Magnet insertion device, magnet insertion method, and manufacturing device and method for rotors for rotating electrical machines

Abstract

To efficiently insert permanent magnets into a workpiece.SOLUTION: A magnet insertion device is disclosed, which comprises: a support jig that supports, in a horizontal position, a workpiece having a plurality of axial holes along a circumferential direction; a magazine; a first fulcrum that supports a first permanent magnet at a first height; a second fulcrum that supports a second permanent magnet at a second height; and an insertion jig that inserts the first permanent magnet and the second permanent magnet delivered from the magazine simultaneously into one axial hole being an insertion target in the workpiece in a second direction. The support jig locates the workpiece with respect to the insertion jig in an attitude in which one side in a first direction becomes lower than the other side in one axial hole being the insertion target. The second fulcrum is adjacent to the first fulcrum from one side in the first direction, and the second height is lower than the first height.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present disclosure relates to a magnet insertion device, a magnet insertion method, a manufacturing device for a rotor for a rotating electric machine, and a manufacturing method for a rotor for a rotating electric machine. [Background technology]

[0002] A known technique involves supporting a circular workpiece having multiple axial holes along the circumferential direction in a horizontal position with the multiple axial holes facing horizontally, and inserting one permanent magnet into each axial hole. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Publication No. 2017-051058 Summary of the Invention [Problem to be solved by the invention]

[0004] However, with the above-described conventional techniques, it is difficult to efficiently insert permanent magnets into the workpiece.

[0005] Therefore, in one aspect, an object of the present disclosure is to efficiently insert a permanent magnet into a workpiece. [Means for solving the problem]

[0006] In one aspect, a support jig that supports a workpiece having a plurality of axial holes along a circumferential direction in a horizontal position in which the plurality of axial holes are oriented horizontally; a magazine that stores a plurality of pairs of first permanent magnets and second permanent magnets arranged in a first direction intersecting the direction of gravity, stacked in the direction of gravity; a first support table that supports the first permanent magnet dispensed from the magazine at a first height; a second support table that supports the second permanent magnet dispensed from the magazine at a second height; an insertion jig that simultaneously inserts the first permanent magnet and the second permanent magnet dispensed from the magazine into one of the axial holes of an insertion target in the workpiece by moving the first permanent magnet and the second permanent magnet in a horizontal second direction that intersects the first direction, The support jig positions the workpiece relative to the insertion jig in the horizontal orientation in which one side of the axial hole of the insertion target in the first direction is lower than the other side when viewed in the second direction, The magnet insertion device is provided such that the second support base is adjacent to the first support base from the one side in the first direction, and the second height is lower than the first height. [Effects of the Invention]

[0007] In one aspect, the present disclosure enables a permanent magnet to be efficiently inserted into a workpiece. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a plan view showing an example of a rotor for a rotating electric machine to be manufactured; [Figure 2] 1 is a side view schematically showing an example of a manufacturing apparatus for a rotor for a rotating electric machine according to the present embodiment (in a state before permanent magnets are inserted). FIG. [Figure 3] 1 is a side view schematically showing an example of a manufacturing apparatus for a rotor for a rotating electric machine according to the present embodiment (in a state where a permanent magnet is being inserted). FIG. [Figure 4] FIG. 2 is a plan view schematically showing a workpiece. [Figure 5] 10 is a side view (as viewed in the X direction) showing the relationship between the magazine, the permanent magnet, and the support base. FIG. [Figure 6] FIG. 10 is a perspective view showing the insertion jig in a single state. [Figure 7] FIG. 10 is a side view showing a part of the workpiece together with the tip ends of two permanent magnets inserted by an insertion jig. [Figure 8] FIG. 8 is a schematic cross-sectional view taken along line AA in FIG. 7. [Figure 9] FIG. 8 is a schematic cross-sectional view taken along line BB in FIG. 7. [Figure 10] 10A and 10B are explanatory diagrams of problems with the first comparative example in which the support base does not have a step forming function. [Figure 11] 10A and 10B are explanatory diagrams illustrating problems with a second comparative example in which the magazine is tilted instead of having a step-forming function for the support base. [Figure 12] 10A and 10B are explanatory diagrams of problems with a second comparative example that includes a support base having a support surface that is inclined relative to the horizontal plane. [Figure 13] 10A and 10B are explanatory diagrams of problems with the first comparative example in which the support base does not have a step forming function. [Figure 14] FIG. 10 is a schematic diagram illustrating a workpiece viewed from the axial direction, illustrating a further effect of the present embodiment. [Figure 14A] FIG. 10 is a front view of a part of the manufacturing apparatus as viewed in the X direction from the X2 side. [Figure 15] 1 is a flowchart showing an example of a method for manufacturing a rotor for a rotating electric machine. [Figure 16] FIG. 10 is a side view (as viewed in the Y direction) schematically showing a manufacturing apparatus according to a modified example. [Figure 17] 10 is a side view (as viewed in the X direction) showing the relationship between the magazine, permanent magnets, and support base according to a modified example. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0009] Each embodiment will be described in detail below with reference to the accompanying drawings. Note that the dimensional ratios in the drawings are merely examples and are not intended to limit the scope of the invention. In addition, shapes and the like in the drawings may be partially exaggerated for the sake of explanation.

[0010] The manufacturing apparatus for a rotor for a rotating electric machine and the manufacturing method for a stator for a rotating electric machine described below can be applied to any stator for a rotating electric machine. As a suitable application example, a method for manufacturing a stator for a rotating electric machine that can function as a power source that generates a propulsion force for a vehicle will be described below. In this case, the rotating electric machine may be used in, for example, a hybrid vehicle or an electric vehicle.

