Motor manufacturing method and motor manufacturing apparatus

Abstract

Provided are a motor manufacturing method and a motor manufacturing device with which a reduction in equipment height in a motor core manufacturing process is achieved and a contribution to the improvement of productivity in the motor core manufacturing process is possible. This motor manufacturing method includes: at a first position, feeding a tablet into a lower mold in a state in which a plurality of cores arranged along an axial direction with an intermediate plate therebetween are above and separated from the lower mold; lowering the plurality of cores toward the lower mold; moving the lower mold and the plurality of cores to a second position facing an upper mold; and, at the second position, filling a resin filling part formed in each of the plurality of cores with a resin.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a motor and a motor manufacturing apparatus.

Background Art

[0002] A rotating electrical machine is provided with a motor core (for example, including a rotor core (rotor iron core) and a stator core (stator iron core). Hereinafter, the rotor core and the stator core are collectively referred to simply as the core). Permanent magnets are respectively attached in a plurality of slots arranged in an annular shape at a predetermined interval in the core. As a method of attaching a permanent magnet to the core, a method of inserting a permanent magnet into a slot and then filling and curing resin around it is known (for example, see Japanese Patent No. 5681027).

Summary of the Invention

Problems to be Solved by the Invention

[0003] By the way, in the technique described in Japanese Patent No. 5681027, when filling resin in a state where a plurality of cores are arranged along the axial direction, in order to put a tablet into the lower mold of the molding apparatus after setting a plurality of cores, it is necessary to form a gap between the stacked cores and the lower mold, and the equipment height increases accordingly. On the other hand, if the tablet is put in advance before installing the core in the molding apparatus, the tablet may be heated before installing a plurality of cores, and the curing of the resin forming the tablet may proceed, making resin filling difficult.

[0004] In view of the above problems, an object of the present disclosure is to provide a motor manufacturing method and a motor manufacturing apparatus capable of reducing the equipment height in the motor core manufacturing process and contributing to an improvement in productivity in the motor core manufacturing process.

Means for Solving the Problems

[0005] To achieve the above objective, a first aspect of the technology of this disclosure is a motor manufacturing method comprising: inserting a tablet into a lower mold with a plurality of cores arranged axially via an intermediate plate at a first position, separated upward from the lower mold; lowering the plurality of cores toward the lower mold; moving the lower mold and the plurality of cores to a second position facing the upper mold; and filling the resin-filled portions formed in each of the plurality of cores with resin at the second position.

[0006] A second aspect of the technology of this disclosure is a motor manufacturing method according to the first aspect, wherein a plurality of lower molds are provided on a support base, and a tablet can be inserted into the lower mold in the first position among the plurality of lower molds.

[0007] A third aspect of the technology of this disclosure is a motor manufacturing method according to the first aspect, wherein the lower mold is provided on a support base, and the lower mold and a plurality of cores are moved to a second position by the rotation of the support base.

[0008] A fourth aspect of the technology of this disclosure is a motor manufacturing method according to the first aspect, wherein the lower mold is provided on a support base, and the lower mold and a plurality of cores are moved to a second position by sliding the support base.

[0009] A fifth aspect of the technology of this disclosure is a motor manufacturing method according to the first aspect, in which a plurality of lower molds are provided on a support base, and a plurality of resin-filled cores are separated from the lower mold located in the third position among the plurality of lower molds.

[0010] A sixth aspect of the technology of this disclosure is a motor manufacturing method according to the first aspect, wherein a plurality of lower molds are provided on a support base, and heating for additional curing of the resin is performed on a plurality of cores placed on the lower mold in the third position among the plurality of lower molds.

[0011] A seventh aspect of the technology of this disclosure is a motor manufacturing method according to the first aspect, in which a plurality of lower molds are provided on a support base, and a plurality of cores before resin filling are arranged above the lower mold in the fourth position among the plurality of lower molds.

[0012] An eighth aspect of the technology of this disclosure is a motor manufacturing method according to the first aspect, wherein a plurality of lower molds are provided on a support base, and the lower mold in the fourth position and / or a plurality of cores before resin filling are preheated.

[0013] A ninth aspect of the technology of the present disclosure is a motor manufacturing apparatus comprising: a support mechanism that supports a plurality of cores arranged axially via an intermediate plate in a first position so as to be able to move up and down to a position in which a tablet can be inserted into a lower mold; a moving mechanism that moves the lower mold and the plurality of cores to a second position facing the upper mold; and a resin filling mechanism that fills resin into resin-filled portions formed in each of the plurality of cores in the second position. [Effects of the Invention]

[0014] In view of the above-mentioned problems, the present disclosure provides a motor manufacturing method and a motor manufacturing apparatus that can reduce the height of motor core manufacturing equipment and contribute to improving productivity in the motor core manufacturing process. [Brief explanation of the drawing]

[0015] [Figure 1] This is a schematic diagram showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment. [Figure 2] This is a perspective view showing the schematic configuration of the rotor core and intermediate plate according to the embodiment. [Figure 3] This is a schematic diagram showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment. [Figure 4] This is a schematic diagram showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment. [Figure 5] This is a schematic diagram showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment. [Figure 6] This is a schematic diagram showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment. [Figure 7]It is a schematic plan view showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment. [Figure 8] It is a flowchart showing an example of a rotor core manufacturing process according to an embodiment. [Figure 9] It is a schematic explanatory view showing an example of the schematic configuration of a rotor core manufacturing apparatus of a comparative example. [Figure 10] It is a schematic plan view showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment. [Figure 11] It is a schematic plan view showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment. [Figure 12] It is a schematic plan view showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment. [Figure 13] It is a schematic plan view showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment. [Figure 14] It is a schematic plan view showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment. [Figure 15] It is a schematic plan view showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment. [Figure 16] It is a schematic plan view showing an example of the schematic configuration of a rotor core manufacturing apparatus according to an embodiment.

Embodiments for Carrying Out the Invention

[0016] Hereinafter, each embodiment for carrying out the present disclosure will be described with reference to the drawings. In the following, the range necessary for the description for achieving the object of the present disclosure is schematically shown, and the range necessary for the description of the relevant part of the present disclosure will be mainly described, and the parts where the description is omitted are assumed to be based on known techniques. In addition, the same or corresponding members in the drawings are denoted by the same or similar reference numerals, and duplicate descriptions are omitted. Further, when a plurality of the same or corresponding members are included in one drawing, in order to make the drawing easy to view, only some of them may be denoted by reference numerals.

[0017] <<First Embodiment>> <Overview of Rotor Core Manufacturing Equipment> First, an overview of the rotor core manufacturing apparatus 10 according to this embodiment will be described with reference to Figures 1 and 2. Figure 1 is a schematic explanatory diagram showing an overview of the rotor core manufacturing apparatus 10 according to this embodiment. Figure 2 is a perspective view showing the schematic configuration of the rotor core 2 and intermediate plate 22 according to this embodiment.

