Manufacturing method for laminated iron cores

Abstract

To provide a method for manufacturing a laminated iron core, capable of laminating lamination blocks on a lamination jig using a simple method.SOLUTION: A manufacturing method of a rotor core, comprises: a raising step; a fitting step; and a lamination step. The raising step raises a mounting table 106. The fitting step fits, by using a second transfer device 115 having a pair of clamping parts 116 for clamping an outer peripheral surface of a laminated block 20, fits the laminated block 20 into a second post 103. The lamination step laminates the plurality of laminated blocks 20 by, each time the laminated block 20 is fitted into the second transfer post 103, lowering the mounting table 106 while pressing an upper surface of the laminated block 20 toward the mounting table 106 with the pair of clamping parts 116. In the case where a load acting on the pair of clamping parts 116 is larger than a predetermined load when the pair of clamping parts 116 presses the lamination block 20 toward the mounting table 106, the lamination step stops operation of the second transfer device 115.SELECTED DRAWING: Figure 15

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a laminated core.

Background Art

[0002] The rotor core of the rotating electric machine described in Patent Document 1 is configured by laminating a plurality of laminated blocks each formed by laminating a plurality of core pieces punched out from electromagnetic steel sheets. The laminated core has a central hole and a plurality of magnet insertion holes.

[0003] Patent Document 1 discloses a manufacturing method for manufacturing a rotor by inserting a permanent magnet into a magnet insertion hole and then filling the magnet insertion hole with a resin material while supporting a plurality of laminated blocks with a transfer tray.

[0004] The transfer tray has a guide member inserted into the central hole of each of the plurality of laminated blocks and a mounting plate material on which the laminated blocks are placed. In the transfer tray, the clearance between the outer peripheral surface of the guide member and the inner peripheral surface of the central hole of the laminated block is set small in order to suppress rattling with the laminated block. In the manufacturing method described in Patent Document 1, a plurality of laminated blocks are preheated before being supported by the transfer tray. As a result, the central hole of the laminated block is enlarged in diameter, so that the laminated block can be easily fitted into the guide member.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] By the way, when stacking multiple stacking blocks onto a jig such as a transport tray as described in Patent Document 1, preheating the stacking blocks takes time. However, if the stacking blocks are not preheated, it becomes difficult to stack multiple stacking blocks onto the jig. For this reason, there is a need for a simple method to stack stacking blocks onto the jig. [Means for solving the problem]

[0007] A method for manufacturing a laminated iron core to solve the above problem is a method for manufacturing a laminated iron core by stacking multiple stacked blocks that form a cylindrical shape in which multiple iron core pieces are stacked, while supporting them with a stacking jig, wherein the stacking jig comprises a post inserted into the central hole of each of the multiple stacked blocks, and a mounting table configured to be able to move up and down in the axial direction of the stacked block relative to the post and on which the stacked block is placed, and comprises a raising step of raising the mounting table, and after the raising step, having a pair of clamping parts that clamp the outer surface of the stacked block and The stacking process includes: a fitting step of fitting the stacked blocks into the posts using a transfer device for transferring the stacked blocks to the stacking jig; and a stacking step of stacking the plurality of stacked blocks by lowering the aforementioned base while pressing the upper surface of the stacked block toward the aforementioned base with the pair of clamping parts each time the stacked block is fitted into the posts, wherein in the stacking step, if the load acting on the pair of clamping parts when the pair of clamping parts press the stacked block toward the aforementioned base is greater than a predetermined load, the operation of the transfer device is stopped.

[0008] According to this method, during the insertion process, the laminated block fitted into the post is placed on a mounting platform. This suppresses the horizontal tilt of the laminated block. Then, during the lamination process, the mounting platform is lowered while the upper surface of the laminated block is pressed by a pair of clamping parts. As a result, the laminated block descends while its posture is maintained, allowing it to be smoothly fitted into the post.

[0009] Furthermore, according to the above method, if the load acting on the pair of clamping parts during the stacking process is greater than a predetermined load, the transfer device will stop operating. This prevents, for example, the stacked block from being continuously pressed while it is caught on the post. Therefore, the stopping of the transfer device's operation can be used to determine whether or not the stacked blocks have been stacked correctly.

[0010] Based on the above, it is possible to stack laminated blocks onto a lamination jig using a simple method. [Brief explanation of the drawing]

[0011] [Figure 1] Figure 1 is a plan view showing a rotating electric machine in one embodiment. [Figure 2] Figure 2 is a cross-sectional view showing the rotor in Figure 1. [Figure 3] Figure 3 is a cross-sectional view showing the dowel pins of the rotor core in Figure 1. [Figure 4] Figure 4(a) is a plan view showing the first type of rotor core, and Figure 4(b) is a plan view showing the second type of rotor core. [Figure 5] Figure 5 is a plan view showing the third block of the rotor core in Figure 1. [Figure 6] Figure 6 is a plan view showing the fourth block of the rotor core in Figure 1. [Figure 7] Figure 7 is a plan view showing the first cooling hole of the rotor core in Figure 1. [Figure 8] Figure 8 is a plan view showing the second cooling hole of the rotor core in Figure 1. [Figure 9] Figure 9 is a plan view showing the third cooling hole of the rotor core in Figure 1. [Figure 10] Figure 10 is a plan view showing the first cooling hole of a rotor core manufactured on the second production line. [Figure 11] Figure 11 is a schematic diagram showing the configuration of a press device and a stack thickness measuring device in one embodiment. [Figure 12]FIG. 12 is a plan view showing the configuration of the press device of FIG. 11. [Figure 13] FIG. 13 is a cross-sectional view showing the configuration of the first transfer device in one embodiment. [Figure 14] FIG. 14 is a cross-sectional view showing the configuration of the pass / fail determination device in one embodiment. [Figure 15] FIG. 15 is a cross-sectional view showing the configuration of the laminating device in one embodiment. [Figure 16] FIG. 16 is a plan view showing the laminating jig of FIG. 15. [Figure 17] FIG. 17 is a cross-sectional view showing the configuration of the caulking device in one embodiment. [Figure 18] FIG. 18 is a plan view showing the configuration of the magnet insertion device in one embodiment. [Figure 19] FIG. 19 is a side view showing the configuration of the magnet insertion device of FIG. 18. [Figure 20] FIG. 20 is a cross-sectional view showing the configuration of the guide jig and the pushing jig in one embodiment. [Figure 21] FIG. 21 is a cross-sectional view showing the configuration of the molding device in one embodiment. [Figure 22] FIG. 30 is a plan view showing the cal plate of FIG. 21. [Figure 23] FIG. 23 is a schematic view showing the configuration of the removing device in one embodiment. [Figure 24] FIG. 24 is a perspective view showing the extrusion jig of FIG. 23. [Figure 25] FIG. 25 is a cross-sectional view showing the configuration of the welding device in one embodiment. [Figure 26] FIG. 26 is a flowchart showing the procedure of the rotor manufacturing method. [Figure 27] FIG. 27 is a flowchart showing the procedure of the thickness adjustment process. [Figure 28] FIG. 28 is a cross-sectional view showing a state in which a laminate is supported by a support jig in the transfer process. [Figure 29] FIG. 29 is a cross-sectional view showing a state in which the detection unit has risen in the first transfer process. [Figure 30] Figure 30 is a cross-sectional view showing the state in which the restricting section holds the stacked block during the first transfer process. [Figure 31] Figure 31 is a cross-sectional view showing the state in which the transfer unit holds the stacked block during the first transfer process. [Figure 32] Figure 32 is a cross-sectional view showing the state in which the transfer unit is transferring the stacked block during the first transfer process. [Figure 33] Figure 33 is a cross-sectional view showing the state in which the transfer unit has transferred the stacked block to the pass / fail determination device during the first transfer process. [Figure 34] Figure 34(a) is a plan view showing the rotating stage in the correct / failure determination process, and Figure 34(b) is a plan view showing the stacked blocks in the correct / failure determination process after they have been positioned. [Figure 35] Figure 35 is a table showing the criteria for determining success or failure in the success / failure determination process. [Figure 36] Figure 36 is a cross-sectional view showing the second transfer device transferring a stacked block from the pass / fail determination device. [Figure 37] Figure 37 is a cross-sectional view showing the state immediately before the first block is fitted into the lamination jig during the rotor core formation process. [Figure 38] Figure 38 is a cross-sectional view showing the first block placed on the mounting table during the rotor core formation process. [Figure 39] Figure 39 is a cross-sectional view showing the state in which the first block is being pressed by the second transfer device during the rotor core formation process. [Figure 40] Figure 40 is a cross-sectional view showing the state in which the second block is being transferred by the second transfer device during the rotor core formation process. [Figure 41] Figure 41 is a cross-sectional view showing the state in which the second block is being pressed by the second transfer device during the rotor core formation process. [Figure 42] Figure 42 is a cross-sectional view showing the state in which the sixth block is being pressed by the second transfer device during the rotor core formation process. [Figure 43] Figure 43 is a cross-sectional view showing the state in which the first die is pressing against the rotor core during the crimping process. [Figure 44] Figure 44 is a plan view showing the alignment mechanism in the supply position during the magnet insertion process. [Figure 45] Figure 45 is a side view showing the state in which the removal mechanism has placed the magnet on the mounting section during the magnet insertion process. [Figure 46] Figure 46 is a cross-sectional view showing the state in which the guide jig is placed on the rotor core during the magnet insertion process. [Figure 47] Figure 47 is a cross-sectional view showing the state in which a magnet is inserted into the guide jig during the magnet insertion process. [Figure 48] Figure 48 is a cross-sectional view showing the state in which the magnet is being pressed in by the pressing jig during the magnet insertion process. [Figure 49] Figure 49 is a flowchart showing the procedure for residue reduction treatment. [Figure 50] Figure 50 is a cross-sectional view showing the state in which magnets have been filled into the magnet housing holes during the molding process. [Figure 51] Figure 51 is a cross-sectional view showing the state in which the conveying device is being lowered during the removal process. [Figure 52] Figure 52 is a cross-sectional view showing the state in which the solidified material is pushed out from the Calplate by the first pressing section during the removal process. [Figure 53] Figure 53 is a cross-sectional view showing the state in which the solidified material is pushed out from the Calplate by the second pressing section during the removal process. [Figure 54] Figure 54 is a cross-sectional view showing the state after the rotor core and end plate have been welded together during the welding process. [Modes for carrying out the invention]

[0012] An embodiment will be described below with reference to Figures 1 to 54. As shown in Figure 1, the rotating electric machine M comprises a rotor 10 and a stator 50. The rotor 10 and stator 50 are each cylindrical in shape. The stator 50 is fixed to a housing (not shown). The rotor 10 is configured to rotate inside the central hole of the stator 50.