[0011] FIG. 1 is a plan view showing an example of a rotor 1 for a rotating electric machine that is preferably manufactured by the manufacturing apparatus and method for a rotor for a rotating electric machine according to this embodiment.

[0012] The rotor 1 for a rotating electric machine is rotatable around a central axis (rotation axis) I. The rotor core 12 of the rotor 1 for a rotating electric machine is in the form of a ring around the central axis I. The rotor core 12 is formed, for example, from a ring-shaped laminated steel plate of a magnetic material. Permanent magnets 16, 17 (see FIG. 2) are embedded inside the rotor core 12. That is, the rotor core 12 has magnet holes 121 that penetrate in the axial direction, and the permanent magnets 16, 17 are inserted into and fixed in the magnet holes 121. In a modified example, the rotor core 12 may be formed from a green compact obtained by compressing and solidifying magnetic powder.

[0013] In this embodiment, two permanent magnets 16 and 17 are inserted into one magnet hole 121. The two permanent magnets 16 and 17 may be arranged in one magnet hole 121 adjacent to each other in the circumferential direction.

[0014] 1, one magnet hole 121 is disposed on each side of the d-axis for one magnetic pole, but additional magnet holes passing through the d-axis may be provided. Alternatively, magnet holes may be provided symmetrically about the d-axis on both the inner diameter side and the outer diameter side, and the magnet holes may be arranged in any manner. This embodiment is applicable to any configuration in which two permanent magnets (or three or more permanent magnets) are provided for one magnet hole.

[0015] 1, the magnet hole 121 has a rectangular shape, but may have an arc shape at the circumferential end or the like. In this embodiment, the permanent magnets 16, 17 are preferably linear (rectangular parallelepiped), but may also have an arc shape or a D-shape when viewed in the axial direction. In this embodiment, as an example, the two permanent magnets 16, 17 have a linear shape and are identical to each other. However, in a modified example, the two permanent magnets 16, 17 may have different shapes.

[0016] 2 and 3 are side views schematically illustrating an example of a manufacturing apparatus 2 for a rotor for a rotating electric machine according to this embodiment, with FIG. 2 illustrating the state before permanent magnets are inserted (a state in which the insertion jig 50 is in the preparation position), and FIG. 3 illustrating the state during insertion of the permanent magnets. FIG. 4 is a plan view schematically illustrating a workpiece 60. FIG. 4 also illustrates an enlarged view of part Q4 as an enlarged view of a portion of the workpiece 60. FIG. 5 is a side view (as viewed in the X direction) showing the relationship between the magazine 30 and the permanent magnets 16, 17 housed therein and the support bases 41, 42. FIG. 6 is a perspective view illustrating the insertion jig 50 in a single state.

[0017] 2 etc., three mutually orthogonal directions, an X direction (an example of the second direction), a Y direction (an example of the first direction), and a Z direction, are defined. Hereinafter, the Z direction will be defined as the up-down direction along the vertical (gravitational) direction, the Z1 side will be defined as the upper side, and the Z2 side will be defined as the lower side.

[0018] As will be described below, the manufacturing apparatus 2 has a function of inserting the permanent magnets 16, 17 into the workpiece 60. The workpiece 60 is an object into which the permanent magnets 16, 17 are inserted. The workpiece 60 is used to form the rotor 1 for a rotating electric machine, and has an annular shape corresponding to the rotor core 12.

[0019] The manufacturing apparatus 2 includes a support jig 20, a magazine 30, support bases 41 and 42, and an insertion jig 50. In this embodiment, as an example, the workpiece 60 is a ring-shaped jig that is different from the rotor core 12, and is a component of the manufacturing apparatus 2. However, in a modified example, the workpiece 60 may be the rotor core 12 itself. Unless otherwise specified below, one magazine 30, one support base 41 and 42, and one insertion jig 50 will be described, but as will be described later, two or more magazines 30, one support base 41 and 42, and one insertion jig 50 may be provided for one workpiece 60.

[0020] The support jig 20 supports an annular workpiece 60. In the following description, the workpiece 60 is assumed to have the same central axis I as the central axis I of the rotor 1 for a rotating electric machine, and the axial, radial, and circumferential directions of the workpiece 60 are defined based on the central axis I. The workpiece 60 has multiple axial holes 62 arranged along the circumferential direction. FIG. 4 shows the multiple axial holes 62 as viewed in the axial direction. Permanent magnets 16, 17 are inserted into each of the multiple axial holes 62 by an insertion jig 50, which will be described later. The multiple axial holes 62 have a shape that allows the permanent magnets 16, 17 to be inserted in the axial direction, and the longitudinal direction (the longitudinal direction as viewed in the axial direction) is the arrangement direction of the inserted permanent magnets 16, 17. The multiple axial holes 62 may have substantially the same shape or exactly the same shape as the magnet holes 121 of the rotor core 12 as viewed in the axial direction. The manufacturing apparatus 2 according to this embodiment does not simultaneously insert the permanent magnets 16, 17 into the multiple axial holes 62, but instead inserts the permanent magnets 16, 17 one by one while changing some (for example, one or two) of the multiple axial holes 62. Hereinafter, the "axial hole 62 to be inserted" refers to the axial hole 62 among the multiple axial holes 62 into which the next permanent magnets 16, 17 are to be inserted, based on that point in time, or the magnet hole 121 into which the permanent magnets 16, 17 are currently inserted.