[0018] As shown in Figure 1, the rotor core manufacturing apparatus 10 is a device capable of filling resin into the magnet insertion holes 4 of a plurality of rotor cores 2 (i.e., performing mold molding). Specifically, the rotor core manufacturing apparatus 10 is a device that fills resin into the magnet insertion holes 4 formed in each of a plurality of rotor cores 2 that are arranged along the axial direction. The rotor core manufacturing apparatus 10 is an example of a "motor manufacturing apparatus" according to the technology of this disclosure. The plurality of rotor cores 2 is an example of a "multiple cores" according to the technology of this disclosure.

[0019] The rotor core manufacturing apparatus 10 comprises an upper die support section 11 and a table section 30. The upper die support section 11 is a mechanism that supports the upper die 33. When resin is being filled into the rotor core 2, the upper die support section 11 positions the upper die 33 opposite the rotor core 2.

[0020] The upper mold support section 11 comprises a support column 12 extending vertically and a horizontal section 14 extending from the upper end of the support column 12 toward the table section 30. The horizontal section 14 is provided with a plurality of lifting rods 16 (three in this case), and the upper mold 33 is positioned below the horizontal section 14 by the lifting rods 16. The upper mold 33 is movable vertically by the lifting rods 16. The upper mold 33 is an example of an "upper mold" according to the technology of this disclosure.

[0021] The table section 30 comprises a rotary table 31 and a plurality of lower molds 32 provided on the rotary table 31. The rotary table 31 is a table-shaped member having a substantially rectangular parallelepiped shape in plan view. The rotary table 31 is provided with a plurality of lower molds 32. In the example shown in Figure 1, two lower molds 32A and 32B are provided on the upper surface of the rotary table 31. A rotating shaft section 36 is provided in the center of the rotary table 31. The rotating shaft section 36 is rotatable by receiving power from a drive source (not shown). The rotary table 31 is rotatable in conjunction with the rotation of the rotating shaft section 36. The table section 30 is an example of a "moving mechanism" according to the technology of this disclosure. The rotary table 31 is an example of a "support base" according to the technology of this disclosure.

[0022] Support plates 20A and 20B are provided above the lower molds 32A and 32B, respectively. Multiple rotor cores 2 are mounted on the lower molds 32A and 32B via the support plates 20A and 20B. Resin filling passages 23 are formed in the support plates 20A and 20B. In the following description, when it is not necessary to distinguish between the lower molds 32A and 32B, they will simply be referred to as "lower mold 32". Also, in the following description, when it is not necessary to distinguish between the support plates 20A and 20B, they will simply be referred to as "support plate 20". Lower mold 32 is an example of a "lower mold" according to the technology of this disclosure.

[0023] A support rod 21 is installed between the support plate 20B and the lower mold 32B. The support rod 21 is extendable and retractable. By extending and retracting the support rod 21, the support plate 20B can be raised and lowered relative to the lower mold 32B. Specifically, the support rod 21 supports the support plate 20B, on which multiple rotor cores 2 are mounted, so that it can be raised and lowered to a position where a tablet T can be inserted. The support plate 20 and the support rod 21 are an example of a "support mechanism" related to the technology of this disclosure.

[0024] The number and shape of the support rods 21 are not particularly limited, as long as sufficient strength is ensured to allow the multiple rotor cores 2 placed on the support plate 20 to be raised and lowered. Also, although the support plate 20B provided on the lower mold 32B is given as an example here, the lower mold 32A is also provided with a support plate 20A and support rods 21 with a similar configuration.

[0025] A plunger 34A is provided in the center of the lower mold 32A. The plunger 34A is housed in a through hole that connects the lower mold 32A and the rotary table 31. Similarly, a plunger 34B is provided in the center of the lower mold 32B. The plunger 34B is housed in a through hole that connects the lower mold 32B and the rotary table 31. In the following description, when it is not necessary to distinguish between plunger 34A and plunger 34B, they will simply be referred to as "plunger 34". Plunger 34 is an example of a "resin filling mechanism" related to the technology of this disclosure.

[0026] A tablet T (i.e., a resin material solidified into a predetermined shape) can be inserted above plungers 34A and 34B. In other words, the space within the through-hole above plungers 34A and 34B functions as a pot, which is a resin reservoir. The rotor core manufacturing apparatus 10 operates under the control of the control device 15. The tablet T is an example of a "tablet" related to the technology of this disclosure.

[0027] In this embodiment, the multiple rotor cores 2 are arranged in a line along the axial direction of the rotor cores 2 (i.e., along the central axis direction of the cylindrical rotor cores 2). In other words, the multiple rotor cores 2 are arranged in multiple stages.

[0028] Specifically, multiple rotor cores 2 are arranged along the axial direction via an intermediate plate 22. In other words, multiple rotor cores 2 are stacked along the axial direction via an intermediate plate 22. Thus, before being set in the rotor core manufacturing apparatus 10, the rotor cores 2 and the intermediate plate 22 are stacked without any gaps. The stacking of the rotor cores 2 is achieved, for example, by using a robotic arm to stack the rotor cores 2 placed on the intermediate plate 22. In this case, the bottommost rotor core 2 does not need to be placed on the intermediate plate 22. The intermediate plate 22 is an example of an "intermediate plate" related to the technology of this disclosure.

[0029] Furthermore, when multiple rotor cores 2 are arranged in a line along the axial direction, the magnet insertion holes 4 of each of the multiple rotor cores 2 are connected via through holes 22A in the intermediate plate 22. In other words, the through holes 22A are formed at positions corresponding to the magnet insertion holes 4 of the rotor cores 2 mounted on the intermediate plate 22.

[0030] In the example shown in Figure 1, four rotor cores 2 are arranged axially via an intermediate plate 22. It should be noted that this is merely one example; two or three rotor cores 2 could be stacked, or five or more rotor cores 2 could be stacked.

[0031] It should be noted that while this explanation uses an example where multiple rotor cores 2 have the same shape (in this case, the same core height (i.e., axial length)), this is merely one example. Multiple rotor cores 2 may have different shapes (for example, different core heights). In addition to differences in core height, there may also be differences in the arrangement and number of magnet insertion holes 4, and / or the diameter of the cores.

[0032] Furthermore, the multiple rotor cores 2 manufactured by the rotor core manufacturing apparatus 10 according to this embodiment may be stacked and used in the same motor core, or they may be used in separate motor cores. In this specification, the term "motor" also includes a semi-finished product in which some parts are attached to the motor core (rotor core or stator core).

[0033] As shown in Figure 2, the rotor core 2 is formed by laminating multiple thin electromagnetic steel sheets. The rotor core 2 has a cylindrical shape, and a through hole 5 is provided in the central part of the rotor core 2 (i.e., the region including the central axis of the cylinder). When the rotor core 2 is assembled as a motor, the shaft that constitutes the rotating axis is inserted into the through hole 5. In addition, the rotor core 2 has multiple (four in Figure 2) magnet insertion holes 4 arranged circumferentially, extending along the axial direction of the rotor core 2 so as to surround the through hole 5. These magnet insertion holes 4 can be configured in a shape into which permanent magnets 3 can be inserted, for example, a rectangular parallelepiped or arc-shaped through hole penetrating in the thickness direction of the rotor core 2, but their specific shape is not particularly limited. Similarly, the number can also be arbitrarily changed, and it is possible to have more than four, for example, 10 to 40, than the four shown in Figure 2. The magnet insertion holes 4 are an example of a "resin-filled part" according to the technology of this disclosure.

