 10) The manufacturing method for the rotor 10 includes a magnet housing step, a placement step, a preheating step, a support step, a transport step, a mold clamping step, a filling step, a separation step, and a mold opening step. The magnet housing step, placement step, preheating step, support step, transport step, mold clamping step, filling step, separation step, and mold opening step are performed in this order.

[0042] In the magnet housing process, magnets 20 are housed in each slot 14 of the rotor core 11, which is supported by the support jig 50. At this time, the lower surface of the magnets 20 is in contact with the upper surface of the spacer 54. In the placement process, the Calplate 90 is placed on the first end face 11a of the rotor core 11, which is supported by the support jig 50. At this time, the positioning pin 53 is inserted into the positioning hole 96. The placement process is performed, for example, when the rotor core 11 is not positioned between the fixed type 60 and the movable type 70.

[0043] In the preheating process, the support jig 50, rotor core 11, and calplate 90 are placed in a heating device (not shown) and preheated to a predetermined temperature. The fixed type 60 and movable type 70 are also preheated to a predetermined temperature.

[0044] As shown by the dashed line in Figure 5, in the support process, a cylindrical resin material 30 with a smaller diameter than the second reduction section 93 is placed in the second reduction section 93 of the Calplate 90. In this way, the resin material 30 is supported by the second reduction section 93. The resin material 30 supported by the second reduction section 93 protrudes above the Calplate 90. By supporting the resin material 30 in the second reduction section 93, the Calplate 90 can be transported while supporting the resin material 30. The support process is performed when the Calplate 90 is not positioned between the fixed type 60 and the movable type 70.

[0045] As shown by the solid line in Figure 5, in the transport process, the Calplate 90 with the resin material 30 supported by the second reduction section 93, and the rotor core 11 are transported together with the support jig 50 between the fixed type 60 and the movable type 70. In the transport process, the rotor core 11 and the Calplate 90 are transported between the fixed type 60 and the movable type 70 as the support jig 50 is transported.

[0046] In the mold clamping process, the fixed mold 60 and the movable mold 70 are clamped together so as to sandwich the support jig 50, rotor core 11, and calplate 90, which were transported in the transport process. At this time, as shown in Figure 6, as the movable mold 70 descends, the resin material 30 that protrudes above the calplate 90 is accommodated in the accommodation hole 71 of the movable mold 70. The resin material 30 accommodated in the accommodation hole 71 is melted by the heat from the preheating process.

[0047] As shown in Figure 7, during the filling process, the plunger 80 descends, pressurizing the resin material 30 within the receiving hole 71 and the filling pot 91. The plunger 80 pushes out the resin material 30 from within the filling pot 91, filling the slot 14 with the resin material 30. During the filling process, the first expanding portion 81 moves to a position beyond the opposing surface 70a. More specifically, the first expanding portion 81 moves into the second expanding portion 92, and the first contracting portion 82 moves into the second contracting portion 93. When the plunger 80 pushes out the resin material 30 from within the filling pot 91, the plunger 80 stops at a position where the first expanding portion 81 is located within the second expanding portion 92 and the first contracting portion 82 is located within the second contracting portion 93. At this time, a gap is formed between the outer surface of the plunger 80 and the inner surface of the filling pot 91, allowing the resin material 30 to flow throughout.

[0048] The resin material 30 filled inside the slot 14 solidifies when heated by the heat of the preheating. This fixes the magnet 20 to the rotor core 11. As shown in Figure 8, in the separation process, the fixed mold 60 and the movable mold 70 are clamped together, and only the plunger 80 retracts from the calplate 90. In other words, in the separation process, the movable mold 70 is in contact with the calplate 90, and the plunger 80 retracts from the calplate 90. This separates the solidified resin material 30 and the plunger 80 in the filling pot 91.

[0049] As shown in Figure 9, during the mold opening process, the movable mold 70 rises together with the plunger 80. This causes the movable mold 70 to retract from the rotor core 11 together with the plunger 80. Although not shown in the diagram, after the mold opening process, the Calplate 90 and support jig 50 are removed from the rotor 10. Then, the resin material 30 remaining in the filling pot 91 of the Calplate 90 is pushed out by a pin or the like, separating the resin material 30 from the Calplate 90.