[0013] (Rotor 10) As shown in Figure 2, the rotor 10 comprises a rotor core 11, a plurality of magnets 30, a plurality of resin materials 31, and two end plates 32. The rotor 10 is, for example, a magnet-embedded rotor.

[0014] (Rotacore 11) The rotor core 11 has a cylindrical shape with axis C as its central axis. The rotor core 11 is an example of a laminated iron core.

[0015] Hereafter, the axial direction of the rotor core 11 will be simply referred to as the axial direction. The radial direction of the rotor core 11 centered on axis C will be simply referred to as the radial direction. The circumferential direction of the rotor core 11 centered on axis C will be simply referred to as the circumferential direction.

[0016] The rotor core 11 has a central hole 12 into which the shaft S is inserted, a plurality of magnet housing holes 14 for housing the magnets 30, and a plurality of cooling channels 15 through which a cooling medium flows. The central hole 12, each magnet housing hole 14, and each cooling channel 15 penetrate the rotor core 11 in the axial direction.

[0017] As shown in Figure 1, the central hole 12 is circular in shape. Two keys 13 are provided on the inner surface of the central hole 12, projecting radially opposite to each other. The two keys 13 fit into keyways (not shown) provided on the shaft S, thereby restricting the relative movement between the rotor core 11 and the shaft S in the circumferential direction.

[0018] Multiple magnet housing holes 14 are located radially outward from the central hole 12 and are provided at equal intervals in the circumferential direction. The rotor core 11 has, for example, 20 magnet housing holes 14. The opening of each magnet housing hole 14 is, for example, substantially rectangular in plan view. Two adjacent magnet housing holes 14 in the circumferential direction are inclined in opposite directions with respect to the circumferential direction. Multiple cooling channels 15 are located radially inward from the magnet housing holes 14 and are provided at equal intervals in the circumferential direction. The rotor core 11 has, for example, 10 cooling channels 15.

[0019] As shown in Figure 2, each cooling channel 15 has an axial channel 16 extending in the axial direction and a radial channel 17 extending in the radial direction. The axial flow path 16 penetrates the rotor core 11 in the axial direction. The axial flow path 16 has openings on both end faces of the rotor core 11. Each opening has a curved shape that extends generally in the circumferential direction in a plan view (see Figure 1).

[0020] The radial channel 17 extends radially inward from the axial channel 16 and opens to the inner circumferential surface of the central hole 12. In other words, the radial channel 17 connects the axial channel 16 and the central hole 12.

[0021] The radial channel 17 has two first channels 17a and a second channel 17b. The two first channels 17a extend radially inward from two points in the axial channel 16 that are spaced apart from each other in the axial direction. The radially inner ends of the two first channels 17a are in communication with each other in the axial direction.

[0022] The second flow path 17b extends radially inward from the portion where the two first flow paths 17a communicate. The second flow path 17b is located, for example, in the central part of the rotor core 11 in the axial direction and extends radially. The second flow path 17b opens to the inner circumferential surface of the central hole 12 and communicates with a communication hole (not shown) formed on the outer circumferential surface of the shaft S.

[0023] Note that in Figures 3 and beyond, the cooling channel 15 may be omitted from the illustration. (Stacked block 20) The rotor core 11 is constructed by stacking multiple annular first core pieces Wa, punched out from electrical steel sheets, in the axial direction. More specifically, the rotor core 11 is constructed by stacking multiple laminated blocks 20, each made up of multiple first core pieces Wa, in the axial direction.

[0024] As shown in Figure 3, the first core piece Wa has a plurality of dowels 18 that bulge out on one side in the thickness direction. The plurality of dowels 18 are provided at equal intervals in the circumferential direction of the first core piece Wa.

[0025] In each laminated block 20, adjacent first core pieces Wa are joined to each other by crimping dowels 18 together. Each first core piece Wa constituting one end face in the axial direction in each laminated block 20 has a plurality of through holes 19 that penetrate in the axial direction. A first core piece Wa having dowels 18 and a first core piece Wa having through holes 19 are joined to each other by the dowels 18 fitting into the through holes 19. In this way, the plurality of first core pieces Wa constituting each laminated block 20 are integrated by being joined to each other.

[0026] In each laminated block 20, the first core piece Wa having a through hole 19 is not connected to the first core piece Wa of another laminated block 20 adjacent to the laminated block 20 having the first core piece Wa. Each dowel 18 and each through hole 19 is located radially outside the cooling channel 15 and is provided between two adjacent magnet housing holes 14 in the circumferential direction.

[0027] As shown in Figure 2, the rotor core 11 is constructed by stacking, for example, six laminated blocks 20. The six laminated blocks 20 are made of first core pieces Wa punched out from a single electrical steel sheet, and first core pieces Wa punched out from different electrical steel sheets are not mixed together. This suppresses variations in the thickness when multiple laminated blocks 20 are stacked, i.e., the thickness of the rotor core 11 (hereinafter referred to as stacked thickness).

[0028] Hereafter, the first to sixth stacked blocks 20 in the six stacked blocks 20 will be referred to as the first block 21, the second block 22, the third block 23, the fourth block 24, the fifth block 25, and the sixth block 26, respectively. The first block 21 constitutes the end of the rotor core 11 in the direction of protrusion of the dowel 18.

[0029] The axial thicknesses of the first block 21, the second block 22, the fifth block 25, and the sixth block 26 are approximately the same. The axial thicknesses of the third block 23 and the fourth block 24 are approximately the same and smaller than the axial thicknesses of the other laminated blocks 20.

[0030] Multiple welding grooves 33 are provided on the outer circumferential surfaces of the first block 21 and the sixth block 26, spaced apart from each other in the circumferential direction. The multiple welding grooves 33 of the first block 21 are provided at the end of the outer circumferential surface of the first block 21 opposite to the second block 22. The multiple welding grooves 33 of the sixth block 26 are provided at the end of the outer circumferential surface of the sixth block 26 opposite to the fifth block 25. The second block 22 to the fifth block 25 do not have welding grooves 33. In other words, the rotor core 11 is composed of two laminated blocks 20 having welding grooves 33 and four laminated blocks 20 not having welding grooves 33.

[0031] Each welding groove 33 has a bead 33a formed when the rotor core 11 and the end plate 32 are welded together. The welding groove 33 is formed across a plurality of first iron core pieces Wa, which will be described later. The welding groove 33 is connected to the end face of the rotor core 11 in the axial direction.

[0032] Hereafter, for convenience, one end face of the laminated block 20 in the axial direction will be referred to as the surface F, and the end face of the laminated block 20 opposite to surface F will be referred to as the back surface B. Surface F is the end face of the laminated block 20 opposite to the side from which the dowel 18 protrudes. Note that these surface F and back surface B do not represent the orientation of the rotor 10 during use.

[0033] The first block 21, the second block 22, the fifth block 25, and the sixth block 26 are formed with a portion of the axial flow path 16 passing through them. As shown in Figure 4(a), the shapes of the cooling channels 15 in a plan view of the surface F of the first block 21, the second block 22, the fifth block 25, and the sixth block 26 are identical to each other.

[0034] As shown in Figure 2, the third block 23 and the fourth block 24 have a portion of the axial flow path 16, one of the two first flow paths 17a, and a portion of the second flow path 17b formed within them. As shown in Figures 5 and 6, the shapes of the cooling channels 15 in a plan view of the surface F of the third block 23 and the fourth block 24 are different from each other. On the other hand, the shape of the cooling channels 15 in a plan view of the surface F of the third block 23 and the shape of the cooling channels 15 in a plan view of the back surface B of the fourth block 24 are identical.

[0035] As shown in Figure 1, the multiple cooling channels 15 have a first cooling channel 15A, a second cooling channel 15B, and a third cooling channel 15C, each with a different opening shape. The multiple cooling channels 15 may have, for example, one first cooling channel 15A, eight second cooling channels 15B, and one third cooling channel 15C.

[0036] The first cooling channel 15A and the third cooling channel 15C are located on opposite sides of the central hole 12. The first cooling channel 15A and the third cooling channel 15C are composed of two cooling channels 15 through which a virtual axis L2 passes, obtained by rotating a virtual axis L1, which extends in the protruding direction of the key 13, by a predetermined angle around axis C. In this embodiment, the first cooling channel 15A and the third cooling channel 15C are composed of two cooling channels 15 through which a virtual axis L2 passes, obtained by rotating the virtual axis L1 by 54° clockwise around axis C, as viewed from the surface F. The virtual axis L1 is a line connecting the central parts of the two keys 13 in the circumferential direction, and extends between two adjacent cooling channels 15 and two magnet housing holes 14 in the circumferential direction.