[0021] The support jig 20 supports the workpiece 60 in an orientation in which the axial hole 62 faces horizontally (in this embodiment, the X direction). That is, the support jig 20 supports the workpiece 60 in an orientation in which the axial direction of the workpiece 60 is horizontally (in this embodiment, the X direction). Hereinafter, such an orientation of the workpiece 60 (an orientation in which the axial direction of the workpiece 60 is horizontally) will also be referred to as a "horizontal orientation." FIGS. 2 and 3 show a state in which the support jig 20 supports the workpiece 60 in a horizontal orientation. Note that the support jig 20 may be rotatable about a rotation axis along the Y axis, and may be able to change the orientation of the workpiece 60 between a horizontal orientation and an orientation in which the axial direction of the workpiece 60 is vertically directed (hereinafter also referred to as an "upward orientation").

[0022] In this embodiment, the support jig 20 supports the workpiece 60 in a horizontal position in which one axial hole 62 of the workpiece 60 to be inserted faces directly in the X direction to the upper part of the insertion jig 50, which will be described later. In a state in which the one axial hole 62 to be inserted faces directly in the X direction to the upper part of the insertion jig 50, it is possible to insert permanent magnets 16, 17 into the one axial hole 62 to be inserted by the insertion jig 50, which will be described later. In other words, of the multiple axial holes 62 of the workpiece 60 in a horizontal position, the one axial hole 62 that faces directly in the X direction to the upper part of the insertion jig 50 is the "one axial hole 62 to be inserted."

[0023] In this embodiment, when the axial hole 62 to be inserted faces the upper portion of the insertion jig 50 in the X direction, the longitudinal direction (longitudinal direction as viewed in the axial direction) of the axial hole 62 to be inserted in the workpiece 60 extends in a substantially horizontal direction. That is, the support jig 20 positions the workpiece 60 with respect to the insertion jig 50 in a horizontal orientation in which the longitudinal direction of the axial hole 62 to be inserted in the workpiece 60 is substantially horizontal. The enlarged view of portion Q4 in FIG. 4 shows the axial hole 62 to be inserted. The state in which the longitudinal direction of the axial hole 62 to be inserted extends in a substantially horizontal direction means that the angle α between the longitudinal direction of the axial hole 62 to be inserted and the horizontal direction is slightly larger than 0 degrees, as shown in the enlarged view of portion Q4 in FIG. 4. The angle α is a relatively small angle, for example, 5 degrees or less, and may be, for example, approximately 3 degrees. Hereinafter, the one axial hole 62 of the insertion target having a longitudinal direction that forms an angle α with respect to the horizontal direction will also be simply referred to as an “inclined axial hole 62.” In the enlarged view of part Q4 in Fig. 4, the one axial hole 62 of the insertion target has a rectangular shape when viewed in the axial direction, but as described above, the shape of the axial hole 62 is arbitrary.

[0024] In this way, in this embodiment, the support jig 20 can position the workpiece 60 relative to the insertion jig 50 in a horizontal position in which the axial hole 62 (one axial hole 62 to be inserted) faces directly in the X direction relative to the top of the insertion jig 50, and one side in the Y direction (the Y2 side in Figure 4) of the one axial hole 62 to be inserted is lower than the other side (the Y1 side) when viewed in the X direction (axial view).

[0025] The support jig 20 may be rotatable about a rotation axis along the X axis, and may be able to change the axial hole 62 that faces the upper part of the insertion jig 50 in the X direction while maintaining the horizontal orientation of the workpiece 60. In this case, the support jig 20 can rotate about a rotation axis concentric with the central axis I, thereby sequentially changing one of the axial holes 62 to be inserted.

[0026] The magazine 30 accommodates multiple pairs of two permanent magnets 16, 17 aligned in the Y direction, stacked in the direction of gravity.

[0027] The magazine 30 has an opening at its bottom end, with support bases 41 and 42 disposed below. The two lowest permanent magnets 16 and 17 in the magazine 30 fall onto the support bases 41 and 42, respectively, and are thereby dispensed (ejected) from the magazine 30. When the two lowest permanent magnets 16 and 17 fall onto the support bases 41 and 42, each of the permanent magnets 16 and 17 in the magazine moves downward by one magnet due to its own weight. In this way, the permanent magnets 16 and 17 in the magazine 30 can be dispensed onto the support bases 41 and 42 in order from the bottom, using gravity.

[0028] The magazine 30 has sidewalls 31 and 32 extending on both sides of the permanent magnets 16 and 17 in the Y direction, and the sidewalls 31 and 32 extend to a height corresponding to the maximum stack height of the permanent magnets 16 and 17. The lower ends of the sidewalls 31 and 32 may be close to the support bases 41 and 42, leaving a necessary clearance. Specifically, when viewed in the Y direction, the sidewall 31 on the Y1 side overlaps with the permanent magnet 16 on the Y1 side (the permanent magnet 16 supported by the support base 41) dispensed from the magazine 30, and the sidewall 32 on the Y2 side overlaps with the permanent magnet 17 on the Y2 side (the permanent magnet 17 supported by the support base 42). The lower ends of the sidewalls 31 and 32 of the magazine 30 also have a function of restricting movement in the Y direction of the permanent magnets 16 and 17 dispensed from the magazine 30 (hereinafter also referred to as a "Y-direction position restriction function"). The position restriction function in the Y direction functions for the permanent magnets 16 and 17 when they are pushed out in the X direction by an insertion jig 50, which will be described later.

[0029] The support bases 41 and 42 are disposed below the magazine 30. In this embodiment, the support bases 41 and 42 are fixed and do not move relative to the magazine 30. The magazine 30 also does not move relative to the equipment, but may be replaceable.

[0030] The support base 41 has a support surface 410 that faces the opening at the bottom end of the magazine 30 from below in the vertical direction. The support base 41 supports the permanent magnets 16 that are dispensed from the opening at the bottom end of the magazine 30 on the support surface 410. The support surface 410 extends in a horizontal plane, but a convex portion or the like may be formed on the periphery of the support surface 410.