[0034] The magnet insertion hole 4 of the rotor core 2 is into which a permanent magnet 3 is inserted and fixed. The permanent magnet 3 can be made up of, for example, a rectangular parallelepiped or a block with an arc shape in plan view that is slightly smaller than the magnet insertion hole 4. Furthermore, it is not necessary whether the permanent magnet 3 is magnetized or not at the time of insertion into the magnet insertion hole 4. Moreover, it is not necessary whether the permanent magnet 3 is divided in the stacking direction or in a direction perpendicular to the stacking direction. When the permanent magnet 3 is inserted into the magnet insertion hole 4, a gap is formed at least partially between the outer surface of the permanent magnet 3 and the inner surface of the magnet insertion hole 4. This gap formed in the magnet insertion hole 4 functions as a space into which resin is filled. These multiple spaces communicate with the through holes 22A provided in the intermediate plate 22.

[0035] In this embodiment, the magnet insertion hole 4 of the rotor core 2 is exemplified as a rectangular parallelepiped shape that opens in the vertical direction and has substantially no gaps in the front-to-back and left-to-right directions. For this reason, the upper mold 33 and lower mold 32 are designed to have substantially flat contact surfaces, but the shape of the contact surfaces of the upper mold 33 and lower mold 32 can be appropriately changed to match the shape of the rotor core 2 being held. For example, when using the rotor core manufacturing apparatus 10 according to this embodiment for resin molding of an inner rotor type stator core, it is preferable to use upper mold 33 and lower mold 32 that include a projection that is inserted into the space formed in the center of the stator core.

[0036] In the example shown in Figure 2, the intermediate plate 22 has a rectangular shape when viewed from above. The rotor core 2 is placed on the upper surface of the intermediate plate 22. The rotor core 2 is placed on the intermediate plate 22 with the central axis of the intermediate plate 22 and the central axis of the rotor core 2 approximately coincide. The intermediate plate 22 also has a shape that can accommodate the rotor core 2 (for example, a width larger than the outer diameter of the rotor core 2, and a plate thickness that can exert sufficient rigidity to support the rotor core 2).

[0037] The intermediate plate 22 has through holes 22A that penetrate in the thickness direction. The through holes 22A are formed in positions opposite to the magnet insertion holes 4 of the rotor core 2. That is, when the rotor core 2 is placed on the intermediate plate 22, the through holes 22A communicate with the magnet insertion holes 4. The number and arrangement of the through holes 22A are determined according to the number and arrangement of the magnet insertion holes 4 in the rotor core 2.

[0038] Furthermore, the intermediate plate 22 has a protrusion 22B that extends from the surface on which the rotor core 2 is mounted (in this case, the top surface). The protrusion 22B is cylindrical and is insertable into a through hole formed in the rotor core 2. By inserting the protrusion 22B into the through hole 5, the rotor core 2 is positioned relative to the intermediate plate 22. In addition, the engagement of the protrusion 22B and the through hole 5 prevents the rotor core 2 from falling off the mounting surface of the intermediate plate 22. The protrusion length of the protrusion 22B (i.e., the height from the mounting surface to the tip) is set appropriately according to the positioning accuracy, etc.

[0039] The cylindrical projection 22B is merely an example, and may also be columnar. Furthermore, the projection 22B may be a series of pin-shaped members provided along the circumferential direction of the rotor core 2. In this case, the pin-shaped members acting as projections 22B are inserted into holes formed in the rotor core 2 (for example, through-holes provided in the rotor core 2 for weight reduction, or through-holes that serve as flow paths for cooling the core).

[0040] Next, the process of molding the rotor core 2 will be described with reference to Figures 3 to 6. Figure 3 is a schematic diagram showing an example of how the rotor core 2 according to this embodiment is installed in the mold. Figure 4 is a schematic diagram showing an example of how molding is performed on the rotor core 2 according to this embodiment. Figure 5 is a schematic diagram showing an example of how molding is performed on the rotor core 2 according to this embodiment. Figure 6 is a schematic diagram showing an example of how the rotor core 2 according to this embodiment is moved out of the mold.

[0041] As shown in Figure 3, multiple rotor cores 2, aligned along the axial direction, are placed on a support plate 20. Here, multiple rotor cores 2 are placed on the support plate 20B. Then, a tablet T is inserted into the lower mold 32B. The tablet T is inserted into the lower mold 32 from between the support plate 20 and the lower mold 32. That is, the tablet T is inserted into the lower mold 32 while the multiple rotor cores 2 are separated from the lower mold 32. Subsequently, as the support plate 20B descends, the multiple rotor cores 2 descend toward the lower mold 32B. Finally, the multiple rotor cores 2 are placed on the lower mold 32 via the support plate 20B.

[0042] The multiple rotor cores 2 placed on the support plate 20 may be preheated by a heating furnace (not shown). Alternatively, after being placed on the support plate 20, the multiple rotor cores 2 may be preheated by a heating device (not shown).

[0043] Subsequently, as shown in Figure 4, the rotary table 31 rotates 180 degrees, moving the lower mold 32B and the multiple rotor cores 2 placed on it to a position facing the upper mold 33. In this way, the multiple rotor cores 2, aligned along the axial direction, are installed inside the mold (i.e., between the upper mold 33 and the lower mold 32 (in this case, the lower mold 32B)).

[0044] As the rotary table 31 rotates 180 degrees, the lower mold 32A, which was originally located below the upper mold 33, moves to the position where the lower mold 32B was located. In other words, the positions of the lower mold 32B and the lower mold 32A are swapped. At this time, preparations for the resin filling operation may be carried out in the lower mold 32A. Specifically, multiple rotor cores 2 are placed on the support plate 20A. Then, tablets T are inserted into the lower mold 32A. Subsequently, as the support plate 20A descends, the multiple rotor cores 2 are placed on the lower mold 32A via the support plate 20A.

[0045] The preparation work in the lower mold 32A described above only needs to be completed before the next rotation of the rotary table 31, and the timing of its performance is not particularly limited. For example, it may be performed during the filling of resin into the rotor core 2 placed on the lower mold 32B, which will be described later.

[0046] As shown in Figure 5, multiple rotor cores 2 are held by an upper mold 33 and a lower mold 32, aligned axially via an intermediate plate 22. The upper mold 33 supports the uppermost rotor core 2 by contacting its upper surface. The lower mold 32 supports the lowest rotor core 2 by contacting it via a support plate 20. The upper mold 33 is movable up and down by a lifting rod 16 powered by an actuator (not shown). The lifting and lowering of the upper mold 33 can be performed mainly to hold the rotor cores 2 inside the mold or to move the rotor cores 2 out of the mold.