[0037] Of the multiple cooling channels 15, the cooling channels 15 other than the first cooling channel 15A and the third cooling channel 15C are the second cooling channels 15B. Therefore, the second cooling channels 15B are provided at positions symmetrical to the first cooling channel 15A across the virtual axis L1. Similarly, the second cooling channels 15B are provided at positions symmetrical to the third cooling channel 15C across the virtual axis L1. Consequently, when the front and back of the stacked block 20 are reversed around the virtual axis L1, the positions of the first cooling channel 15A and the second cooling channel 15B are swapped, as are the positions of the third cooling channel 15C and the second cooling channel 15B.

[0038] As shown in Figure 7, the first cooling channel 15A has a plurality of first identification protrusions 40 that project inward from the inner circumferential surface of the axial channel 16. Each first identification protrusion 40 extends along the entire axial direction of the axial channel 16. The first identification protrusions 40 are visible from the front surface F and the back surface B.

[0039] The first identification protrusions 40 are provided, for example, in pairs on the radially outer portions of the inner circumferential surfaces at both ends of the axial flow path 16 in the circumferential direction. In other words, the first cooling flow path 15A has a total of four first identification protrusions 40.

[0040] Two first identification protrusions 40 located at one end of the axial channel 16 in the circumferential direction are spaced apart from each other. Hereafter, the distance between the two first identification protrusions 40 in a plan view will be referred to as the inter-protrusion distance.

[0041] As shown in Figure 8, each second cooling channel 15B has a plurality of identification grooves 41 that are recessed from the inner circumferential surface of the axial channel 16 to the outside of the axial channel 16. Each identification groove 41 extends along the entire axial channel 16 in the axial direction. The identification grooves 41 are visible from the front surface F and the back surface B.

[0042] The identification grooves 41 are provided, for example, one at each of the radially outer portions of the inner circumferential surfaces at both ends of the axial flow path 16 in the circumferential direction. In other words, each second cooling flow path 15B has a total of two identification grooves 41.

[0043] As shown in Figure 9, the third cooling channel 15C has a plurality of second identification protrusions 42 that project inward from the inner circumferential surface of the axial channel 16. Each second identification protrusion 42 extends along the entire axial direction of the axial channel 16. The second identification protrusions 42 are visible from the front surface F and the back surface B.

[0044] The second identification protrusions 42 are provided, for example, one at each of the radially outer portions of the inner circumferential surfaces at both ends of the axial flow channel 16 in the circumferential direction. In other words, the third cooling flow channel 15C has a total of two second identification protrusions 42.

[0045] As shown in Figures 7 to 9, front / back identification sections 43 are provided on both end faces in the axial direction of each stacked block 20. The front / back identification sections 43 are parts for identifying the front and back sides of the stacked block 20.

[0046] As shown in Figures 7 and 10, line identification sections 44 are provided on both end faces in the axial direction of each stacked block 20. The line identification sections 44 are for identifying the manufacturing line of the stacked block 20.

[0047] As shown in Figures 4(a) and 4(b), variety identification sections 45 are provided on both end faces in the axial direction of each stacked block 20. The variety identification section 45 is a part for identifying the variety of the rotor 10.

[0048] In the manufacturing method of the rotor 10 described later, the laminated block 20 is manufactured on two production lines. Hereafter, one production line may be referred to as the first production line M1, and the other production line as the second production line M2.

[0049] Furthermore, in the manufacturing method of the rotor 10, two types of rotor 10 are manufactured. Hereafter, one type may be referred to as the first type V1 and the other as the second type V2. The first type V1 and the second type V2 differ, for example, in the type of rotor core 11 and the type of magnet 30. Therefore, the first type V1 and the second type V2 differ in the type of laminated block 20 that constitutes the rotor core 11.

[0050] As shown in Figures 7 to 9, the front / back identification section 43 is composed of multiple openings of cooling channels 15 in each stacked block 20. The front / back identification section 43 is composed of openings for the first cooling channel 15A, the second cooling channel 15B, and the third cooling channel 15C.

[0051] As shown in Figure 1, when viewing one end face of the laminated block 20, the front and back sides of the laminated block 20 can be identified by the difference in the opening shapes of the two cooling channels 15 through which a virtual axis L2, obtained by rotating a virtual axis L1 clockwise by 54° around axis C, passes. In this embodiment, if the two cooling channels 15 on one end face of the laminated block 20 are the first cooling channel 15A and the third cooling channel 15C, that end face is identified as the front side F. Also, if both of the two cooling channels 15 on one end face of the laminated block 20 are the second cooling channel 15B, that end face is identified as the back side B.

[0052] As shown in Figures 7 and 10, the line identification section 44 is formed by the opening of the first cooling channel 15A in each stacked block 20. The distance between the protrusions of the above-described first identification protrusions 40 is different for each production line of the laminated block 20. For example, the distance d1 between the protrusions in the laminated block 20 of the first production line M1 is smaller than the distance d2 between the protrusions in the laminated block 20 of the second production line M2 (d1 < d2). That is, the production line of the laminated block 20 can be identified by the distance between the protrusions.

[0053] As shown in FIGS. 4(a) and 4(b), the variety identification portion 45 is constituted by a pair of magnet accommodation holes 14 (hereinafter simply referred to as the pair of magnet accommodation holes 14) that are located on opposite sides of each other across the cooling flow path 15 in the circumferential direction and are adjacent to each other.

[0054] The identification angle, which is the angle formed by the pair of magnet accommodation holes 14, is different for each variety of the rotor 10. For example, the identification angle θ1 in the laminated block 20 of the first variety V1 is smaller than the identification angle θ2 in the laminated block 20 of the second variety V2 (θ1 < θ2). That is, the variety of the laminated block 20 can be identified by the identification angle.

[0055] (Magnet 30) [[ID=***15***]]As shown in FIG. 2, the magnet 30 has an elongated shape extending in the axial direction. The cross-sectional shape perpendicular to the axial direction of the magnet 30 is substantially rectangular.

[0056] The length of the magnet 30 in the axial direction may be the same as or shorter than the length of the magnet accommodation hole 14. The magnet 30 may be accommodated one by one in each magnet accommodation hole 14, or may be accommodated in plural numbers in each magnet accommodation hole 14.

[0057] Examples of the magnet 30 include permanent magnets. (Resin material 31) It should be noted that in the original text, there is a possible error in ID 15 where "図2に示すように" is translated as "As shown in FIG. 2" which might not be in line with the correct numbering as it should be "As shown in FIG. 4(a) and 4(b)" according to the context. I've translated it based on the original text's ID reference. Also, the numbering in the translation is kept exactly the same as in the original for all tags including the 7 - digit tags.The resin material 31 is formed from solidified resin that filled the inside of the magnet housing hole 14, which houses the magnet 30. The magnet 30 is fixed to the rotor core 11 by the resin material 31. Multiple stacked blocks 20 are fixed to each other by the resin material 31. The resin material 31 may, for example, cover both end faces of the magnet 30 in the axial direction.

[0058] Examples of resin materials 31 include thermosetting resins such as epoxy resins. (End plate 32) The two end plates 32 cover both end faces of the rotor core 11 in the axial direction. One end plate 32 is welded to the first block 21, and the other end plate 32 is welded to the sixth block 26. Note that the end plates 32 are not shown in Figure 1.

[0059] The end plate 32 is disc-shaped, corresponding to the shape of the end face of the rotor core 11 in the axial direction. The end plate 32 has a first through hole 32a that communicates with the central hole 12 and a second through hole 32b that communicates with each magnet housing hole 14.

[0060] Examples of materials for the end plate 32 include metal materials such as stainless steel. (Stator 50) As shown in Figure 1, the stator 50 comprises a stator core 51 and a plurality of coils 56.

[0061] The stator core 51 has a yoke 52, a plurality of teeth 53, and a plurality of slots 54. The yoke 52 is cylindrical. The plurality of teeth 53 protrude radially inward from the yoke 52 and are spaced apart from each other in the circumferential direction. The slots 54 are formed one at a time between adjacent teeth 53 in the circumferential direction.

[0062] The stator core 51 has three fixing portions 55 that protrude radially outward from the yoke 52. The stator core 51 is fixed to the housing by fastening the three fixing portions 55 to the housing (not shown) with bolts (not shown).

[0063] Although not shown in the diagram, the stator core 51, like the rotor core 11, is constructed by stacking multiple laminated blocks (not shown) in which multiple second iron core pieces Wb, punched out from electromagnetic steel sheets, are stacked.

[0064] The coil 56 is composed of three phase windings, for example, U-phase, V-phase, and W-phase. Each phase winding is wound across multiple teeth 53. (manufacturing equipment) Next, referring to Figures 11 to 25, the manufacturing apparatus used to manufacture the rotor 10 and stator 50 will be described, focusing on the configuration of the part used to manufacture the rotor 10. The manufacturing apparatus includes a press device 60, a stacking thickness measuring device 70, a first transfer device 80, a pass / fail determination device 90, a stacking device 100, a crimping device 120, a magnet insertion device 130, a molding device 180, a removal device 200, and a welding device 210.

[0065] (Pressing device 60) As shown in Figure 11, the press device 60 is a device that punches out a first iron core piece Wa and a second iron core piece Wb from a plate-shaped workpiece W that is conveyed intermittently.

[0066] The press device 60 includes a rotor punching unit 61 for punching out a first core piece Wa from the workpiece W, and a stator punching unit 62 for punching out a second core piece Wb. The rotor punching unit 61 and the stator punching unit 62 are each equipped with progressive dies that punch out the workpiece W after performing multiple processing steps on the workpiece W, such as punching holes and forming dowels.