[0031] The support base 42 has a support surface 420 that faces the opening at the bottom end of the magazine 30 from below in the vertical direction. The support base 42 supports the permanent magnets 17 that are dispensed from the opening at the bottom end of the magazine 30 on the support surface 420. The support surface 420 extends in a horizontal plane, but a convex portion or the like may be formed on the periphery of the support surface 420.

[0032] 5, the support base 42 is adjacent to the support base 41 from one side in the Y direction (the Y2 side in this embodiment). In the example shown in FIG. 5, the support base 42 is adjacent to the support base 41 with the insertion jig 50 sandwiched therebetween.

[0033] The support surface 420 of the support base 42 is lower than the support surface 410 of the support base 41. That is, a height H2 (see FIG. 5) of the support surface 420 of the support base 42 is lower than a height H1 of the support surface 410 of the support base 41. Therefore, the height of the permanent magnets 17 supported by the support base 42 is different from the height of the permanent magnets 16 supported by the support base 41. That is, the support base 41 supports the permanent magnets 16 dispensed from the magazine 30 at a height H1, whereas the support base 42 supports the permanent magnets 17 dispensed from the magazine 30 at a height H2 (an example of a second height) that is lower than the height H1 (an example of a first height).

[0034] In this way, the support bases 41, 42 of this embodiment have support surfaces 410, 420 of different heights H1, H2, so that the permanent magnets 16, 17 dispensed from the magazine 30 can be supported at different heights H1, H2. This allows the permanent magnets 16, 17 to be easily inserted into an inclined axial hole 62, as will be described later with reference to FIGS. 7 to 9. The difference between the heights H1, H2 may be adapted according to the angle α (see FIG. 4) of the axial hole 62 to be inserted as described above. Hereinafter, this support function of the support bases 41, 42 will also be referred to as a "step-forming function." The technical significance of the step-forming function will be described in detail later.

[0035] The insertion jig 50 is movable along the X direction. The insertion jig 50 may be movable linearly (translationally) along the X direction. As shown in FIGS. 2 and 3, the insertion jig 50 is disposed on the X1 side of the two permanent magnets 16, 17 dispensed from the magazine 30. As shown in FIG. 5, the insertion jig 50 overlaps the two permanent magnets 16, 17 dispensed from the magazine 30 when viewed in the X direction. In the example shown in FIG. 5, the upper part of the insertion jig 50 (the portion overlapping the two permanent magnets 16, 17) has a rectangular shape when viewed in the X direction, but may have other shapes. The insertion jig 50 may have, for example, a claw-like shape as shown in FIG. 6, or other shapes.

[0036] As the insertion jig 50 moves toward the X2 side along the X direction, the X2-side end face of the insertion jig 50 abuts against the X1-side end faces of the two permanent magnets 16 and 17 dispensed from the magazine 30. In this abutting state, as the insertion jig 50 moves further toward the X2 side along the X direction, the permanent magnets 16 and 17 are moved toward the X2 side. As the insertion jig 50 moves further toward the X2 side along the X direction, the permanent magnets 16 and 17 are inserted in the X direction into one of the axial holes 62 of the insertion target in the workpiece 60. FIG. 3 shows a state in which the insertion jig 50 has moved toward the X2 side from the state shown in FIG. 2 . As the insertion jig 50 moves toward the X2 side along the X direction, the two permanent magnets 16 and 17 on the support bases 41 and 42 move toward the X2 side along the X direction. That is, the two permanent magnets 16 and 17 on the support bases 41 and 42 are pushed toward the workpiece 60 by the insertion jig 50. In this way, the insertion jig 50 can insert the two permanent magnets 16, 17 into the axial hole 62 located at the destination (X2 side) of the two permanent magnets 16, 17.

[0037] The insertion jig 50 may simultaneously insert the two permanent magnets 16, 17 into one axial hole 62 that is an insertion target in the workpiece 60. Note that "simultaneously" does not strictly mean insertion in a manner that causes absolutely no misalignment of the two permanent magnets 16, 17 in the X direction, but means a manner in which there is a time when the two permanent magnets 16, 17 are moving simultaneously toward one axial hole 62, and it is acceptable for the two permanent magnets 16, 17 to be slightly misaligned in the X direction.

[0038] In this embodiment, the insertion jig 50 is disposed between the support bases 41 and 42 in the Y direction, as shown in FIG. 5 . In this case, the two permanent magnets 16, 17 on the support bases 41, 42 can be moved simultaneously in the X direction using one insertion jig 50. As described above, in this embodiment, the insertion jig 50 is a common jig for the two permanent magnets 16, 17 dispensed from the magazine 30, and therefore can move the two permanent magnets 16, 17 in the X direction without causing any substantial misalignment in the X direction. However, in a modified example, the insertion jig 50 may be realized by combining a jig that moves the permanent magnet 16 in the X direction and a jig that moves the axial hole 62 in the X direction.

[0039] Here, a preferred configuration of the workpiece 60 will be further described with reference to FIGS. 7 to 9, along with the insertion operation of the insertion jig 50 for the two permanent magnets 16 and 17.

[0040] Fig. 7 is a side view showing a portion of the workpiece 60 (a portion relating to one axial hole 62 into which the magnets are to be inserted) along with the tip portions of the two permanent magnets 16, 17 being inserted by the insertion jig 50. Fig. 7 shows the inside of the axial hole 62 of the workpiece 60 in a perspective view so that the state of the permanent magnets 16, 17 inside the axial hole 62 can be seen. Fig. 8 is a schematic cross-sectional view taken along line AA in Fig. 7. Fig. 9 is a schematic cross-sectional view taken along line BB in Fig. 7.