[0050] <Operation of this embodiment> When the plunger 80 pushes out the resin material 30 from the filling pot 91, the first enlarged portion 81 is positioned within the second enlarged portion 92. This prevents the resin material 30 from entering the containment hole 71. Consequently, it prevents the solidified resin material 30 from remaining in the containment hole 71.

[0051] Furthermore, when the plunger 80 pushes out the resin material 30 from the filling pot 91, the first expanding portion 81 stops within the second expanding portion 92, and the first contracting portion 82 stops within the second contracting portion 93. This prevents the depth of the region where the resin material 30 exists within the filling pot 91 from becoming partially larger compared to when the plunger 80 does not have the first contracting portion 82. Therefore, a decrease in the fluidity of the resin material 30 can be suppressed.

[0052] <Effects of this embodiment> (1) When the plunger 80 pushes out the resin material 30 in the filling pot 91, the plunger 80 stops at a position where the first expanding portion 81 is located within the second expanding portion 92 and the first contracting portion 82 is located within the second contracting portion 93.

[0053] According to the above configuration, the productivity of the rotor 10 can be improved. (2) The width of the second enlarged section 92 gradually increases in the axial direction as it approaches the movable type 70.

[0054] According to the above configuration, the resin material 30 solidified in the filling pot 91 becomes easier to separate from the Calplate 90. (3) The width of the second reduction section 93 is constant in the axial direction.

[0055] According to the above configuration, by supporting the resin material 30 before melting with the second shrinking portion 93, displacement of the resin material 30 relative to the Calplate 90 can be suppressed. More specifically, the inner circumferential surface of the second shrinking portion 93 can restrict the movement and tilting of the resin material 30 relative to the Calplate 90. Therefore, the Calplate 90 can be moved while the resin material 30 is supported by the second shrinking portion 93. As a result, after the resin material 30 is supported by the Calplate 90, the Calplate 90 can be positioned between the fixed type 60 and the movable type 70. Therefore, compared to the case where the resin material 30 is positioned on the Calplate 90 located between the fixed type 60 and the movable type 70, the configuration and process for positioning the resin material 30 on the Calplate 90 located between the fixed type 60 and the movable type 70 can be omitted.

[0056] (4) The width of the second reduction section 93 is smaller than the width of the accommodating hole 71. According to the above configuration, when moving the Calplate 90 with the resin material 30 supported in the second reduction section 93, the inner circumferential surface of the second reduction section 93, which is narrower than the accommodation hole 71, can restrict the movement and tilting of the resin material 30 relative to the Calplate 90. Then, by clamping the Calplate 90, with the resin material 30 supported in the second reduction section 93, together with the rotor core 11 using the fixed mold 60 and the movable mold 70, the resin material 30 can be positioned inside the accommodation hole 71 of the movable mold 70. As a result, the above-mentioned effect (3) can be achieved while smoothly clamping the fixed mold 60 and the movable mold 70.

[0057] (5) The filling pot 91 has a communication hole 94 that opens to the bottom surface of the second reduction section 93 and connects the second reduction section 93 and the slot 14. According to the above configuration, since the communication hole 94 is opened in the second narrowing section 93 into which the plunger 80 enters, the filling pressure is more easily applied to the resin material 30 flowing through the communication hole 94 compared to the case where the communication hole 94 opens on the bottom surface of the second expanding section 92. Therefore, a decrease in the fluidity of the resin material 30 passing through the communication hole 94 can be suppressed.

[0058] (6) The width of the second enlargement section 92 is greater than the width of the housing hole 71. The plunger 80 is configured to be retractable from the calplate 90 when the movable mold 70 and the fixed mold 60 are clamped together.

[0059] According to the above configuration, the plunger 80 retracts from the calplate 90, thereby separating the solidified resin material 30 and the plunger 80 within the filling pot 91. Here, since the plunger 80 has a first retraction portion 82, the solidified resin material 30 tends to adhere to the plunger 80. In this case, when the plunger 80 retracts from the calplate 90, the resin material 30 and the plunger 80 may not be completely separated, and some of the resin material 30 may adhere to the plunger 80.