[0047] As described above, the upper mold 33 may be movable in the vertical direction. When the upper mold 33 descends and presses against the upper surface of the rotor core 2 with a predetermined pressing force, multiple rotor cores 2 can be held between the upper mold 33 and the lower mold 32. The shape and material of the surfaces of the upper mold 33 and the lower mold 32 that face the rotor core 2 can be adjusted so that the resin filled into the magnet insertion hole 4 does not leak out of the rotor core 2. Specifically, the contact surfaces can be adjusted so that they are airtight when the rotor core 2 is sandwiched between the upper mold 33 and the lower mold 32.

[0048] In this embodiment, as described above, a structure is adopted in which the upper mold 33 is directly moved up and down. However, other structures can be adopted as long as the vertical positions of the upper mold 33 and the lower mold 32 can be changed relatively. Specifically, for example, instead of moving the upper mold 33 in the vertical direction, the lower mold 32 may be moved in the vertical direction, or both the upper mold 33 and the lower mold 32 may be moved in the vertical direction.

[0049] Between the lower mold 32 and the support plate 20, a resin filling passage 23 is formed for supplying softened resin R to the multiple magnet insertion holes 4 of the rotor core 2. The path structure of the resin filling passage 23 is appropriately set according to the number and shape of the magnet insertion holes 4 of the rotor core 2, the shape of the pot, etc.

[0050] Since the rotor core 2, in which the magnet insertion hole 4 is filled with resin, can often be changed to other shapes, it is preferable to prepare several support plates 20 in advance, each having a resin filling passage 23 with a different structure, and replace them as appropriate to match the rotor core 2 held in the upper mold 33 and lower mold 32.

[0051] The plunger 34 presses against the resin R, which has been softened by heating the tablet T with a heater (not shown). In the example shown in Figure 5, the resin R is pressed by a cylindrical plunger 34B located in the center of the lower mold 32B. As a result, the softened resin R flows and, after passing through the resin filling passage 23, is filled into the magnet insertion hole 4 of the rotor core 2.

[0052] The flowing resin R first enters the magnet insertion hole 4 of the lowest rotor core 2, then enters the magnet insertion holes 4 of the second and third rotor cores 2, and finally enters the magnet insertion hole 4 of the uppermost rotor core 2. In this way, the resin R fills each of the magnet insertion holes 4 of the multiple rotor cores 2.

[0053] Resin R mainly consists of thermosetting resin materials. Specifically, resin R can be made primarily from thermosetting resin materials such as epoxy resin, phenolic resin, unsaturated polyester resin, or cyanate resin. In addition to the thermosetting resin material, resin R may also contain curing agents, fillers, etc.

[0054] As shown in Figure 6, after the resin R has been filled, the rotary table 31 rotates 180 degrees, causing the lower mold 32B and the multiple rotor cores 2 placed on it to move from below the upper mold 33. In this way, the multiple rotor cores 2, which are aligned along the axial direction, are discharged from the mold. The discharged multiple rotor cores 2 are separated from the support plate 20 and removed from the rotor core manufacturing apparatus 10. The multiple rotor cores 2 are then transported to the next process.

[0055] Meanwhile, the rotation of the rotary table 31 causes the positions of the lower mold 32B and the lower mold 32A to be swapped, so that the multiple rotor cores 2 placed on the lower mold 32A are installed inside the mold. Then, resin R is filled into each of the magnet insertion holes 4 of the multiple rotor cores 2.

[0056] Referring to Figure 7, the positional relationship between the lower molds 32A and 32B in a series of mold forming processes will be explained. Figure 7 is a schematic plan view showing an example of the configuration of the rotor core manufacturing apparatus 10 according to this embodiment.

[0057] As shown in Figure 7, first, multiple rotor cores 2, arranged axially via an intermediate plate 22, are placed on the lower mold 32 of the rotor core manufacturing apparatus 10. Here, the lower mold 32A is positioned at the location where molding takes place (i.e., the filling position E2), and the lower mold 32B is positioned at the location where preparation work for molding is performed (i.e., the standby position E1). The multiple rotor cores 2 are placed on the lower mold 32B at the standby position E1.

[0058] In standby position E1, the preparation work described above can be performed. Specifically, multiple rotor cores 2 are placed on the support plate 20B. Then, a tablet T is inserted into the lower mold 32B. Subsequently, as the support plate 20B descends, the multiple rotor cores 2 are placed on the lower mold 32B via the support plate 20B. Standby position E1 is an example of the "first position" related to the technology of this disclosure.

[0059] After the preparation work is completed, the rotary table 31 rotates 180 degrees, causing the lower mold 32B and the multiple rotor cores 2 to move from the standby position E1 to the filling position E2. At the filling position E2, resin is filled into the multiple rotor cores 2 placed on the lower mold 32B. Meanwhile, the lower mold 32A moves from the filling position E2 to the standby position E1. At the standby position E1, the preparation work described above is performed on the lower mold 32A. The filling position E2 is an example of the "second position" related to the technology of this disclosure.

[0060] After the resin filling is complete, the rotary table 31 rotates 180 degrees again, causing the lower mold 32B to move from the filling position E2 to the standby position E1. Multiple rotor cores 2 are separated from the lower mold 32B once it has moved to the standby position E1. Meanwhile, the lower mold 32A moves from the standby position E1 to the filling position E2, and resin is filled into the rotor cores 2 placed on the lower mold 32A.

[0061] After the lower mold 32B returns to the standby position E1, cleaning is performed, followed by preparation work for mold forming again. In this way, mold forming and the preparation work or cleaning work for it are performed continuously as the lower molds 32A and 32B switch positions.

[0062] <Rotor Manufacturing Method> Next, the rotor manufacturing method according to this embodiment will be described with reference to Figure 8. Figure 8 is a flowchart showing an example of the rotor manufacturing process according to this embodiment.

[0063] In the rotor manufacturing method according to this embodiment, first, as shown in Figure 8, the rotor core 2 is placed on the intermediate plate 22 (step S01). In this case, the rotor core 2 is positioned relative to the intermediate plate 22 by inserting the protruding portion 22B into the through hole 5 of the rotor core 2. Note that the rotor core 2 that is at the bottom when stacked does not need to be placed on the intermediate plate 22.

[0064] Next, the permanent magnet 3 and the rotor core 2 to which the permanent magnet 3 is attached are prepared, and the permanent magnet 3 is inserted into the magnet insertion hole 4 of the rotor core 2 (step S02). Then, the multiple rotor cores 2 are arranged in a line along the axial direction via the intermediate plate 22 (step S03).

[0065] Next, the intermediate plate 22, rotor core 2, and permanent magnet 3 are preheated (step S04). This preheating is performed using known heating means (not shown). The heating temperature can be, for example, around 100 to 180°C.

[0066] Multiple rotor cores 2, aligned along the axial direction, are placed on a support plate 20 (step S05). Tablets T are introduced into the lower mold 32 from between the support plate 20 and the lower mold 32 (step S06). A heater (not shown) is operated over the tablets T introduced into the lower mold 32 to soften the resin R (step S07). Specifically, heating in the pot reduces the viscosity of the resin forming the tablets T, resulting in softened resin (hereinafter referred to as "softened resin") R. Preferably, the heater used for this heating is controlled so that no localized temperature differences occur in the tablets T. Due to this heating, the tablets T melt, their viscosity decreases, and they change into highly fluid softened resin R.