[0041] In this embodiment, the workpiece 60 preferably has a tapered shape in which the hole area (area as viewed in the axial direction) of the axial hole 62 becomes larger on the X1 side (the entrance side for the permanent magnets 16, 17). That is, the workpiece 60 has an expanded diameter portion 69 at the X1 side end of the normal portion 68 as a portion around the axial hole 62. In the normal portion 68, the axial hole 62 has a shape that coincides with the above-mentioned magnet hole 121 or is slightly larger than the magnet hole 121. In the expanded diameter portion 69, the axial hole 62 is significantly larger than the above-mentioned magnet hole 121, and has a shape in which the hole area increases toward the X1 side (the entrance side for insertion).

[0042] By having the tapered shape of the workpiece 60 in this way, the step-forming function described above makes it possible to more easily insert the two permanent magnets 16, 17, which have a difference in height, into the inclined axial hole 62. That is, even if the tip ends (tip ends on the X2 side) of the two permanent magnets 16, 17 are slightly misaligned with respect to the axial hole 62 in the normal portion 68 when viewed in the axial direction, there is a high possibility that they can be inserted into the axial hole 62 in the expanded diameter portion 69. Then, if the tip ends of the two permanent magnets 16, 17 can be inserted into the axial hole 62 in the expanded diameter portion 69, the tapered shape makes it possible to guide the tip ends of the two permanent magnets 16, 17 into the axial hole 62 in the normal portion 68 while correcting the misalignment.

[0043] When the axial hole 62 faces the insertion jig 50, the centers O1 and O2 (e.g., centroids in the axial view) of the permanent magnets 16 and 17 of the support bases 41 and 42 may be located on a center line L0 along the longitudinal direction of the axial hole 62, as shown schematically in FIG. 8 . The center line L0 is a straight line passing through the center of the axial hole 62 in a direction perpendicular to the longitudinal direction of the axial hole 62 in the axial view. However, when the axial hole 62 faces the insertion jig 50, the centers O1 and O2 of the permanent magnets 16 and 17 of the support bases 41 and 42 may be located slightly below the center line L0 of the axial hole 62. In this case, the permanent magnets 16 and 17 can be guided to their correct positions (inside the axial hole 62 at the normal portion 68) by being scooped up by the tapered shape.

[0044] Next, the effects of this embodiment will be described in comparison with a comparative example with reference to FIGS.

[0045] Figure 10 is an explanatory diagram of the problem with the first comparative example, which does not have a step-forming function for the support bases 41 and 42, and is a diagram that schematically shows the positional relationship between the two permanent magnets 16 and 17 and the axial hole 62 (the axial hole 62 to be inserted) when viewed in the axial direction.

[0046] As shown schematically by arrow R10 in Fig. 10 , in the first comparative example, when inserting the two permanent magnets 16, 17, the two permanent magnets 16, 17 that are aligned horizontally in the Y direction tend to interfere with the inclined axial hole 62. This is also true when a tapered shape as described above with reference to Fig. 7 is formed on the entrance side of the axial hole 62. For example, if the permanent magnet 16 is placed directly facing the permanent magnet 17 as a reference, the orientation of the permanent magnet 16 becomes too oblique with respect to the horizontal plane when following the tapered shape, and it tends to interfere with the upper part of the axial hole 62.

[0047] In contrast, according to this embodiment, as described above with reference to FIGS. 7 to 9, the step forming function of the support bases 41 and 42 is provided, making it possible to avoid the problems that occur in the first comparative example.

[0048] Fig. 11 is an explanatory diagram of the problems with the second comparative example in which the magazine 30 is tilted instead of having the step-forming function of the support bases 41, 42. Fig. 11 shows a schematic view of the magazine 30 and the multiple permanent magnets 16, 17 housed therein as viewed in the axial direction. Fig. 11 also shows a normal state on the left side and an abnormal state that may occur on the right side.

[0049] In the second comparative example, the magazine 30 is tilted to match the angle α of the tilted axial hole 62. When the magazine 30 is tilted as in the second comparative example, the stacked permanent magnets 16, 17 tend to lose stability in their position (e.g., rotation around the X-axis) due to differences in the resistance of the stacked permanent magnets 16, 17 when they fall. The abnormal state shown on the right side of FIG. 11 is a state in which the lower permanent magnet 16 has fallen over. When such an abnormality occurs, the permanent magnets 16 become clogged inside the magazine 30, which can easily cause the production line to stop.

[0050] In contrast to this, according to this embodiment, by providing the step forming function of the support bases 41 and 42, it is not necessary to tilt the magazine 30, and it is possible to avoid the problem that occurs in the second comparative example.

[0051] Fig. 12 is an explanatory diagram of the problem with the third comparative example, which includes support bases 41A and 42A having support surfaces 410A and 410A inclined relative to the horizontal plane instead of the support bases 41 and 42. Fig. 12 shows the support bases 41A and 42A (and the insertion jig 50) together with the permanent magnets 16 and 17 dispensed from the magazine 30A as viewed in the axial direction.

[0052] In the third comparative example, the support surfaces 410A, 420A are inclined to match the angle α of the inclined axial hole 62. When the support surfaces 410A, 420A are inclined as in the third comparative example, the Y-direction inner dimension W12 of the magazine 30A must be significantly larger than the total width dimension W0 of the permanent magnets 16, 17. Specifically, the Y-direction inner dimension W12 of the magazine 30A must have a margin with respect to the maximum Y-direction dimension W1 of the two permanent magnets 16, 17 when they are supported by the support surfaces 410A, 420A. Because the Y-direction dimension W1 is significantly larger than the total dimension W0, the inner dimension W12 of the magazine 30A must have a correspondingly larger margin with respect to the total dimension W0.