[0060] In this regard, with the above configuration, since the width of the second enlargement portion 92 is greater than the width of the housing hole 71, the outer edge of the resin material 30 solidified in the second enlargement portion 92 is covered by the opposing surface 70a. Then, with the movable mold 70 and the fixed mold 60 clamped together, the plunger 80 retracts from the calplate 90. As a result, when the plunger 80 retracts, the resin material 30 solidified in the filling pot 91 is pressed down by the opposing surface 70a of the movable mold 70, thus enabling effective separation of the resin material 30 and the plunger 80.

[0061] (7) In the filling process, the plunger 80 is stopped at a position where the first enlarged portion 81 is located within the second enlarged portion 92 and the first reduced portion 82 is located within the second reduced portion 93. According to the above configuration, the same effect as effect (1) above can be achieved.

[0062] (8) In the support process, the resin material 30 is supported by the second shrinking section 93 while the Calplate 90 is not positioned between the fixed mold 60 and the movable mold 70. In the transport process, the Calplate 90, with the resin material 30 supported by the second shrinking section 93, is transported between the fixed mold 60 and the movable mold 70. In the mold clamping process, the rotor core 11 and the Calplate 90 transported in the transport process are clamped together axially by the movable mold 70 and the fixed mold 60.

[0063] According to the above configuration, compared to the case where the resin material 30 is placed on the calplate 90 located between the fixed type 60 and the movable type 70, the configuration and process for placing the resin material 30 between the fixed type 60 and the movable type 70 can be omitted.

[0064] (9) In the separation process, the plunger 80 is retracted from the calplate 90 while the fixed mold 60 and the movable mold 70 are clamped together, thereby separating the resin material 30 in the filling pot 91 from the plunger 80.

[0065] According to the above configuration, the same effect as effect (6) above can be achieved. <Example of changes> This embodiment can be implemented with the following modifications. This embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0066] The width of the second enlarged portion 92 may be the same as the width of the accommodating hole 71. • In the separation process, the plunger 80 may be configured to retract from the calplate 90 simultaneously with the movable type 70.

[0067] A calplate 90, in which the resin material 30 is supported by the second reduction portion 93, may be placed on the first end face 11a of the rotor core 11, which is positioned between the fixed type 60 and the movable type 70. The resin material 30 may be placed in the filling pot 91 of the Calplate 90, which is positioned between the fixed type 60 and the movable type 70.

[0068] The filling pot 91 may have a plurality of communication holes 94 that open to the bottom surface of the second reduction section 93 and communicate with each of the plurality of slots 14. The communication hole 94 may open into the bottom surface of the second enlarged portion 92. In this case, the communication hole 94 may open into the portion of the bottom surface of the second enlarged portion 92 that does not face the plunger 80.

[0069] The width of the second reduction section 93 may be greater than or equal to the width of the accommodating hole 71. In this case, it is preferable that the resin material 30 is placed in the filling pot 91 of the Calplate 90, which is positioned between the fixed type 60 and the movable type 70, without performing a support process.

[0070] The inclination angle of the inner circumferential surface of the second reduction section 93 may be changed as appropriate. The width of the second reduction section 93 may gradually increase, for example, as it approaches the movable mold 70 in the axial direction. The inclination angle of the inner circumferential surface of the second enlarged portion 92 may be changed as appropriate. The width of the second enlarged portion 92 may be constant, for example, in the axial direction.

[0071] • During the filling process, the first expanding portion 81 may stop at a position where it is on the same plane as the opposing surface 70a. Even with this configuration, it is possible to prevent the resin material 30 from entering the containment hole 71. Furthermore, in this configuration, the entire first shrinking portion 82 is located inside the filling pot 91. Therefore, compared to the case where the plunger 80 does not have the first shrinking portion 82, it is possible to prevent the depth of the region where the resin material 30 is present inside the filling pot 91 from becoming partially larger.

[0072] The manufacturing apparatus 40 does not necessarily have to be equipped with a support jig 50. Instead of the support jig 50, a calplate 90 may be placed between the fixed mold 60 and the rotor core 11. In this case, the plunger 80 is configured to be able to extend and retract relative to the fixed mold 60.