[0067] Next, the support plate 20 on which the multiple rotor cores 2 are placed is lowered (step S08). As a result, the multiple rotor cores 2 are placed on the lower mold 32 via the support plate 20. Then, the rotary table 31 is rotated (step S09). As a result, the multiple rotor cores 2, which are aligned along the axial direction via the intermediate plate 22, are installed in the mold.

[0068] By moving the upper mold 33 downward, the rotor core 2 is held within the upper mold 33 and the lower mold 32 (i.e., the mold) (step S10). At this time, the upper mold 33 is adjusted to press against the upper surface of the rotor core 2 with a predetermined pressure, thereby bringing the upper mold 33 and the upper surface of the rotor core 2, and the lower mold 32 and the lower surface of the intermediate plate 22 into close contact.

[0069] When the tablet T is transformed into softened resin R, the softened resin R is filled into the magnet insertion holes 4 via the plunger 34 (step S11). Specifically, the plunger 34 is moved upward to press the resin R and inject the softened resin R into the resin filling passage 23. The softened resin R that has flowed through the resin filling passage 23 is then filled into the magnet insertion holes 4 of each of the multiple rotor cores 2 that are aligned along the axial direction. In order to smoothly fill the magnet insertion holes 4 with softened resin R in step S10, air holes (not shown) for releasing air from the magnet insertion holes 4 may be provided at appropriate locations on the upper mold 33 and the intermediate plate 22, for example.

[0070] The mold heater (not shown) is operated to harden the softening resin R in the magnet insertion hole 4 (step S12). For example, the mold heater may be operated before, during, and / or after the resin is filled, and the resin may harden as it is being filled. That is, steps S11 and S12 may proceed simultaneously. When hardening the softening resin R, it is preferable to heat it at 100 to 180°C for several minutes. As the softening resin R hardens due to this heating, the permanent magnet 3 is fixed in the magnet insertion hole 4 of the rotor core 2 by resin molding. The heating time in step S12 can be appropriately adjusted according to the specific composition of the resin used in the tablet T.

[0071] Once the series of resin molding processes described above are complete, the upper mold 33 is raised and the rotary table 31 is rotated (step S13). This causes the resin-molded rotor core 2 to be removed from the mold. The removed rotor core 2 is then taken to another device for, for example, shaft mounting (step S14). After the removal of the rotor core 2 is complete, the lower mold 32 is cleaned (step S15). Cleaning the lower mold 32 may include cleaning the support plate 20, the lower mold 32, or the inside of the pot using cleaning materials such as brushes.

[0072] As described above, according to the rotor core manufacturing apparatus 10 of this first embodiment, multiple rotor cores 2 that are aligned along the axial direction in the standby position E1 can be separated from the lower mold 32, and tablets T can be introduced into the lower mold 32 in this state. As a result, the height of the equipment can be reduced by the amount of the upper mold 33 and its support structure compared to the case in which multiple rotor cores 2 are installed and tablets T are introduced below the upper mold 33. In addition, since tablets T can be introduced into the lower mold 32 with the rotor cores 2 stacked, resin filling can be performed in a relatively short time compared to the case in which tablets T are introduced and then the rotor cores 2 are installed. As a result, the problem of the resin hardening too much before filling, which would make filling difficult, is suppressed.

[0073] For example, consider the case where multiple rotor cores 2 are installed between the upper mold 33 and the lower mold 132, aligned along the axial direction, as shown in Figure 9. In this case, in order to place the multiple rotor cores 2 on the support plate 120, the upper mold 33 must be raised by the amount of the support plate 120's rise plus the amount of space required for installing the multiple rotor cores 2. Furthermore, when molding multiple rotor cores 2, the amount of resin required for filling increases, and the height of the tablet T increases, so the amount of the support plate 120 must be raised becomes even larger. As a result, the height of the rotor core manufacturing apparatus 100 increases.

[0074] Furthermore, if the tablet T is placed into the lower mold 132 in advance, the support plate 120 can be lowered, thereby reducing the equipment height. However, in this case, the time from placement to the start of filling is longer compared to the case where multiple rotor cores 2 are installed before placing the tablet T. In particular, when multiple rotor cores 2 are installed in an axially aligned state, the weight and height increase compared to the case of a single core, requiring careful work and taking time to install in the molding machine. As a result, if the resin hardens faster than expected due to the passage of time since placement, it becomes difficult to fill the resin. With this configuration, as described above, the equipment height can be reduced by the absence of the upper mold 33 and its support structure, and the resin can be filled in a relatively short time after placing the tablet T.

[0075] Furthermore, according to the rotor core manufacturing apparatus 10 of this first embodiment, the lower mold 32 is provided on the rotary table 31. It is possible to load tablets T into the lower mold 32, which is in standby position E1. This allows for the loading of tablets T into the lower mold 32, which is not inside the mold, thus improving work efficiency. In other words, since the loading of tablets T, which is a preparatory step necessary for resin filling, can be performed outside the mold, the time the mold is occupied can be reduced, contributing to improved work efficiency in the rotor core manufacturing process.

[0076] Furthermore, according to the rotor core manufacturing apparatus 10 of this first embodiment, the lower mold 32 is provided on the rotary table 31, and the rotation of the rotary table 31 moves the multiple rotor cores 2 placed on the lower mold 32 to the filling position E2. Since a circular path can be adopted as the movement trajectory of the lower mold 32 and the multiple rotor cores 2, the degree of freedom of the equipment layout of the rotor core manufacturing apparatus 10 is improved.

[0077] In this first embodiment, an example in which the rotary table 31 rotates 180 degrees was described, but the technology of this disclosure is not limited to this. The rotary table 31 may also rotate 90 degrees. In this case, the rotary table 31 is an L-shaped table in plan view, and the rotating shaft portion 36 is provided at the bent portion of the L-shape.

[0078] <<Second Embodiment>> In the first embodiment described above, an example was given in which a rotary table 31 is used in the table section 30, but the technology of this disclosure is not limited thereto. In this second embodiment, a slide table 40 is used instead of the rotary table 31.

[0079] As shown in Figure 10, the slide table 40 is a table-shaped member having a substantially rectangular parallelepiped shape in plan view. The slide table 40 is a table that can slide along its longitudinal direction. The slide table 40 is supported, for example, by a guide rail mechanism and is able to move along the guide rail by receiving power from a drive source (not shown). The slide table 40 is provided with a plurality of lower molds 32. In the example shown in Figure 10, the slide table 40 is provided with lower molds 32A and 32B.

[0080] First, multiple rotor cores 2, arranged axially via an intermediate plate 22, are placed on the lower mold 32 of the rotor core manufacturing apparatus 10. Here, the lower mold 32A is positioned at the standby position E1, and the lower mold 32B is positioned at the filling position E2. The multiple rotor cores 2 are placed on the lower mold 32A, which is in the standby position E1.