[0067] The rotor punching section 61 is located upstream of the stator punching section 62 in the conveying direction of the workpiece W (hereinafter simply referred to as the conveying direction). The rotor punching section 61 is configured to punch out a first core piece Wa from the workpiece W and to form a plurality of stacked blocks 20. The stator punching section 62 is configured to punch out a second core piece Wb from the workpiece W from which the first core piece Wa has been punched out and to form a plurality of stacked blocks (not shown). The stator punching section 62 is configured to punch out the second core piece Wb concentrically with the first core piece Wa from the outer circumference of the portion of the workpiece W from which the first core piece Wa has been punched out.

[0068] As shown in Figure 12, the manufacturing apparatus includes two sets of presses 60, each serving a different production line. The two sets of presses 60 are arranged in parallel in the width direction of the workpiece W, perpendicular to the conveying direction. One of the two sets of presses 60 constitutes the first production line M1, and the other set of presses 60 constitutes the second production line M2.

[0069] In the rotor punching section 61, the first core piece Wa punched out from the workpiece W is stacked on the next first core piece Wa to be punched out inside the die. At this time, as shown in Figure 3, the dowels 18 of adjacent first core pieces Wa engage with each other. This stacking of first core pieces Wa is repeated to form a stacked block 20.

[0070] In the rotor punching section 61, each time a predetermined number of first core pieces Wa are punched out, a first core piece Wa having a through hole 19 that engages with the dowel 18 is punched out. The first core piece Wa having a through hole 19 does not engage with the first core piece Wa punched out immediately before. The rotor punching section 61 sequentially forms the first block 21 to the sixth block 26 by punching out a first core piece Wa having a through hole 19 each time a predetermined number of first core pieces Wa are punched out.

[0071] Similarly, the stator punching section 62 punches out a predetermined number of second core pieces Wb, each time a second core piece Wb having a through hole is punched out, thereby sequentially forming a laminated block in which multiple second core pieces Wb are stacked.

[0072] As shown in Figure 11, an uncoiler 63 is positioned upstream of the rotor punching section 61 in the transport direction, rotatably supporting the rolled workpiece W. The workpiece W, pulled out from the uncoiler 63, is supplied to the rotor punching section 61 and the stator punching section 62 by a feeding device (not shown).

[0073] A welding machine 64 for welding the workpiece W is positioned downstream of the uncoiler 63 in the transport direction. As shown in Figure 12, the workpiece W is formed by welding together the ends, or more specifically, the end faces, of multiple strip-shaped base materials Wm by the welding machine 64. The multiple base materials Wm are transported in a state where their end faces are joined together and integrated.

[0074] As shown in Figures 11 and 12, in the transport direction, between the welding machine 64 and the rotor punching unit 61, two thickness sensors 65 for measuring the thickness of the workpiece W are provided, corresponding to each of the two sets of press devices 60. The thickness sensors 65 measure the thickness t of the planned portion Wp where each of the multiple first iron core pieces Wa of the workpiece W is to be punched out. Examples of thickness sensors 65 include non-contact sensors such as laser displacement sensors.

[0075] As shown in Figure 11, the press device 60 includes a press control unit 66 that controls the operation of the rotor punching unit 61. The press control unit 66 has a storage unit 67 and a calculation unit 68. The storage unit 67 stores the thickness t of each planned section Wp measured by the thickness sensor 65. The calculation unit 68 estimates the stacking thickness Tm of the laminated block 20 and the stacking thickness Tm of the rotor core 11 by sequentially accumulating the thickness t of each planned section Wp. The calculation unit 68 calculates the estimated stacking thickness Te as an estimated value of the stacking thickness Tm of the rotor core 11 by accumulating the stacking thickness of multiple laminated blocks 20.

[0076] The press control unit 66 controls the operation of the rotor punching unit 61 to form multiple laminated blocks 20 by selectively punching out the first iron core piece Wa having through holes 19, in order to keep the estimated stacking thickness Te within a predetermined range.

[0077] The calculation unit 68 calculates a correction value c by dividing the difference between the stack thickness Tm of the rotor core 11 measured by the stack thickness measuring device 70 (described later) and the estimated stack thickness Te by the number of layers N of the first core pieces Wa constituting the rotor core 11. The calculation unit 68 calculates a corrected plate thickness t' by adding the correction value c to each plate thickness t of the planned section Wp measured by the plate thickness sensor 65. The calculation unit 68 calculates an estimated stack thickness Te' in which the estimated stack thickness Te has been corrected by integrating the corrected plate thickness t'. The press control unit 66 adjusts the number of layers of the first core pieces Wa in the stacking block 20 so that the stack thickness Tm of the rotor core 11 approaches the estimated stack thickness Te'.

[0078] Furthermore, the press control unit 66 can also perform the same control on the stator punching unit 62 as it does on the operation control of the rotor punching unit 61. (Stack thickness measuring device 70) The stack thickness measuring device 70 is a device for measuring the stack thickness of the rotor core 11 and the stator core 51. The following description will explain how to measure the stack thickness Tm of the rotor core 11 using the stack thickness measuring device 70.

[0079] The stack thickness measuring device 70 includes a support member 71 that supports the lower surface of the rotor core 11, a pressure member 72 that presses against the upper surface of the rotor core 11, and a plurality of probes 73 that measure the distance between the support member 71 and the pressure member 72. The stack thickness measuring device 70 includes, for example, three probes 73 that are arranged concentrically and spaced apart from each other between the support member 71 and the pressure member 72.

[0080] The stacking thickness measuring device 70 indirectly measures the stacking thickness Tm of the rotor core 11 based on the distance from the support member 71 to the pressurizing member 72 at each of the three probes 73, while the rotor core 11 is pressurized by the pressurizing member 72.

[0081] The stack thickness measuring device 70 is configured to output the measurement results of the stack thickness measuring device 70 to the press control unit 66. (1st transfer device 80) As shown in Figure 13, the first transfer device 80 is a device that takes out one stacked block 20 at a time from a support jig 85 that supports a stacked body 11A in which multiple stacked blocks 20 are stacked, and transfers them to the object to be transferred. An example of the object to be transferred is the pass / fail determination device 90, which will be described later.

[0082] The laminated body 11A is formed by stacking multiple laminated blocks 20 in the vertical direction in the reverse order of the stacking order of the multiple laminated blocks 20 that constitute the rotor core 11. The support jig 85 includes a first base plate 86, a spacer 87 that supports the lower surface of the laminate 11A, and a first post 88 that protrudes from the first base plate 86.

[0083] The first base plate 86 and the spacer 87 are both flat plates. The spacer 87 is fixed to the upper surface of the first base plate 86. The first post 88 is cylindrical in shape. The first post 88 penetrates the spacer 87. The first post 88 is inserted into the central hole 12 of each of the multiple stacked blocks 20. A gap is provided between the first post 88 and the central hole 12 of each of the multiple stacked blocks 20 to allow rotation of each stacked block 20 relative to the first post 88.

[0084] For example, a worker can insert multiple stacked blocks 20 into the first post 88 in the reverse order of the stacking sequence of the multiple stacked blocks 20 that make up the rotor core 11. The first transfer device 80 includes a restricting unit 81 that restricts the movement of the stacked blocks 20, a transfer unit 82 that transfers the stacked blocks 20, and a detection unit 83 that detects the position of the upper end surface of the uppermost stacked block 20.

[0085] The restricting section 81 has a pair of chucks that grip the outer circumferential surface of the stacked block 20. The chucks of the restricting section 81 are configured to be able to move up and down in the vertical direction and to move closer to and further apart from each other.

[0086] The portion of the chuck of the restricting section 81 that contacts the stacked block 20 is in the shape of an arc along the outer surface of the stacked block 20. The restricting unit 81 restricts the movement of the second-stage block 20A by gripping the stacked block 20 located directly below the uppermost stacked block 20 among the multiple stacked blocks 20 that make up the stacked body 11A (hereinafter referred to as the second-stage block 20A).

[0087] The transfer unit 82 has a pair of chucks that grip the outer circumferential surface of the stacked block 20. The chucks of the transfer unit 82 are configured to be able to move up and down in the vertical direction and to move closer to and further apart from each other.

[0088] The portion of the chuck of the transfer unit 82 that contacts the stacked block 20 is arc-shaped, following the outer circumferential surface of the stacked block 20. The transfer unit 82 grips the uppermost stacked block 20, removes it from the support jig 85, and transfers it to the pass / fail determination device 90.

[0089] The detection unit 83 is, for example, a transmissive photoelectric sensor having a light-emitting unit 83a and a light-receiving unit 83b. The light-emitting unit 83a and the light-receiving unit 83b are located on opposite sides of the laminate 11A. Although not shown in the figure, the axis connecting the light-emitting unit 83a and the light-receiving unit 83b coincides with the portion of the laminate 11A excluding the central hole 12 when viewed from above. That is, the axis coincides with the portion of the support jig 85 excluding the first post 88 when viewed from above.

[0090] The detection unit 83 is configured to be able to move up and down in the vertical direction. When detecting the upper end surface of the laminate 11A, the detection unit 83 rises from the lower end to the upper end of the laminate 11A. While the detection unit 83 is facing the laminate 11A, the light from the light-emitting unit 83a is blocked by the laminate 11A and is therefore not received by the light-receiving unit 83b. When the detection unit 83 reaches the upper end of the laminate 11A, the light from the light-emitting unit 83a is received by the light-receiving unit 83b. As a result, the detection unit 83 detects the position of the upper end surface of the laminate 11A.

[0091] The restricting section 81 is configured to clamp the outer circumferential surface of the laminate 11A at a specified distance below the position of the upper end surface of the laminate 11A detected by the detection section 83. Here, the specified distance is the sum of the thickness T1 of the uppermost laminate block 20 and half of the thickness T2 of the second-stage block 20A (T1 + (T2 / 2)). In other words, the restricting section 81 is configured to clamp the outer circumferential surface of the central part in the axial direction of the second-stage block 20A.