[0053] As described above, the magazine 30 (and the magazine 30A as well) has a position restriction function in the Y direction. That is, the lower ends of the side wall portions 31, 32 of the magazine 30 have a function of restricting movement of the permanent magnets 16, 17 in the Y direction. This position restriction function in the Y direction functions more effectively when the difference between the inner dimension W5 (see FIG. 5) of the magazine 30 in the Y direction (the distance in the Y direction between the inner surfaces of the side wall portions 31, 32) and the total width dimension W0 of the permanent magnets 16, 17 is smaller (however, W5>W0).

[0054] In this regard, in the third comparative example, as described above, the Y-direction inner dimension W12 of the magazine 30A has a relatively large margin with respect to the total dimension W0, making it difficult for the Y-direction position restriction function to function effectively. If the Y-direction position restriction function does not function effectively, the tips of the permanent magnets 16, 17 tend to open up during insertion, as shown schematically in FIG. 13 (see arrows R13). As shown in FIG. 13, if the tips of the permanent magnets 16, 17 open up during insertion, interference between the permanent magnets 16, 17 is likely to occur at the entrance side of the axial hole 62. Note that in this embodiment (as in the third comparative example), the insertion jig 50 presses the central portions of the permanent magnets 16, 17 (the Y2 side of the permanent magnet 16 and the Y1 side of the permanent magnet 17), so the tips of the permanent magnets 16, 17 tend to open up, and the Y-direction position restriction function is highly useful.

[0055] In contrast, according to this embodiment, the Y-direction internal dimension W5 (see FIG. 5) of the magazine 30 can be set to have a minimum margin with respect to the total dimension W0, which is the maximum Y-direction dimension of the two permanent magnets 16, 17 aligned on a horizontal plane. Specifically, the Y-direction internal dimension of the magazine 30 is adapted based on the total widthwise dimension W0 of the permanent magnets 16, 17 so that the permanent magnets 16, 17 do not significantly tilt with respect to the horizontal plane within the magazine 30. This makes it possible to minimize the Y-direction internal dimension of the magazine 30 with respect to the total dimension W0, thereby effectively restricting the position in the Y direction and avoiding the above-mentioned problem (see FIG. 13) that is likely to occur in the third comparative example.

[0056] 14A and 14B are explanatory diagrams illustrating further effects of this embodiment, and are schematic diagrams showing the workpiece 60 as viewed in the axial direction. Fig. 14A is a front view of a part of the manufacturing apparatus 2 as viewed in the X direction from the X2 side.

[0057] As described above, according to this embodiment, the two permanent magnets 16, 17 can be easily inserted into the inclined axial holes 62, and therefore the two permanent magnets 16, 17 can be inserted in parallel into the two axial holes 62.

[0058] For example, the two axial holes 62 in region A1 shown in FIG. 14 extend in a substantially horizontal direction. Therefore, each of the two axial holes 62 in region A1 can be defined as "one axial hole 62 to be inserted." The two axial holes 62 in region A1 are inclined symmetrically with respect to a vertical line passing through the central axis I when viewed in the axial direction. Therefore, as shown in FIG. 14A , by providing two sets of the above-described support bases 41, 42 so as to have a configuration symmetrical with respect to a vertical line passing through the central axis I when viewed in the axial direction, two permanent magnets 16, 17 can be inserted in parallel into the two axial holes 62 in region A1.

[0059] As described above, according to this embodiment, two permanent magnets 16, 17 can be inserted in parallel into two axial holes 62, thereby reducing the cycle time (CT). For example, the time required for the insertion process can be halved compared to when the permanent magnets 16, 17 are inserted one by one into the multiple axial holes 62 of one workpiece 60.

[0060] Next, a method for manufacturing the rotor 1 for a rotating electric machine will be described with reference to FIG. 15 together with FIGS. 14 and 14A.

[0061] FIG. 15 is a flowchart showing an example of a method for manufacturing the rotor 1 for a rotating electric machine.

[0062] This manufacturing method first includes a preparation step (step S150) of preparing the workpiece 60 and the manufacturing device 2. If the manufacturing device 2 has already been prepared, it is only necessary to prepare the workpiece 60.

[0063] 14 is prepared, and the manufacturing apparatus 2 has the magazine 30, support tables 41 and 42, and insertion jig 50 arranged symmetrically with respect to a vertical plane passing through the apparatus center O0 (see FIG. 14A) when viewed in the axial direction. Note that the apparatus center O0 here is defined as the position through which the central axis I of the workpiece 60 passes when the workpiece 60 is positioned horizontally by the support jig 20.

[0064] Hereinafter, the magazine 30, the support bases 41 and 42, and the insertion jig 50 on the Y1 side in the Y direction with respect to the device center O0 will also be referred to as the Y1-side magazine 30, the Y1-side support bases 41 and 42, and the Y1-side insertion jig 50, respectively. Furthermore, the magazine 30, the support bases 41 and 42, and the insertion jig 50 on the Y2 side in the Y direction with respect to the device center O0 will also be referred to as the Y2-side magazine 30, the Y2-side support bases 41 and 42, and the Y2-side insertion jig 50, respectively.