[0081] After preparation work is performed at the standby position E1, the slide table 40 slides (in this case, to the left when viewed from the front of the paper), causing the lower mold 32A and the multiple rotor cores 2 to move from the standby position E1 to the filling position E2. At the filling position E2, resin is filled into the multiple rotor cores 2 placed on the lower mold 32A. Meanwhile, the lower mold 32B moves from the filling position E2 to the standby position E3. Preparation work is performed on the lower mold 32B at the standby position E3.

[0082] After resin filling is performed, the slide table 40 slides in the opposite direction to the previous movement (in this case, to the right when viewed from the front of the paper), causing the lower mold 32A to move from the filling position E2 to the standby position E1. Multiple rotor cores 2 are separated from the lower mold 32A, which has moved to the standby position E1. Meanwhile, the lower mold 32B moves from the standby position E3 to the filling position E2, and resin is filled into the rotor cores 2 placed on the lower mold 32A.

[0083] For the lower mold 32A, which is in standby position E1, cleaning is performed, followed by preparation work for mold forming again. In this way, mold forming and the preparation work or cleaning work for it are performed continuously as the lower molds 32A and 32B change positions.

[0084] As described above, the rotor core manufacturing apparatus 10 according to this second embodiment provides the same effects as the first embodiment described above. Furthermore, according to the rotor core manufacturing apparatus 10 according to this second embodiment, the lower mold 32 is provided on the slide table 40, and the sliding movement of the slide table 40 moves the multiple rotor cores 2 placed on the lower mold 32 to the filling position E2. As a result, a linear path can be adopted as the movement trajectory of the lower mold 32 and the multiple rotor cores 2, thereby improving the flexibility of the equipment layout of the rotor core manufacturing apparatus 10.

[0085] In the second embodiment described above, an example was given in which two lower molds 32A and 32B are provided on the slide table 40, but the technology of this disclosure is not limited thereto. For example, three or more lower molds 32 may be provided on the slide table 40.

[0086] <<Third Embodiment>> In the first embodiment described above, an example was given in which the rotor core manufacturing apparatus 10 is provided with two lower molds 32A and 32B, but the technology of this disclosure is not limited thereto. In this third embodiment, the rotor core manufacturing apparatus 10 is provided with four lower molds 62A to 62D.

[0087] As shown in Figure 11, the rotor core manufacturing apparatus 10 according to this embodiment has a table section 60. The table section 60 is composed of a rotary table 61 and a plurality of lower dies 62 provided on the rotary table 61. The rotary table 61 is a table-shaped member having a circular shape in plan view. A plurality of lower dies 62 are provided on the upper surface of the rotary table 61. In the example shown in Figure 1, four lower dies 62A to 62D are provided. A rotating shaft section 63 is provided in the center of the rotary table 61. The rotating shaft section 63 is rotatable by receiving power from a drive source (not shown). The rotary table 61 is rotatable in conjunction with the rotation of the rotating shaft section 63. The rotary table 61 is an example of a "support base" according to the technology of this disclosure.

[0088] For the sake of clarity, the following explanation will use the lower mold 62A and the multiple rotor cores 2 mounted on the lower mold 62A as examples. Similar procedures may be performed on the lower molds 62B to 62D and the multiple rotor cores 2 mounted on them. In the following explanation, when it is not necessary to distinguish between the lower molds 62A to 62D, they will simply be referred to as "lower mold 62". Lower mold 62 is an example of a "lower mold" relating to the technology of this disclosure.

[0089] When the lower mold 62A is in the setup position S1, the multiple rotor cores 2, which are aligned along the axial direction, are placed on the support plate 20A. That is, the multiple rotor cores 2 are positioned above the lower mold 62A. Setup position S1 is an example of the "fourth position" according to the technology of this disclosure. Then, with the multiple rotor cores 2 placed on the support plate 20A, the rotary table 61 rotates 90 degrees, causing the lower mold 62A to move from the setup position S1 to the loading position S2. Loading position S2 is an example of the "first position" according to the technology of this disclosure.

[0090] As shown in Figure 12, when the lower mold 62A is in the loading position S2, a tablet T is loaded into the lower mold 62A. The tablet T is loaded into the lower mold 62A from between the support plate 20A and the lower mold 62A. Subsequently, as the support plate 20A descends, the multiple rotor cores 2 are placed on the lower mold 62A via the support plate 20A. Then, with the multiple rotor cores 2 placed on the lower mold 62A, the rotary table 61 rotates 90 degrees, causing the lower mold 62A and the multiple rotor cores 2 to move from the loading position S2 to the filling position S3. The filling position S3 is an example of the "second position" according to the technology of this disclosure.

[0091] As shown in Figure 13, when the lower mold 62A is in the filling position S3, the multiple rotor cores 2 are held by the upper mold 65 and the lower mold 62A, aligned axially via the intermediate plate 22. The plunger 64A presses the resin R, which has been softened by heating the tablet T by a heater (not shown). As a result, the softened resin R flows and, after passing through the resin filling passage 23, fills the magnet insertion holes 4 of the rotor cores 2.

[0092] With the resin R filling complete, the rotary table 61 rotates 90 degrees, causing the lower mold 62A and the multiple rotor cores 2 to move from the filling position S3 to the separation position S4. That is, the multiple rotor cores 2, which are aligned along the axial direction, are discharged from the mold. The separation position S4 is an example of a "third position" according to the technology of this disclosure.

[0093] As shown in Figure 14, when the lower mold 62A is in the separation position S4, the multiple rotor cores 2 are separated from the support plate 20A. That is, the multiple rotor cores 2 are separated from the lower mold 62A. The multiple rotor cores 2 removed from the rotor core manufacturing apparatus 10 are transported to the next process.

[0094] As described above, the rotor core manufacturing apparatus 10 according to this third embodiment provides the same effects as the first embodiment described above.

[0095] Furthermore, according to the rotor core manufacturing apparatus 10 of this third embodiment, a plurality of lower molds 62 are provided on the rotary table 61. Then, a plurality of rotor cores 2 are separated from the lower molds 62 in the separation position S4. As a result, the separation work of the plurality of rotor cores 2 can be performed on the lower molds 62 that are not inside the mold, thus improving work efficiency. In other words, since the separation work can be performed outside the mold, the time occupied by the mold can be reduced, which contributes to improving the work efficiency of the rotor core manufacturing process.

[0096] Furthermore, in the case of multiple rotor cores 2 arranged along the axial direction, if the multiple rotor cores 2 are to be separated within the mold, the upper mold 65 must be raised by the amount required for the separation work. In this configuration, since the separation work is performed outside the mold, there is no need to raise the upper mold 65, and the height of the equipment can be reduced.

[0097] Furthermore, according to the rotor core manufacturing apparatus 10 of this third embodiment, a plurality of lower molds 62 are provided on the rotary table 61. Then, a plurality of rotor cores 2 are placed on the lower molds 62 at the setup position S1 via support plates 20. This allows the placement of a plurality of rotor cores 2 on the lower molds 62 that are not inside the mold, thus improving work efficiency. In other words, since the placement work can be performed outside the mold, the time occupied by the mold can be reduced, contributing to improved work efficiency in the rotor core manufacturing process.