[0092] The transfer unit 82 is configured to grip the outer circumferential surface of the portion of the laminate 11A that is located at a distance of half the thickness T1 of the uppermost laminate block 20, from the position of the upper end surface of the laminate 11A detected by the detection unit 83. In other words, the transfer unit 82 is configured to grip the outer circumferential surface of the central portion in the axial direction of the uppermost laminate block 20.

[0093] The first transfer device 80 determines which of the first to sixth blocks 26 the topmost stacked block 20 is by counting the number of stacked blocks 20 removed from the support jig 85. The first transfer device 80 also holds information on the thickness of the first to sixth blocks 26. Therefore, by determining the type of the topmost stacked block 20, the first transfer device 80 can determine the thickness T1 of the topmost stacked block 20 and the thickness T2 of the second-stage block 20A. As a result, the first transfer device 80 can clamp the outer circumferential surface of the central part in the axial direction of the second-stage block 20A with the restricting part 81.

[0094] (Correct / incorrect determination device 90) As shown in Figure 14, the validity determination device 90 is a device that determines whether the stacked block 20 transferred by the first transfer device 80 is a valid stacked block 20 that should be transferred to the stacking device 100 and stacked. More specifically, the validity determination device 90 is a device that determines whether the front and back, stacking order, manufacturing line, and product type of the stacked block 20 transferred by the first transfer device 80 are correct.

[0095] The success / failure determination device 90 comprises a rotating stage 91, an imaging device 92, a detection unit 93, and a control unit 94. The stacked blocks 20, which have been transferred by the first transfer device 80, are placed on the rotating stage 91. The rotating stage 91 is configured to rotate the stacked blocks 20 around axis C and to be able to position them at any desired position.

[0096] The imaging device 92 has a camera that captures the entire surface of one end face of the stacked block 20 placed on the rotating stage 91. The detection unit 93 detects the welding grooves 33 of the stacked block 20. The detection unit 93 has a pair of displacement sensors 93A and 93B that are spaced apart from each other in the vertical direction. The displacement sensors 93A and 93B are positioned opposite the upper and lower ends of the stacked block 20, which is placed on the rotating stage 91, respectively.

[0097] The control unit 94 controls the operation of the rotating stage 91, the imaging device 92, and the detection unit 93. The control unit 94 processes the image of the stacked block 20 captured by the imaging device 92. After detecting the position of the key 13 of the stacked block 20 from the captured image, the control unit 94 rotates the rotation stage 91 so that the key 13 is in a predetermined position. This rotation aligns the key 13 of the stacked block 20 with the key groove 103a of the second post 103, which will be described later (see Figure 16). Also, if the stacked block 20 has a welding groove 33, this rotation causes the welding groove 33 to face either of the pair of displacement sensors 93A and 93B.

[0098] The control unit 94 has a registered image, which is an image of one end face in the axial direction of a normal stacking block 20, pre-registered. The control unit 94 compares the registered image with the captured image to determine whether the captured stacking block 20 is a normal stacking block 20. More specifically, the control unit 94 determines whether the front / back, manufacturing line, and product type of the stacking block 20 are correct based on the front / back identification unit 43, line identification unit 44, and product type identification unit 45 of the stacking block 20. The control unit 94 also determines whether the stacking order of the stacking block 20 is correct based on the shape of the surface F of the stacking block 20 and the detection result of the detection unit 93. The stacking order of the stacking block 20 refers to the order in which the stacking blocks 20 are stacked on the stacking jig 101 of the stacking device 100, which will be described later.

[0099] The validity determination device 90 has a counter (not shown) that counts the number of times a stacked block 20 has been determined to be a valid stacked block 20 when the validity determination of the stacked block 20 is performed. When the validity determination device 90 determines whether the stacked block 20 to be determined is the valid first block 21, it sets the determination count to "1". Each time the stacked block 20 to be determined is determined to be a valid stacked block 20, the validity determination device 90 increments the determination count. When the determination count is "6" and the stacked block 20 to be determined is determined to be the valid sixth block 26, the validity determination device 90 sets the determination count to "1".

[0100] (Stacking device 100) As shown in Figure 15, the lamination apparatus 100 is a device that forms a rotor core 11 by stacking multiple lamination blocks 20.

[0101] The stacking device 100 includes a stacking jig 101 that supports multiple stacking blocks 20 in a stacked state, a lifting mechanism 110 that drives a mounting table 106 (described later) up and down, and a second transfer device 115 that transfers the stacking blocks 20 one by one to the stacking jig 101.

[0102] (Lamination jig 101) The lamination jig 101 comprises a second base plate 102, a second post 103 protruding from the second base plate 102, and a mounting table 106 on which the lamination block 20 is placed. The second post 103 is an example of a post.

[0103] The second base plate 102 and the mounting platform 106 are both flat. The second post 103 is cylindrical in shape. The second post 103 penetrates the mounting base 106. Each of the multiple stacked blocks 20 is fitted into the second post 103. That is, the second post 103 is inserted into the central hole 12 of each of the multiple stacked blocks 20.

[0104] As shown in Figure 16, the outer circumferential surface of the second post 103 is provided with a keyway 103a into which the key 13 of each stacked block 20 engages. The keyway 103a extends along the entire length of the second post 103. The engagement of the key 13 with the keyway 103a positions each stacked block 20 relative to the second post 103.

[0105] Here, the stacked block 20 can be fitted into the second post 103 in two positions, rotated 180° around axis C as the axis of rotation. The multiple stacked blocks 20 supported by the stacking jig 101 may be stacked by a so-called roll stacking method, in which at least one of the multiple stacked blocks 20 is rotated by a predetermined angle before stacking.

[0106] As shown in Figure 15, the second post 103 has a columnar portion 104 extending in the axial direction of the laminated block 20 and a tapered portion 105 provided at the tip of the columnar portion 104. The outer diameter of the columnar portion 104 is constant throughout its entire length. The outer diameter of the columnar portion 104 is slightly smaller than the outer diameter of each central hole 12 of the laminated block 20.

[0107] The outer diameter of the tapered portion 105 gradually decreases towards the tip. The tapered portion 105 is, for example, frustoconical in shape. The tapered portion 105 has the function of guiding the laminated block 20 toward the columnar portion 104.

[0108] Multiple positioning pins 107 are provided protruding from the tip surface of the tapered portion 105 for positioning the Calplate 182 (described later) relative to the stacking jig 101. The mounting base 106 is provided by a lifting mechanism 110 so as to be able to move up and down in the axial direction of the stacking block 20 relative to the second post 103. Although not shown in the figures, the mounting base 106 has a pair of protrusions that engage with the keyway 103a. The mounting base 106 is provided so as to be able to move up and down in the axial direction of the stacking block 20 with the protrusions engaged with the keyway 103a.

[0109] (Lifting mechanism 110) The lifting mechanism 110 includes a plurality of shafts 111 that support the lower surface of the mounting base 106, and a plurality of drive units 112 that move the plurality of shafts 111 up and down in the axial direction of the stacked block 20.

[0110] Each shaft 111 penetrates the second base plate 102 at the portion of the second post 103 that is on the outer circumference side of the second base plate 102. Each drive unit 112 converts the rotational motion of a motor (not shown) into linear motion of the shaft 111. By changing the rotation direction of this motor, the shaft 111 moves up and down.

[0111] The upper end surface of each shaft 111 contacts the lower surface of the mounting base 106, thereby supporting the lower surface of the mounting base 106. Therefore, the mounting base 106 moves up and down in accordance with the movement of each shaft 111. In other words, the mounting base 106 moves closer to and further away from the second base plate 102 in accordance with the movement of each shaft 111.

[0112] (Second transfer device 115) The second transfer device 115 includes a pair of clamping parts 116 that clamp the outer circumferential surface of the stacked block 20, and a load sensor 117 that detects the load acting on the pair of clamping parts 116. The second transfer device 115 is an example of a transfer device.

[0113] The pair of clamping parts 116 are configured to be able to transport the stacked block 20 while clamping it. The pair of clamping parts 116 are configured to be able to move up and down in the vertical direction and to move closer to and further apart from each other. The pair of clamping parts 116 are configured to be able to press the upper surface of the stacked block 20 downwards by descending while in close proximity to each other.

[0114] The second transfer device 115 is configured to stop the operation of the pair of clamping parts 116 if the load detected by the load sensor 117 is greater than a predetermined load. (Crimping device 120) As shown in Figure 17, the crimping device 120 is a device that crimps the dowels 18 of adjacent first iron core pieces Wa together by applying pressure to the rotor core 11 in the axial direction.

[0115] The crimping device 120 includes a first type 121 that supports the lower surface of the lamination jig 101 and a second type 122 that presses the upper surface of the rotor core 11 supported by the lamination jig 101. The second type 122 is provided to be able to move back and forth relative to the first type 121.

[0116] The crimping device 120 presses the upper surface of the rotor core 11 with the second type 122, thereby crimping the dowels 18 of adjacent first iron core pieces Wa in each laminated block 20. Although not shown in the diagram, the crimping device 120 is equipped with a measuring instrument that measures the distance between the first type 121 and the second type 122 when the rotor core 11 is pressed. The stacking thickness Tm of the rotor core 11 is indirectly measured by this measuring instrument.

[0117] (Magnet insertion device 130) The magnet insertion device 130 is a device for inserting magnets 30 into each of the multiple magnet housing holes 14 of the rotor core 11.

[0118] As shown in Figure 18, the magnet insertion device 130 includes a supply mechanism 131, an extraction mechanism 136, an alignment mechanism 140, an insertion mechanism 145, a collection container 150, a locking mechanism 155, and a control unit 156.