[0073] The inclination angle of the outer surface of the first reduction portion 82 may be changed as appropriate. The width of the first reduction portion 82 may be constant, for example, in the axial direction. The inclination angles of the inner circumferential surface of the second enlarged portion 92 and the inner circumferential surface of the communication hole 94 may be changed as appropriate. The width of the second enlarged portion 92 and the width of the communication hole 94 may be constant in the axial direction, for example.

[0074] The cross-sections of the plunger 80 and the filling pot 91 are not limited to a circular shape, but may also be polygonal, for example. The resin material 30 may be a thermoplastic resin.

[0075] As shown in Figure 10, the Calplate 90 may have a filling pot 91, a runner 100 connected to the filling pot 91, and a communication hole 101 connecting the runner 100 to the slot 14. The runner 100 functions as a flow path that supplies the resin material 30 in the filling pot 91 to a slot 14 different from the slot 14 that communicates with the communication hole 94 of the filling pot 91. The runner 100 opens on the upper surface of the Calplate 90 and extends from a part of the circumferential direction of the filling pot 91 toward the other slot 14. The opening of the runner 100 is closed by the opposing surface 70a of the movable mold 70 when the fixed mold 60 and the movable mold 70 are clamped. The communication hole 101 opens on the bottom surface of the runner 100. The bottom surface of the runner 100 is flush with the bottom surface of the second reduction section 93. Therefore, the communication hole 94 and the communication hole 101 open on the same plane. With this configuration, since the bottom surface of the runner 100 is flush with the bottom surface of the second reduction section 93, it becomes easier to separate the resin material 30 solidified in the filling pot 91 from the calplate 90 by pushing it out with pins inserted into the communication holes 94 and 101. This is because, since there is no step between the bottom surface of the runner 100 and the bottom surface of the second reduction section 93, the solidified resin material 30 is less likely to remain on the bottom surfaces of the runner 100 and the second reduction section 93.

[0076] <Note> The above embodiment includes the configuration described in the following appendix. [Note 1] A rotor manufacturing apparatus for manufacturing a rotor comprising a cylindrical rotor core having a slot penetrating in the axial direction, magnets housed in the slot, and a resin material filled in the slot to fix the magnets to the rotor core, comprising: a first mold and a second mold for clamping the rotor core having the magnets housed in the slot in the axial direction; a filling pot for introducing the resin material into the slot, a cal plate disposed between the first mold and the rotor core; and a plunger disposed in a housing hole formed in the first mold and configured to retract in and out relative to an opposing surface of the first mold facing the cal plate, and for pushing the resin material in the filling pot toward the slot, wherein the plunger has an enlarged portion and a reduced portion that protrudes from the enlarged portion and constitutes the tip of the plunger, and is narrower than the enlarged portion, and when the plunger pushes the resin material in the filling pot, the plunger moves to a position where at least the enlarged portion is on the same plane as the opposing surface.

[0077] [Note 2] When the enlarged portion is referred to as the first enlarged portion and the reduced portion as the first reduced portion, the filling pot has a second enlarged portion that opens toward the first mold and a second reduced portion that opens toward the bottom surface of the second enlarged portion and is narrower than the second enlarged portion, and when the plunger pushes out the resin material in the filling pot, the plunger stops at a position where the first enlarged portion is located within the second enlarged portion and the first reduced portion is located within the second reduced portion, the rotor manufacturing apparatus according to [Note 1].

[0078] [Note 3] The rotor manufacturing apparatus described in [Note 2], wherein the width of the second enlarged portion gradually increases in the axial direction toward the first type. [Note 4] The rotor manufacturing apparatus according to [Note 2] or [Note 3], wherein the width of the second reduction portion is constant in the axial direction.

[0079] [Note 5] The width of the second reduction portion is smaller than the width of the receiving hole. A rotor manufacturing apparatus according to any one of [Note 2] to [Note 4]. [Note 6] The filling pot has a communication hole that opens to the bottom surface of the second reduction section and connects the second reduction section and the slot, as described in any one of [Note 2] to [Note 5].