[0065] Next, this manufacturing method includes an initial dispensing process (step S151) in which permanent magnets 16, 17 are initially dispensed from the Y1-side and Y2-side magazines 30 onto the Y1-side and Y2-side support bases 41, 42. In this case, the initial dispensing process includes a Y1-side supporting process (an example of a first supporting process) in which the permanent magnets 16 dispensed from the Y1-side and Y2-side magazines 30 are supported at a height H1 using the Y1-side and Y2-side support bases 41, and a Y2-side supporting process (an example of a second supporting process) in which the permanent magnets 17 dispensed from the Y1-side and Y2-side magazines 30 are supported at a height H2 using the Y1-side and Y2-side support bases 42. Note that if the permanent magnets 17 have already been dispensed in the preparation process, the initial dispensing process may be omitted. Furthermore, the Y1-side supporting process and the Y2-side supporting process are performed in parallel to shorten the CT, but they do not necessarily need to be performed strictly synchronized.

[0066] Next, this manufacturing method includes an initial positioning step (step S152) of positioning the workpiece 60 relative to the Y1-side and Y2-side insertion jigs 50. Here, the workpiece 60 is positioned in a horizontal orientation with its central axis I passing through the device center O0, and the two axial holes 62 in the region A1 are positioned horizontally so as to directly face the Y1-side and Y2-side insertion jigs 50 located on both sides of the device center O0 in the Y direction. Note that the support table 42 may be configured to achieve this initial positioning step when it rotates around a rotation axis along the Y axis from a state in which it supports the workpiece 60 in a vertical orientation. Note that this initial positioning step may be performed simultaneously with or before the above-mentioned initial removal step (step S151).

[0067] Next, this manufacturing method includes an insertion process (step S154) in which the permanent magnets 16, 17 on the Y1-side and Y2-side support bases 41, 42 are inserted into the workpiece 60 using the Y1-side and Y2-side insertion jigs 50. In this case, the insertion process includes a Y1-side insertion process in which the permanent magnets 16, 17 on the Y1-side support bases 41, 42 are inserted into the Y1-side axial hole 62 of the two axial holes 62 in the region A1 by moving the Y1-side insertion jig 50 toward the X2 side in the X direction, and a Y2-side insertion process in which the permanent magnets 16, 17 on the Y2-side support bases 41, 42 are inserted into the Y2-side axial hole 62 of the two axial holes 62 in the region A1 by moving the Y2-side insertion jig 50 toward the X2 side in the X direction. Note that the Y1-side insertion process and the Y2-side insertion process are preferably performed in parallel to shorten the CT, but they do not necessarily have to be performed strictly synchronized. In this way, the two permanent magnets 16 and 17 are inserted in parallel into the two axial holes 62 of the workpiece 60 that are the insertion targets, by the insertion jigs 50 on the Y1 side and the Y2 side.

[0068] Next, this manufacturing method includes a step (step S156) of returning the Y1-side and Y2-side insertion jigs 50 to their original preparation positions (see FIG. 2). When the Y1-side insertion jig 50 (and the same applies to the Y2-side insertion jig 50) is moved toward the X1 side in the X direction to its original preparation position, the remaining permanent magnets 16, 17 in the Y1-side magazine 30 simultaneously drop by the height of one magnet, and the lowest permanent magnet 16, 17 is dispensed onto the Y1-side support bases 41, 42. Similarly, the Y1-side process and the Y2-side process are performed in parallel to shorten the CT, but they do not necessarily have to be performed strictly synchronized.

[0069] Next, the manufacturing method includes a determination step (step S158) of determining whether or not the insertion of the permanent magnets 16, 17 into all of the axial holes 62 of the current workpiece 60 has been completed. The determination step may be realized based on the number of times a workpiece rotation step, which will be described later, is performed on the current workpiece 60.

[0070] On the other hand, if all insertion has not been completed, the present manufacturing method includes a workpiece rotation step (step S160) in which the support jig 20 is rotated around the central axis I of the workpiece 60, thereby rotating the workpiece 60 supported by the support jig 20 around the central axis I. Note that the entire support jig 20 does not need to rotate; only the portion supporting the workpiece 60 may rotate. For example, the rotation mechanism 22 of the manufacturing apparatus 2 shown in FIG. 14A may rotate around an X-direction axis (= central axis I) passing through the apparatus center O0, thereby rotating the workpiece 60 rotatably supported by the support jig 20. In the present manufacturing method, the workpiece 60 is rotated 45 degrees. For example, when the workpiece 60 is rotated 45 degrees from a state in which the two axial holes 62 in the region A1 shown in FIG. 14 directly face the insertion jigs 50 on the Y1 and Y2 sides, respectively, the two axial holes 62 in the region A2 directly face the insertion jigs 50 on the Y1 and Y2 sides, respectively.

[0071] When the workpiece rotation process (step S160) is completed, the insertion process (step S154) is performed on two new axial holes 62 to be inserted. In this manner, the insertion process is performed sequentially on two axial holes 62 at a time while the workpiece 60 is rotated by 45 degrees. For example, in the example shown in FIG. 14, the insertion process is performed sequentially on two axial holes 62 in each of the regions from region A1 to region A8.

[0072] When the permanent magnets 16, 17 have been inserted into all of the axial holes 62 of the current workpiece 60 in this manner, the manufacturing method includes a step (step S162) of transferring the workpiece 60, with the permanent magnets 16, 17 inserted into all of the axial holes 62, to the next step. For example, the support jig 20 may rotate about a rotation axis along the Y axis to return the current workpiece 60 to an upward orientation. At this time, the workpiece 60 may be positioned in its upward orientation on the rotor core 12, which is a new, separate workpiece. This allows the permanent magnets 16, 17 in the workpiece 60 to be easily inserted into each of the magnet holes 121 of the rotor core 12.

[0073] Next, a modified example will be described with reference to FIGS.