[0098] (First torture) In the third embodiment described above, an example was given in which a plurality of rotor cores 2 are separated from the lower mold 62 at the separation position S4, but the technology of this disclosure is not limited thereto. In this first modified example, at the separation position S4, heating is performed on the plurality of rotor cores 2 placed on the lower mold 62 for additional curing of the resin.

[0099] As shown in Figure 15, when the lower mold 62A is in the separation position S4, additional heating is performed on the multiple rotor cores 2 placed on the support plate 20A. This additional heating is performed by a heating device 66. The heating device 66 comprises a main body 66A that surrounds the multiple rotor cores 2 and a resistance heating heater 66B provided inside. The heating device 66 is movable relative to the multiple rotor cores 2 and is retracted to a position that does not interfere with the rotational movement of the multiple rotor cores 2 when not performing heating. In this modified example, the separation position S4 is an example of a "third position" according to the technology of this disclosure.

[0100] The heating method is not particularly limited. For example, the heating equipment 66 may use a hot air circulation furnace, or a heating method using a lamp heater, high-frequency heater, block heater, and / or infrared heater. Furthermore, although the heating equipment 66 has been described here as heating from the radially outer side of the multiple rotor cores 2, this is merely one example. For example, heating may be performed by a mold heater (not shown) provided on the lower mold 62A. Alternatively, heating may be performed by a heater that contacts the upper surface of the uppermost rotor core 2 of the multiple rotor cores 2. Moreover, multiple rotor cores 2 may be heated while sandwiched between the lower mold 62A and a heater.

[0101] Heating by the heating equipment 66 promotes the further hardening of the resin R filling the magnet insertion holes 4 of the multiple rotor cores 2. When further hardening the resin R, it is preferable to heat it at, for example, 100 to 180°C for several minutes to several hours. As the softened resin R hardens due to this heating, the permanent magnets 3 are fixed in the magnet insertion holes 4 of the rotor cores 2 by resin molding. The heating time can be appropriately adjusted according to the specific composition of the resin used in the tablet T.

[0102] The additional curing of resin R improves the heat resistance and elastic modulus of the cured resin R, thus improving the performance of the rotating electric machine when the rotor core 2 is used as a motor. At the separation position S4, after additional curing has been performed on multiple rotor cores 2, the multiple rotor cores 2 are separated from the lower mold 62A.

[0103] As described above, in this first modified example, multiple lower molds 62 are provided on the rotary table 61. Then, at the separation position S4, heating for additional hardening is performed on the multiple rotor cores 2. This allows for additional hardening of the multiple rotor cores 2 on the lower molds 62 that are not inside the mold, thus improving work efficiency. In other words, since additional hardening can be performed outside the mold, the time the mold is occupied can be reduced, contributing to improved work efficiency in the rotor core manufacturing process.

[0104] Here, an example has been described in which heating for additional curing is performed at the separation position S4, and after heating, multiple rotor cores 2 are separated from the lower mold 62A. However, the technology of this disclosure is not limited to this. For example, heating for additional curing may be performed at an additional curing position located between the separation position S4 and the filling position S3. In this case, the additional curing position functions as a "third position" according to the technology of this disclosure. Furthermore, heating for additional curing may also be performed while the rotary table 61 is rotating.

[0105] Furthermore, although this description has given an example of a configuration in which additional curing is achieved by heating with a heating device 66, the technology of this disclosure is not limited to this. For example, the curing of the resin may be promoted by leaving multiple rotor cores 2 as a single unit without using a heating device 66, and by the heat accumulated in the rotor cores 2. In this case, the time for which the multiple rotor cores 2 are left is, for example, several minutes to several hours.

[0106] (Second variation) In the third embodiment described above, an example was given in which a plurality of rotor cores 2 are arranged on the lower mold 62 at the setup position S1, but the technology of this disclosure is not limited thereto. In this first modified example, preheating is performed on the plurality of rotor cores 2 at the setup position S1.

[0107] As shown in Figure 16, when the lower mold 62A is in the setup position S1, preheating is performed on the multiple rotor cores 2 placed on the support plate 20A. Preheating is performed by a heating device 68. The heating device 68 comprises a main body 68A that surrounds the multiple rotor cores 2 and a resistance heating heater 68B provided inside. The heating device 68 is movable relative to the multiple rotor cores 2 and is retracted to a position that does not interfere with the rotational movement of the multiple rotor cores 2 when not performing heating. In this modified example, the setup position S1 is an example of the "fourth position" according to the technology of this disclosure.

[0108] The heating method is not particularly limited. For example, the heating equipment 68 may use a hot air circulation furnace, or a heating method using a lamp heater, high-frequency heater, block heater, and / or infrared heater. Furthermore, although the heating equipment 68 has been described here as heating from the radially outer side of the multiple rotor cores 2, this is merely one example. For example, heating may be performed by a mold heater (not shown) provided on the lower mold 62A. Alternatively, heating may be performed by a heater that contacts the upper surface of the uppermost rotor core 2 of the multiple rotor cores 2. Moreover, multiple rotor cores 2 may be heated while sandwiched between the lower mold 62A and a heater.

[0109] When filling the magnet insertion holes 4 with resin, if the multiple rotor cores 2 are at a low temperature, the resin will cool down, reducing its fluidity. As a result, the degree to which the resin fills the magnet insertion holes 4 may be insufficient. Preheating the multiple rotor cores 2 ensures the fluidity of the resin, making it easier to fill.

[0110] At setup position S1, after the multiple rotor cores 2 have been preheated, the lower mold 62A and the multiple rotor cores 2 move to the loading position S2.

[0111] As explained above, in this second modified example, multiple lower molds 62 are provided on the rotary table 61. Then, at the setup position S1, preheating is performed on the multiple rotor cores 2. This allows preheating of the multiple rotor cores 2 to be performed on the lower molds 62 that are not inside the mold, thus improving work efficiency. In other words, since preheating can be performed outside the mold, the time the mold is occupied can be reduced, contributing to improved work efficiency in the rotor core manufacturing process.

[0112] Here, an example of a configuration in which preheating is performed after multiple rotor cores 2 are installed on the support plate 20A at the setup position S1 has been described, but the technology of this disclosure is not limited to this. For example, preheating may be performed at a preheating position provided between the setup position S1 and the input position S2. In this case, the preheating position functions as a "fourth position" according to the technology of this disclosure. Furthermore, preheating may also be performed while the rotary table 61 is rotating.

[0113] Furthermore, although this second modification describes an example of a configuration in which multiple rotor cores 2 are preheated, the technology of this disclosure is not limited thereto. Instead of preheating the multiple rotor cores 2, or together with preheating the multiple rotor cores 2, preheating of the lower mold 62 may be performed. In this case, preheating of the lower mold 62 may be performed by a mold heater (not shown).

[0114] It goes without saying that the first modified example described above and this second modified example may be combined. That is, additional curing of the resin may be performed at the separation position S4, and preheating of the rotor core 2 may be performed at the setup position S1.