[0080] [Note 7] The rotor manufacturing apparatus according to any one of [Note 2] to [Note 6], wherein the width of the second enlarged portion is greater than the width of the housing hole, and the plunger is configured to be retractable from the calplate when the first mold and the second mold are clamped together.

[0081] [Note 8] A method for manufacturing a rotor comprising a cylindrical rotor core having a slot penetrating in the axial direction, magnets housed in the slot, and a resin material filled in the slot to fix the magnets to the rotor core, comprising a mold clamping step of clamping the rotor core and the cal plate between a first mold and a second mold in the axial direction, with a cal plate having a filling pot for introducing the resin material into the slot placed on one end face in the axial direction of the rotor core in which the magnets housed in the slot, and the first mold A method for manufacturing a rotor, comprising: a filling step of filling the slot with resin material by using a plunger which is positioned in a formed receiving hole and configured to extend and retract relative to an opposing surface facing the first type of calplate, wherein the plunger has an enlarged portion and a reduced portion which protrudes from the enlarged portion and constitutes the tip of the plunger, and which is narrower than the enlarged portion, and in the filling step, the plunger is moved to a position in which at least the enlarged portion is on the same plane as the opposing surface.

[0082] [Note 9] When the enlarged portion is referred to as the first enlarged portion and the reduced portion as the first reduced portion, the filling pot has a second enlarged portion that opens toward the first mold and a second reduced portion that opens toward the bottom surface of the second enlarged portion and is narrower than the second enlarged portion, and in the filling process, the plunger is stopped at a position where the first enlarged portion is located within the second enlarged portion and the first reduced portion is located within the second reduced portion, the method for manufacturing a rotor as described in [Note 8].

[0083] [Note 10] When the enlarged portion is referred to as the first enlarged portion and the reduced portion as the first reduced portion, the filling pot has a second enlarged portion that opens toward the first mold and a second reduced portion that opens toward the bottom surface of the second enlarged portion and is narrower than the second enlarged portion, and the method for manufacturing a rotor according to [Note 8] or [Note 9] comprises a support step in which the resin material is supported by the second reduced portion when the cal plate is not located between the first mold and the second mold, and a transport step in which the cal plate with the resin material supported by the second reduced portion is transported between the first mold and the second mold, and in the mold clamping step, the rotor core and the cal plate transported in the transport step are clamped by the first mold and the second mold.

[0084] [Note 11] When the enlarged portion is referred to as the first enlarged portion and the reduced portion as the first reduced portion, the filling pot has a second enlarged portion that opens toward the first mold and a second reduced portion that opens toward the bottom surface of the second enlarged portion and is narrower than the second enlarged portion, the width of the second enlarged portion being greater than the width of the receiving hole, and the method of manufacturing a rotor according to any one of [Note 8] to [Note 10], comprising a separation step of separating the resin material in the filling pot from the plunger by retracting the plunger from the calplate while the first mold and the second mold are clamped together. [Explanation of Symbols]

[0085] 10…Rota 11…Rotor core 11a...first end surface 11b…Second end surface 12… Iron core piece 13...Center hole 13a... Key 14…Slot 20…Magnets 30… Resin material 40...Manufacturing equipment 50…Support fixture 51…Base plate 51a...Through hole 52...Post 53…Positioning pin 54…Spacer 54a…Center hole 60…Fixed type 70…Movable type 70a... Opposite side 71…Containment port 80... Plunger 81...First Enlarged Section 82...1st reduction part 90... Calplate 91… Filling pot 92...Second Enlargement Section 93…Second reduction part 94...Communication hole 95…recess 96…Positioning hole 100... Runner 101...Communication hole

Claims

1. A rotor manufacturing apparatus for manufacturing a rotor comprising a cylindrical rotor core having a slot penetrating in the axial direction, magnets housed in the slot, and a resin material filling the slot to fix the magnets to the rotor core, A first mold and a second mold clamp the rotor core, in which the magnet is housed, in the slots in the axial direction, The slot has a filling pot for introducing the resin material, and a cal plate is disposed between the first mold and the rotor core, The first type includes a plunger which is positioned within a receiving hole formed in the first type and is configured to be able to move in and out relative to the opposing surface of the first type that faces the Calplate, and which pushes the resin material in the filling pot toward the slot, The plunger has an enlarged portion and a reduced portion that protrudes from the enlarged portion and forms the tip of the plunger, and whose width is reduced compared to the enlarged portion. When the plunger pushes out the resin material from the filling pot, the plunger moves to a position where at least the enlarged portion is on the same plane as the opposing surface. Rotor manufacturing equipment.