[0074] Fig. 16 is a side view (side view as viewed in the Y direction) that schematically shows a manufacturing apparatus 2B according to a modified example. Fig. 17 is a side view (side view as viewed in the X direction) that shows the relationship between the magazine 30B and permanent magnets 16, 17 and support bases 41B, 42B according to this modified example.

[0075] In this modification, the support bases 41B and 42B are configured to move up and down within the magazine 30B. In this case, the support bases 41B and 42B move upward to dispense the permanent magnets 16 and 17 from above the magazine 30B. At this time, the support bases 41B and 42B support the permanent magnets 16 and 17 at different heights, similar to the support bases 41 and 42 in the above-described embodiment. Also, in this modification, the insertion jig 50B is movable in the X direction, similar to the insertion jig 50 in the above-described embodiment. As shown in FIGS. 16 and 17 , the insertion jig 50B abuts on the upper side of the X1-side end faces of the permanent magnets 16 and 17 and pushes the permanent magnets 16 and 17 toward the X2 side, thereby similarly achieving the insertion process. When the insertion process is completed and the insertion jig 50B returns to its original preparation position, the support bases 41B and 42B rise by the height of one permanent magnet 16 and 17 (see arrow R16 in Figure 16), thereby enabling the next permanent magnet 16 and 17 to be dispensed.

[0076] This modification also provides the same effects as those of the above-described embodiment.

[0077] Although each embodiment has been described in detail above, it is not limited to the specific embodiment, and various modifications and changes are possible within the scope of the claims. It is also possible to combine all or a plurality of components of the above-described embodiments. [Explanation of symbols]

[0078] 1 Rotor for rotating electric machine, 2 Manufacturing device (magnet insertion device), 20 Support jig, 30, 30B Magazine, 41, 41B Support base (first support base), 42, 42B Support base (second support base), 50, 50B Insertion jig, 16 Permanent magnet (first permanent magnet), 17 Permanent magnet (second permanent magnet), 60 Workpiece, 62 Axial hole

Claims

1. a support jig that supports a workpiece having a plurality of axial holes along a circumferential direction in a horizontal orientation in which the plurality of axial holes are oriented horizontally; a magazine that stores a plurality of pairs of first permanent magnets and second permanent magnets arranged in a first direction that intersects with the direction of gravity, stacked in the direction of gravity; a first support table that supports the first permanent magnet dispensed from the magazine at a first height; a second support table that supports the second permanent magnet dispensed from the magazine at a second height; an insertion jig that simultaneously inserts the first permanent magnet and the second permanent magnet dispensed from the magazine into one of the axial holes of an insertion target in the workpiece by moving the first permanent magnet and the second permanent magnet in a horizontal second direction that intersects the first direction, The support jig positions the workpiece relative to the insertion jig in the horizontal orientation in which one side of the axial hole of the insertion target in the first direction is lower than the other side when viewed in the second direction, the second support base is adjacent to the first support base from the one side in the first direction, and the second height is lower than the first height.

2. The magnet insertion device according to claim 1 , wherein the insertion jig is disposed between the first support base and the second support base in the first direction.

3. 3. The magnet insertion device according to claim 1, wherein the insertion jig, the first support base, and the second support base are arranged symmetrically with respect to a vertical plane passing through a central axis of the workpiece in the horizontal orientation, on both sides of the vertical plane.

4. A manufacturing apparatus for manufacturing a rotor for a rotating electric machine, comprising: A magnet insertion device according to any one of claims 1 to 3, The manufacturing apparatus for a rotor for a rotating electric machine includes: a first permanent magnet and a second permanent magnet that are used in the rotor;

5. preparing a workpiece having a plurality of axial holes arranged along a circumferential direction; preparing a magazine that stores a plurality of pairs of first permanent magnets and second permanent magnets arranged in a first direction intersecting the direction of gravity, stacked in the direction of gravity; preparing an insertion jig; preparing a first support stand and a second support stand adjacent to the first support stand from one side in the first direction; a first supporting step of supporting the first permanent magnet dispensed from the magazine at a first height using the first support base; a second supporting step of supporting the second permanent magnet dispensed from the magazine at a second height lower than the first height using the second support base; a positioning step of positioning the workpiece relative to the insertion jig using a support jig that supports the workpiece, in a horizontal orientation of the workpiece in which the plurality of axial holes are oriented horizontally, and in which the one side in the first direction of one of the axial holes to be inserted is lower than the other side when viewed in the second direction; a magnet insertion method including an insertion step of inserting the first permanent magnet and the second permanent magnet dispensed from the magazine into one of the axial holes of the insertion target of the workpiece positioned by the positioning step by moving the first permanent magnet and the second permanent magnet using the insertion jig in a horizontal second direction that intersects the first direction.

6. the positioning step includes positioning the workpiece relative to the insertion jig in the horizontal orientation in which the axial holes of the two insertion targets are symmetrically positioned with respect to a vertical plane passing through a central axis of the workpiece, 6. The magnet insertion method according to claim 5, wherein the first supporting step, the second supporting step, and the insertion step for the axial holes of the two insertion targets are performed using the insertion jig, the first support base, and the second support base, which are arranged symmetrically on both sides of the vertical plane with respect to the vertical plane.

7. The magnet insertion method according to claim 5 or 6, wherein the workpiece has a tapered shape on the entrance side of the axial hole.

8. A manufacturing method for manufacturing a rotor for a rotating electric machine, comprising: The magnet insertion method according to any one of claims 5 to 7, The method for manufacturing a rotor for a rotating electric machine further includes a step of inserting the first permanent magnet and the second permanent magnet inserted in the workpiece into magnet holes of the rotor.

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