[0115] Furthermore, in the third embodiment described above, additional curing of the resin and separation of the multiple rotor cores 2 from the lower mold 62 may be performed at the filling position S3. However, as mentioned above, from the viewpoint of reducing the mold occupancy time, it is desirable that the additional curing of the resin and separation of the multiple rotor cores 2 from the lower mold 62 be performed at the separation position S4.

[0116] Furthermore, in the third embodiment described above, the installation of multiple rotor cores 2, preheating of multiple rotor cores 2, and loading of tablets T may be performed at the setup position S1.

[0117] Furthermore, although the third embodiment described above included an example in which four lower molds 62 are provided on the rotary table 61, the technology of this disclosure is not limited thereto. For example, three lower molds 62 may be provided, or five or more lower molds 62 may be provided. Also, the shape of the rotary table 61 does not have to be circular; for example, it may be polygonal.

[0118] (Other variations) Furthermore, although the above embodiments have described examples in which resin is filled by a plunger 34 or 64 provided in the center of the lower mold 32 or 62, the technology of this disclosure is not limited thereto. For example, the resin may be filled by an annular plunger that presses an annular resin tablet. Alternatively, a tablet positioned along the circumferential direction of the lower mold 32 or 62 opposite the magnet insertion hole 4 may be pressed by a multi-plunger configured to include a plurality of plungers.

[0119] Furthermore, although the above embodiments have described an example in which the intermediate plate 22 is rectangular when viewed from above, the technology of this disclosure is not limited to this. The intermediate plate 22 may be of other polygonal shapes or circular shapes.

[0120] The descriptions and illustrations presented above are detailed explanations of the technical aspects of this disclosure and are merely examples of the technical aspects. For example, the above descriptions of the structure, function, operation, and effect are examples of the structure, function, operation, and effect of the technical aspects of this disclosure. Therefore, it goes without saying that you may delete unnecessary parts, add new elements, or replace elements in the descriptions and illustrations presented above, as long as you do not deviate from the essence of the technical aspects of this disclosure. Furthermore, in order to avoid confusion and facilitate understanding of the technical aspects of this disclosure, explanations of common technical knowledge and the like that do not require special explanation to enable the implementation of the technical aspects of this disclosure have been omitted from the descriptions and illustrations presented above.

[0121] In this specification, "A and / or B" is synonymous with "at least one of A and B." That is, "A and / or B" means that it may be A alone, or B alone, or a combination of A and B. Furthermore, in this specification, the same concept as "A and / or B" applies when expressing three or more things linked by "and / or."

[0122] All documents, patent applications, and technical standards described herein are incorporated by reference to the same extent as if each individual document, patent application, and technical standard were specifically and individually noted to be incorporated by reference.

[0123] The following additional information is disclosed regarding the above embodiments. <Note 1> In the first position, with multiple cores arranged axially via an intermediate plate and separated upward from the lower mold, the tablet is inserted into the lower mold. To lower the above multiple cores toward the lower mold, Moving the lower mold and the multiple cores described above to a second position opposite the upper mold, and, The second position includes filling each of the multiple cores with resin. Motor manufacturing method. <Note 2> The lower molds described above are provided in multiple locations on the support base. Of the multiple lower molds mentioned above, the tablet can be inserted into the lower mold in the first position. Motor manufacturing method as described in Appendix 1. <Note 3> The lower mold shown above is mounted on a support base. As the support base rotates, the lower mold and the multiple cores are moved to the second position. Motor manufacturing method as described in Appendix 1 or Appendix 2. <Note 4> The lower mold shown above is mounted on a support base. As the support base slides, the lower mold and the multiple cores are moved to the second position. Motor manufacturing method as described in Appendix 1 or Appendix 2. <Note 5> The lower molds described above are provided in multiple locations on the support base. Among the multiple lower molds, the multiple cores filled with the resin are separated from the lower mold in the third position. A motor manufacturing method described in any one of the appendices 1 through 4. <Note 6> The lower molds described above are provided in multiple locations on the support base. Of the multiple lower molds, the multiple cores placed on the lower mold in the third position are subjected to heating for further curing of the resin. A motor manufacturing method described in any one of the appendices 1 through 5. <Note 7> The lower molds described above are provided in multiple locations on the support base. Of the multiple lower molds, the multiple cores before resin filling are positioned above the lower mold in the fourth position. A motor manufacturing method described in any one of the appendices 1 through 6. <Note 8> The lower molds described above are provided in multiple locations on the support base. Of the multiple lower molds, the lower mold in the fourth position and / or the multiple cores before the resin is filled are preheated. A motor manufacturing method described in any one of the appendices 1 through 7.

[0124] Furthermore, the disclosure of Japanese Patent Application No. 2024-057132, filed on March 29, 2024, is incorporated herein by reference in its entirety. All documents, patent applications, and technical standards described herein are incorporated herein by reference to the same extent as if each individual document, patent application, and technical standard were specifically and individually described as being incorporated by reference.

Claims

1. In the first position, with multiple cores arranged axially via an intermediate plate and separated upward from the lower mold, the tablet is inserted into the lower mold. To lower the plurality of cores toward the lower mold, Moving the lower mold and the plurality of cores to a second position facing the upper mold, and This includes filling the resin-filled portions formed in each of the plurality of cores at the second position with resin. Motor manufacturing method.

2. Multiple lower molds are provided. The motor manufacturing method according to claim 1.

3. The lower mold has a resin filling mechanism for filling the resin filling section with resin. The motor manufacturing method according to claim 1.

4. The aforementioned lower mold is provided in multiple locations on the support base. Among the multiple lower molds, the tablet can be inserted into the lower mold in the first position. The motor manufacturing method according to claim 1.

5. The lower mold is mounted on a support base, As the support base rotates, the lower mold and the plurality of cores are moved to the second position. The motor manufacturing method according to claim 1.

6. The lower mold is mounted on a support base, As the support base slides, the lower mold and the plurality of cores are moved to the second position. The motor manufacturing method according to claim 1.

7. The aforementioned lower mold is provided in multiple locations on the support base. Among the multiple lower molds, the multiple cores filled with the resin are separated from the lower mold in the third position. The motor manufacturing method according to claim 1.

8. The aforementioned lower mold is provided in multiple locations on the support base. Heating is performed on the lower mold in the third position among the multiple lower molds to further cure the resin. The motor manufacturing method according to claim 1.

9. The aforementioned lower mold is provided in multiple locations on the support base. Of the multiple lower molds, the multiple cores before resin filling are positioned above the lower mold in the fourth position. The motor manufacturing method according to claim 1.

10. The aforementioned lower mold is provided in multiple locations on the support base. Of the multiple lower molds, the lower mold in the fourth position and / or the multiple cores before the resin is filled are preheated. The motor manufacturing method according to claim 1.

11. In the first position, a support mechanism supports multiple cores arranged axially via an intermediate plate, allowing them to be raised and lowered to a position where the tablet can be inserted into the lower mold. A moving mechanism for moving the lower mold and the plurality of cores to a second position facing the upper mold, The second position includes a resin filling mechanism that fills resin into resin-filled portions formed in each of the plurality of cores. Motor manufacturing equipment.

Images