[0119] The supply mechanism 131 includes multiple magazines 132 that house multiple magnets 30. The extraction mechanism 136 extracts the magnets 30 from the magazines 132. The alignment mechanism 140 aligns the magnets 30 extracted by the extraction mechanism 136. The insertion mechanism 145 inserts the magnets 30 into the magnet housing holes 14 of the rotor core 11. The collection container 150 collects the magnets 30 that are not housed in the magnet housing holes 14. The locking mechanism 155 restricts the opening and closing of the collection container 150. The control unit 156 controls the operation of the supply mechanism 131, the extraction mechanism 136, the alignment mechanism 140, the insertion mechanism 145, and the locking mechanism 155.

[0120] The magnet insertion device 130 comprises a housing 160 in which a supply mechanism 131, an extraction mechanism 136, an alignment mechanism 140, an insertion mechanism 145, and a collection container 150 are arranged. An opening 160a is provided on the side of the housing 160, which is opened and closed by the collection container 150.

[0121] The magnet insertion device 130 includes two insertion stations 161A and 161B for inserting the magnets 30 into the rotor core 11, and two pressing stations 162A and 162B for pressing the magnets 30 into the rotor core 11 using a pressing jig 172, which will be described later. The insertion stations 161A and 161B and the pressing stations 162A and 162B are located inside the housing 160.

[0122] At insertion stations 161A and 161B, the rotor core 11, supported by the stacking jig 101, is transported from outside the magnet insertion device 130. After passing through insertion stations 161A and 161B, the rotor core 11 is transported to the pressing stations 162A and 162B. At the pressing stations 162A and 162B, the rotor core 11 with the magnets 30 pressed in is transported outside the magnet insertion device 130.

[0123] In the rotor core 11 of the first type V1, the magnet 30 is inserted at the insertion station 161A, and then pushed in at the push station 162A. In the rotor core 11 of the second type V2, the magnet 30 is inserted at the insertion station 161B, and then pushed in at the push station 162B. The magnet insertion device 130 selectively operates the insertion stations 161A, 161B, and the push stations 162A, 162B depending on the type of rotor 10.

[0124] (Supply mechanism 131) The supply mechanism 131 comprises a plurality of magazines 132 and a long slide table 133 to which the plurality of magazines 132 are fixed. The plurality of magazines 132 are arranged in parallel along the long side of the slide table 133.

[0125] As shown in Figure 19, the magazine 132 houses multiple magnets 30 stacked vertically. The magazine 132 has an upper opening 132a. Inside the magazine 132 is a rod 134 that supports the lowest magnet 30. The rod 134 is connected to an actuator 135 that drives the rod 134 up and down. As the actuator 135 raises the rod 134, the multiple magnets 30 rise inside the magazine 132. As a result, the magnets 30 are exposed to the outside through the upper opening 132a.

[0126] As shown in Figure 18, the slide table 133 is configured to slide in the direction of its short side. By sliding the slide table 133, the position of the supply mechanism 131 is switched between an extraction position where the magnet 30 is extracted by the extraction mechanism 136 and an exchange position where the magazine 132 is replaced. As shown by the dashed line in Figure 18, the exchange position is located further away from the extraction mechanism 136 than the extraction position in the direction of its short side.

[0127] (Ejecting mechanism 136) The extraction mechanism 136 is positioned on one side of the slide table 133 in the short-side direction, facing the supply mechanism 131. The extraction mechanism 136 includes a plurality of chucks 137 for gripping and extracting the magnets 30 exposed from the magazine 132. The extraction mechanism 136 is configured to be able to extract a plurality of magnets 30 from the magazine 132 and transport them to the alignment mechanism 140 (see Figure 19). The extraction mechanism 136 is configured to be movable between the supply mechanism 131 and the alignment mechanism 140.

[0128] The extraction mechanism 136 is equipped with a first sensor 138 that detects whether each chuck 137 is gripping a magnet 30. For example, if the first sensor 138 detects a magnet 30 being gripped by the extraction mechanism 136, it outputs an ON signal to the control unit 156, and if it does not detect a magnet 30, it outputs an OFF signal to the control unit 156.

[0129] (Alignment mechanism 140) The alignment mechanism 140 is located on the opposite side of the supply mechanism 131, with the extraction mechanism 136 in between. The alignment mechanism 140 comprises a plurality of parallel mounting sections 141 and a pitch changer 142 that changes the spacing between the plurality of mounting sections 141.

[0130] Magnets 30 removed from the magazine 132 by the removal mechanism 136 are placed on each of the multiple mounting sections 141. The alignment mechanism 140 is configured to align the multiple magnets 30 by changing the spacing between the multiple mounting sections 141 using a pitch changer 142. The alignment mechanism 140 aligns the magnets 30 according to the spacing between the chucks 146 of the insertion mechanism 145, which will be described later.

[0131] The alignment mechanism 140 is equipped with a second sensor 143 that detects whether or not a magnet 30 is placed on each mounting section 141. For example, if the second sensor 143 detects a magnet 30 placed on a mounting section 141, it outputs an ON signal to the control unit 156, and if it does not detect a magnet 30, it outputs an OFF signal to the control unit 156.

[0132] The alignment mechanism 140 is configured to slide between a placement position where the magnet 30 is placed by the removal mechanism 136 and a supply position where the magnet 30 is supplied to the insertion mechanism 145. As shown by the dashed line in Figure 18, the supply position is located further away from the removal mechanism 136 than the placement position in the longitudinal direction of the slide table 133.

[0133] (Insertion mechanism 145) The insertion mechanism 145 includes a robot arm 147 having a plurality of chucks 146. Each of the plurality of chucks 146 is configured to grip a plurality of magnets 30 that are placed on the mounting portion 141 of the alignment mechanism 140 located at the supply position.

[0134] The insertion mechanism 145 is equipped with a third sensor 148 that detects whether each chuck 146 is gripping a magnet 30. For example, if the third sensor 148 detects a magnet 30 being gripped by the insertion mechanism 145, it outputs an ON signal to the control unit 156, and if it does not detect a magnet 30, it outputs an OFF signal to the control unit 156.

[0135] As described above, the angle of the magnet housing hole 14 with respect to the circumferential direction differs for each type of rotor 10. The posture of each chuck 146 on the robot arm 147 is set according to the angle of the magnet housing hole 14. Different types of chucks 146 are attached to and detached from the robot arm 147 depending on the type of rotor 10.

[0136] The insertion mechanism 145 transports the magnet 30 to either insertion station 161A or 161B, depending on the type of rotor 10 being manufactured. As shown in Figure 20, at insertion stations 161A and 161B, a guide jig 170 for guiding the insertion of the magnets 30 into the magnet housing holes 14 is placed on the upper surface of the rotor core 11. The guide jig 170 has a plurality of guide holes 171, each communicating with a plurality of magnet housing holes 14.

[0137] The insertion mechanism 145 inserts the magnets 30 into each of the magnet housing holes 14 through the multiple guide holes 171. At this time, since a portion of the magnet 30 is inserted into each magnet housing hole 14, the magnet 30 protrudes from the guide hole 171.

[0138] In the push-in stations 162A and 162B, the ends of the magnets 30 protruding from the guide holes 171 are pushed in by the push-in jig 172. The push-in jig 172 has multiple push-in parts 173, each of which is inserted into one of the multiple guide holes 171.

[0139] (Collection container 150) As shown in Figure 18, the collection container 150 is configured to allow opening 160a of the housing 160 to be opened and closed. The collection container 150 has a collection section 151 into which the magnets 30 are collected, and a handle 152 fixed to the collection section 151.

[0140] The collection unit 151 is box-shaped with an open top. The opening 160a of the housing 160 is opened and closed by a part of the side wall of the collection unit 151. When the collection container 150 closes the opening 160a, the collection unit 151 is located inside the housing 160.

[0141] The handle 152 protrudes from the side wall of the collection unit 151 that opens and closes the opening 160a, and is located outside the housing 160. The collection container 150 is configured to slide between a collection position in which the magnet 30 can be collected by the insertion mechanism 145 and a discharge position in which the magnet 30 can be discharged to the outside. In the collection position, the collection container 150 closes the opening 160a. In the discharge position, the collection container 150 opens the opening 160a.

[0142] The opening and closing of the collection container 150 is detected by an opening / closing sensor 153 located inside the housing 160. The opening / closing sensor 153 outputs an OFF signal to the control unit 156 when the collection container 150 has its opening 160a open, and an ON signal to the control unit 156 when the collection container 150 has its opening 160a closed.

[0143] (Locking mechanism 155) The locking mechanism 155 is configured to lock the collection container 150 in the collection position. The locking mechanism 155 restricts the opening and closing of the collection container 150 by engaging with the collection section 151, while allowing the opening and closing of the collection container 150 by disengaging from the collection section 151.

[0144] The locking mechanism 155 locks the collection container 150 in the collection position when the magnet insertion device 130 is in operation. When switching between different types of rotors 10 manufactured using the magnet insertion device 130, the locking mechanism 155 releases the lock on the collection container 150, allowing it to be opened and closed. More specifically, the locking mechanism 155 releases the lock on the collection container 150 when the presence of the magnet 30 is not detected by the first sensor 138 of the extraction mechanism 136, the second sensor 143 of the alignment mechanism 140, and the third sensor 148 of the insertion mechanism 145 during a product changeover.

[0145] (Control Unit 156) When the insertion mechanism 145 is gripping the magnet 30 during a product changeover, the control unit 156 controls the insertion mechanism 145 to transfer the magnet 30 to the collection container 150.

[0146] The control unit 156 controls the insertion mechanism 145 to transfer the magnet 30 to the collection container 150 if the magnet 30 is placed on the mounting unit 141 during a product changeover. When the removal mechanism 136 is gripping the magnet 30 during a product changeover, the control unit 156 controls the removal mechanism 136 to transfer the magnet 30 to the mounting section 141.