2. When the enlarged portion is referred to as the first enlarged portion and the reduced portion as the first reduced portion, The filling pot has a second enlarged section that opens toward the first mold, and a second reduced section that opens on the bottom surface of the second enlarged section and is narrower in width than the second enlarged section. When the plunger pushes the resin material out of the filling pot, the plunger stops at a position where the first expanding portion is located within the second expanding portion and the first contracting portion is located within the second contracting portion. A rotor manufacturing apparatus according to claim 1.

3. The width of the second enlarged portion gradually increases in the axial direction toward the first type. A rotor manufacturing apparatus according to claim 2.

4. The width of the second reduction portion is constant in the axial direction. A rotor manufacturing apparatus according to claim 2.

5. The width of the second reduction portion is smaller than the width of the receiving hole. A rotor manufacturing apparatus according to claim 2.

6. The filling pot has a communication hole that opens to the bottom surface of the second reduction section and connects the second reduction section and the slot. A rotor manufacturing apparatus according to claim 2.

7. The width of the second enlarged portion is greater than the width of the receiving hole. The plunger is configured to be retractable from the calplate when the first and second types are clamped together. A rotor manufacturing apparatus according to any one of claims 2 to 6.

8. A method for manufacturing a rotor comprising a cylindrical rotor core having a slot penetrating in the axial direction, a magnet housed in the slot, and a resin material filling the slot to fix the magnet to the rotor core, A mold clamping step is performed in which the rotor core and the Calplate are clamped in the axial direction by a first mold and a second mold, with a Calplate having a filling pot for introducing the resin material into the slot placed on one end face in the axial direction of the rotor core in which the magnet is housed in the slot, The process includes a filling step of filling the slots by pushing out the resin material in the filling pot using a plunger that is positioned in a receiving hole formed in the first mold and is configured to be retractable relative to the opposing surface of the first mold facing the Calplate, The plunger has an enlarged portion and a reduced portion that protrudes from the enlarged portion and forms the tip of the plunger, and whose width is reduced compared to the enlarged portion. In the filling step, the plunger is moved to a position where at least the enlarged portion is on the same plane as the opposing surface. A method for manufacturing a rotor.

9. When the enlarged portion is referred to as the first enlarged portion and the reduced portion as the first reduced portion, The filling pot has a second enlarged section that opens toward the first mold, and a second reduced section that opens on the bottom surface of the second enlarged section and is narrower in width than the second enlarged section. In the filling process, the plunger is stopped at a position where the first enlarged portion is located within the second enlarged portion and the first reduced portion is located within the second reduced portion. The method for manufacturing a rotor according to claim 8.

10. When the enlarged portion is referred to as the first enlarged portion and the reduced portion as the first reduced portion, The filling pot has a second enlarged section that opens toward the first mold, and a second reduced section that opens on the bottom surface of the second enlarged section and is narrower in width than the second enlarged section. A support step in which the resin material is supported by the second reduction portion while the Calplate is not positioned between the first type and the second type, The process includes a transport step of transporting the Calplate, in which the resin material is supported in the second reduction portion, between the first mold and the second mold. In the mold clamping step, the rotor core and the calplate conveyed in the conveying step are clamped together in the axial direction by the first mold and the second mold. The method for manufacturing a rotor according to claim 8.

11. When the enlarged portion is referred to as the first enlarged portion and the reduced portion as the first reduced portion, The filling pot has a second enlarged section that opens toward the first mold, and a second reduced section that opens on the bottom surface of the second enlarged section and is narrower in width than the second enlarged section. The width of the second enlarged portion is greater than the width of the receiving hole. The device includes a separation step of separating the resin material in the filling pot from the plunger by retracting the plunger from the calplate while the first and second molds are clamped together. The method for manufacturing a rotor according to claim 8.

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