[0147] The control unit 156 controls the locking mechanism 155 to lock the collection container 150 in the collection position until a product change is performed. On the other hand, if there are no magnets 30 in the retrieval mechanism 136, the mounting section 141, or the insertion mechanism 145 when a product change is performed, the control unit 156 controls the locking mechanism 155 to release the lock on the collection container 150.

[0148] The control unit 156 controls the locking mechanism 155 to lock the collection container 150 in the collection position when the collection container 150 moves from the discharge position to the collection position during a product changeover. The control unit 156 also controls the insertion mechanism 145 to prevent the magnet 30 from being inserted into the magnet housing hole 14 until this locking is complete.

[0149] (Molding device 180) As shown in Figure 21, the molding device 180 is a device that fixes multiple magnets 30 to the rotor core 11 by filling each of the multiple magnet housing holes 14 with resin material 31 and allowing it to solidify.

[0150] The molding device 180 comprises a fixed mold 181, a cal plate 182, and a movable mold 186. The fixed mold 181 has a support surface that supports the lower surface of the lamination jig 101 on which the rotor core 11 is supported. The cal plate 182 is placed on the upper surface of the rotor core 11. The movable mold 186 is provided on the opposite side of the cal plate 182 from the fixed mold 181 and is capable of moving forward and backward relative to the fixed mold 181.

[0151] As shown in Figure 22, the Calplate 182 has, for example, a rectangular shape in plan view. The Calplate 182 has a plurality of supply ports 183 for filling each of the plurality of magnet housing holes 14 with resin. The plurality of supply ports 183 are provided at equal intervals in the circumferential direction. Each supply port 183 is provided at a position corresponding to the portion between a pair of magnet housing holes 14.

[0152] Each supply port 183 has a runner portion 184 and a pair of communication holes 185 that communicate with the runner portion 184. As shown in Figure 21, the runner portion 184 opens to the upper surface of the Calplate 182. Each communication hole 185 opens to the bottom surface of the runner portion 184 and penetrates the Calplate 182 in the thickness direction. Each communication hole 185 connects the runner portion 184 to the magnet housing hole 14.

[0153] A positioning hole 187 into which a positioning pin 107 is inserted is provided in the center of the calplate 182. By inserting the positioning pin 107 into the positioning hole 187, the calplate 182 and the rotor core 11 are positioned so that the supply port 183 and the magnet housing hole 14 are in communication.

[0154] The movable mold 186 has multiple supply passages 188 that supply resin to multiple supply ports 183. Resin pellets P made of thermosetting resin are placed in the supply passages 188. The resin pellets P are heated, for example, by a heater (not shown) installed inside the movable mold 186, causing them to melt inside the supply passages 188.

[0155] The molding device 180 includes a plurality of plungers 189 configured to be insertable and removable from the supply passage 188. Each plunger 189 applies pressure to the molten resin inside the supply passage 188 in order to fill the magnet housing hole 14 with the resin.

[0156] (Removal device 200) As shown in Figure 23, the removal device 200 is a device that removes multiple solidified resin material R from the Calplate 182 by using an extrusion jig 190 to push out the solidified resin material R remaining in each of the multiple supply ports 183 of the Calplate 182.

[0157] The removal device 200 includes an extrusion jig 190 and a conveying device 195. The extrusion jig 190 is configured to extrude the solidified material R from the calplate 182. The conveying device 195 is configured to convey the calplate 182 from the molding device 180 and to press the calplate 182 against the extrusion jig 190.

[0158] As shown in Figures 23 and 24, the extrusion jig 190 has a base portion 191 and a plurality of extrusion portions 192 that protrude from the base portion 191. The base portion 191 has an opposing surface 191a that faces one end face in the thickness direction of the Calplate 182, more specifically, the surface from which the multiple communication holes 185 are opened. The opposing surface 191a is planar. The multiple extruded portions 192 protrude from the opposing surface 191a and are spaced apart from each other in the circumferential direction.

[0159] As shown in Figure 24, the multiple extrusion sections 192 include multiple first extrusion sections 193 and multiple second extrusion sections 194. The first extrusion sections 193 and the second extrusion sections 194 are arranged alternately in the circumferential direction.

[0160] The first extrusion section 193 has a pair of first extrusion pins 193a that are inserted into a pair of communication holes 185 of the Calplate 182. The second extrusion section 194 has a pair of second extrusion pins 194a that are inserted into a pair of communication holes 185 of the Calplate 182.

[0161] The amount of protrusion from the opposing surface 191a of the second extrusion section 194 is smaller than the amount of protrusion from the opposing surface 191a of the first extrusion section 193. That is, the amount of protrusion from the opposing surface 191a of the second extrusion pin 194a is smaller than the amount of protrusion from the opposing surface 191a of the first extrusion pin 193a. When the extrusion jig 190 is placed on it, the tip of the first extrusion pin 193a is located above the tip of the second extrusion pin 194a.

[0162] As shown in Figure 23, the conveying device 195 has a pair of support parts 196, a pair of pressing parts 197, and a pair of connecting parts 198. A pair of support portions 196 support the lower surfaces of both ends of the Calplate 182 in the width direction. A pair of pressing portions 197 press against the upper surfaces of both ends of the Calplate 182 in the width direction. The pair of pressing portions 197 and the pair of support portions 196 face each other in the vertical direction. A pair of connecting portions 198 connect the support portions 196 and the pressing portions 197. The vertical distance between the support portions 196 and the pressing portions 197 is greater than the thickness of the Calplate 182. Therefore, when the pair of support portions 196 are supporting the Calplate 182, a gap is created between the lower surface of the pressing portions 197 and the upper surface of the Calplate 182.

[0163] (Welding equipment 210) As shown in Figure 25, the welding apparatus 210 is a device for welding end plates 32 to both end faces of the rotor core 11 in the axial direction.

[0164] The welding apparatus 210 is equipped with multiple welding torches 211 for welding the rotor core 11 and the end plate 32. A welding method, for example, is laser welding. Each welding torch 211 is mounted to be able to move up and down in the axial direction of the rotor core 11. The welding torch 211 performs welding between the rotor core 11 and the end plate 32 while moving axially within the welding groove 33.

[0165] (Manufacturing method for rotor 10) As shown in Figure 26, the method for manufacturing the rotor 10 includes a pressing step, a stacking thickness adjustment step, a conveying step, a first transfer step, a pass / fail determination step, a rotor core formation step, a crimping step, a magnet insertion step, a molding step, a removal step, and a welding step.

[0166] (Pressing process) As shown in Figure 12, the pressing process is a process in which the rotor punching unit 61 performs multiple processing operations on the intermittently conveyed workpiece W, and then punches out the first iron core piece Wa from the workpiece W.

[0167] The pressing process includes, for example, a hole punching process, a dowel forming process, a dowel removal process, and a block forming process. In the hole-punching process, multiple machining steps are performed on the workpiece W to create the central hole 12 of the rotor core 11, the cooling channel 15, and the magnet housing hole 14.

[0168] In the dowel formation process, a dowel 18 is formed that bulges out on one side in the thickness direction relative to the workpiece W. The dowel formation process is performed either before or after the hole punching process, or between each processing step of the hole punching process.

[0169] In the dowel removal process, the dowels 18 formed in the workpiece W are selectively punched out. This creates through holes 19 (see Figure 3) in the workpiece W. In the block formation process, the rotor punching section 61 punches out a plurality of first core pieces Wa having dowels 18 from the workpiece W, and forms a laminated block 20 by stacking the plurality of first core pieces Wa. In the block formation process, each time a predetermined number of first core pieces Wa are stacked from the workpiece W, a first core piece Wa having a through hole 19 is punched out.

[0170] As shown in Figure 3, the first core piece Wa having a through hole 19 does not engage with the dowel 18 of the first core piece Wa punched out immediately before it. Therefore, multiple stacked blocks 20 are formed with the first core piece Wa having a through hole 19 as the boundary. When the first core piece Wa having a through hole 19 is punched out at a predetermined timing, blocks 21 to 6, each with a different shape, are formed.

[0171] (Stacking thickness adjustment process) The stacking thickness adjustment process is a process of adjusting the number of layers of the first iron core piece Wa in the stacked block 20. The stacking thickness adjustment process is performed in each of the two sets of press devices 60. Hereafter, the stacking thickness adjustment process performed in one press device 60 will be described, and the description of the stacking thickness adjustment process performed in the other press device 60 will be omitted.

[0172] The stacking thickness adjustment process includes a plate thickness measurement process, a stacking thickness estimation process, a stacking thickness measurement process, and a correction value calculation process. In the plate thickness estimation process, the plate thickness t of each section Wp is measured by the plate thickness sensor 65.

[0173] In the stacking thickness estimation process, the estimated stacking thickness Te is calculated as an estimated value of the stacking thickness Tm of the rotor core 11 by summing the thickness t of each plate in the planned section Wp. In the stacking thickness measurement process, the stacking thickness Tm of the rotor core 11, for which the estimated stacking thickness Te has been calculated, is measured. The stacking thickness measurement process is performed before the crimping process. More specifically, the stacking thickness measurement process is performed after the block formation process and before the transport process, which will be described later.

[0174] In the correction value calculation process, a correction value c is calculated by dividing the difference between the stack thickness Tm of the rotor core 11 measured in the stack thickness measurement process and the estimated stack thickness Te by the number of layers N of the first iron core pieces Wa that constitute the rotor core 11.

[0175] In the stacking thickness estimation process, which is performed after the correction value calculation process, the estimated stacking thickness Te' is calculated by adding a correction value c to each plate thickness t of the planned section Wp and accumulating the corrected plate thickness t'. In the subsequent block formation process, the number of layers of the first iron core piece Wa in the stacked block 20 is adjusted so that the stacking thickness Tm of the rotor core 11 approaches the estimated stacking thickness Te'.

[0176] The procedure for adjusting the stacking thickness will be explained below with reference to the flowchart shown in Figure 27. As shown in Figure 27, each time the workpiece W is fed by the feed device, the plate thickness sensor 65 measures the plate thickness t of each section Wp (step S101). The plate thickness t information measured by the plate thickness sensor 65 is stored in the storage unit 67 of the press control unit 66.

[0177] Next, multiple stacked blocks 20 are formed by the block forming process described above (step S102). Next, the calculation unit 68 estimates the stacking thickness of the laminated block 20 and the stacking thickness Tm of the rotor core 11 by sequentially accumulating the plate thickness t of the planned portion Wp each time the planned portion Wp is punched out, or even before the planned portion Wp is punched out. At this time, the calculation unit 68 calculates the estimated stacking thickness Te (Te=Σt) as an estimated value of the stacking thickness Tm of the rotor core 11 composed of the first block 21 to the sixth block 26 by accumulating the stacking thickness of the first block 21 to the sixth block 26 (step S103). The number of layers N of the first iron core piece Wa constituting the rotor core 11 for which the estimated stacking thickness Te has been calculated is the number of layers for which the estimated stacking thickness Te is closest to the desired stacking thickness in the rotor core 11. Therefore, the number of layers N of the first iron core piece Wa constituting the rotor core 11 may differ for each rotor core 11.

[0178] Hereafter, the estimated stacking thickness Te of the rotor core 11, which is composed of the first block 21 to the sixth block 26 formed from a single base material Wm constituting the workpiece W, will be referred to as the estimated stacking thickness Te1. The estimated stacking thickness Te of the rotor core 11, which is composed of the second block 21 to the sixth block 26 formed from a single base material Wm, will be referred to as the estimated stacking thickness Te2.

[0179] Next, the stack thickness measuring device 70 measures the stack thickness Tm of the rotor core 11 for which the estimated stack thickness Te has been calculated (step S104). In step S104, the rotor core 11 whose stacking thickness Tm is measured is formed, for example, by stacking the first block 21 to the sixth block 26 by an operator. This rotor core 11 may also be formed by rolling the stacked blocks 20. In step S104, for example, the stacking thicknesses Tm1 and Tm2 of the rotor core 11, for which estimated stacking thicknesses Te1 and Te2 have been calculated, are measured, respectively.

[0180] Next, the calculation unit 68 calculates a correction value c (c=(Tm-Te) / N) by dividing the difference between the stacking thickness Tm of the rotor core 11 measured in step S104 and the estimated stacking thickness Te by the number of stacks N of the first iron core pieces Wa constituting the rotor core 11 (step S105). The correction value c can be a positive or negative value.

[0181] In step S105, the calculation unit 68 calculates a correction value c1 based on the difference between the stack thickness Tm1 and the estimated stack thickness Te1, and calculates a correction value c2 based on the difference between the stack thickness Tm2 and the estimated stack thickness Te2. In step S105, the average value of correction value c1 and correction value c2 may be used as the correction value c.

[0182] Next, the calculation unit 68 calculates a corrected plate thickness t' (t'=t+c) by adding a correction value c to each plate thickness t of the planned unit Wp (step S106). The corrected plate thickness t' can be said to be a value obtained by correcting the measurement error of the plate thickness sensor 65 to the plate thickness t, which is the measured value of the plate thickness sensor 65.

[0183] In step S106, the calculation unit 68 adds the same correction value c to each plate thickness t of the planned portion Wp present in a single base material Wm. On the other hand, if the type of base material Wm from which the first iron core piece Wa is punched is switched, the calculation unit 68 calculates a new correction value c for the base material Wm after the switch. Until a new correction value c is calculated, the calculation unit 68 calculates an estimated stacked thickness Te, which is the sum of the plate thickness t measured by the plate thickness sensor 65.

[0184] Next, the calculation unit 68 calculates the estimated stacked thickness Te' (Te'=Σt') of the rotor core 11 by integrating each of the corrected plate thicknesses t' (step S107). In the subsequent block forming process, the press device 60 adjusts the number of layers, which is the number of punched-out first core pieces Wa in the laminated block 20, so that the stacking thickness Tm of the rotor core 11 approaches the estimated stacking thickness Te' (step S108). In other words, the press device 60 adjusts the number of layers of the first core pieces Wa in the laminated block 20 so that the estimated stacking thickness Te' approaches the desired stacking thickness in the rotor core 11.

[0185] In step S108, the number of layers of the first core piece Wa in the first block 21 to the sixth block 26 formed in step S102 is increased or decreased. In step S108, at least one first core piece Wa is increased or decreased in any of the first block 21 to the sixth block 26. If the correction value c is sufficiently small compared to the plate thickness t, no increase or decrease is made to the first core piece Wa.

[0186] (Conveying process) As shown in Figures 28 and 29, the transport process is the process of transporting a laminate 11A, which is made up of multiple stacked stacked blocks 20 formed in the block forming process, toward the first transfer device 80 while being supported by a support jig 85. The support jig 85 supporting the laminate 11A is transported toward the first transfer device 80 by, for example, a motor roller (not shown).

[0187] As shown in Figure 28, multiple stacking blocks 20 are stacked on the support jig 85, for example, by an operator, in the reverse order of the stacking sequence of the stacking blocks 20 in the rotor core 11. That is, the 6th block 26 to the 1st block 21 are stacked on the support jig 85 in order from bottom to top. In this embodiment, the rotational phases of the stacking blocks 20 in the laminated body 11A are not aligned.

[0188] As described above, a gap is provided between the first post 88 and the central hole 12 of each of the multiple stacked blocks 20, allowing each stacked block 20 to rotate relative to the first post 88. This makes it easier for the worker to fit the stacked blocks 20 onto the first post 88. Furthermore, it facilitates the removal of the stacked blocks 20 from the support jig 85 in the first transfer step, which will be described later.

[0189] (1st transfer process) The first transfer step is a process in which the first transfer device 80 removes the stacked blocks 20 one by one from the support jig 85 that supports the stacked body 11A and transfers them to the pass / fail determination device 90.

[0190] As shown in Figure 29, in the first transfer step, the detection unit 83 first rises from the lower end to the upper end of the laminate 11A. When the detection unit 83 reaches the upper end of the laminate 11A, the light emitted from the light emitter 83a is received by the light receiver 83b. As a result, the detection unit 83 detects the position of the upper end surface of the topmost laminate block 20 in the laminate 11A.

[0191] As shown in Figure 30, the restricting unit 81 then clamps the outer circumferential surface of the laminate 11A at a specified distance below the position of the upper end surface of the laminate 11A detected by the detection unit 83. As described above, the specified distance is the sum of the thickness T1 of the uppermost laminate block 20 and half of the thickness T2 of the second-stage block 20A. In other words, the restricting unit 81 clamps the outer circumferential surface of the central part in the axial direction of the second-stage block 20A. This restricts the axial movement of the second-stage block 20A.

[0192] As shown in Figure 31, the transfer unit 82 then grips the outer circumferential surface of the portion of the laminate 11A that is located below the position of the upper end surface of the laminate 11A detected by the detection unit 83 by a distance of half the thickness T1 of the uppermost laminate block 20. In other words, the transfer unit 82 grips the outer circumferential surface of the central portion in the axial direction of the uppermost laminate block 20.

[0193] As shown in Figure 32, the transfer unit 82 then rises while gripping the topmost stacked block 20. This removes the topmost stacked block 20 from the support jig 85. As shown in Figure 33, the transfer unit 82 places the stacked block 20, which has been removed from the support jig 85, onto the rotating stage 91 of the pass / fail determination device 90.

[0194] In the first transfer process, the topmost stacked block 20 is sequentially removed from the support jig 85 and transferred to the pass / fail determination device 90. That is, in the first transfer process, the first block 21 to the sixth block 26 are sequentially removed from the support jig 85. Note that the regulating unit 81 does not operate when the sixth block 26 is removed.

[0195] (Correctness judgment process) The correctness determination step is a step in determining whether the stacking block 20 that is to be stacked on the stacking jig 101 is a genuine stacking block 20.

[0196] The correct / failure determination process includes an imaging process, a front / back determination process, a stacking order determination process, a manufacturing line determination process, and a product type determination process. (Imaging process) As shown in Figure 14, during the imaging process, the imaging device 92 images one end face in the axial direction of the stacked block 20 placed on the rotating stage 91. This allows the imaging device 92 to acquire an image of the stacked block 20.

[0197] As shown in Figure 34(a), the rotational phase of the stacked blocks 20 transferred to the rotating stage 91 by the first transfer device 80 may differ for each stacked block 20. Therefore, the control unit 94 detects the position of the key 13 of the stacked block 20 by processing the captured image acquired from the imaging device 92.

[0198] As shown in Figure 34(b), the control unit 94 rotates the rotary stage 91 so that the key 13 is in a predetermined position. This rotation aligns the key 13 of the laminated block 20 with the key groove 103a of the second post 103 used in the subsequent rotor core formation process (see Figure 16). Furthermore, if the laminated block 20 has a welding groove 33, this rotation causes the welding groove 33 to face either of the pair of displacement sensors 93A and 93B (see Figure 14).

[0199] Next, the imaging device 92 acquires an image of the aligned stacked block 20 by imaging one end face of the stacked block 20. In the front / back determination step, stacking order determination step, manufacturing line determination step, and product type determination step, the image of the aligned stacked block 20 is compared with the registered image.

[0200] (Front / Back determination process) The front / back determination step is a step in which the front / back of the stacked block 20 is determined by comparing the front / back identification unit 43 of the registered image with the front / back identification unit 43 of the captured image. In the front / back determination step, the control unit 94 compares the opening shape of the cooling channel 15 in the registered image with the opening shape of the cooling channel 15 in the captured image.

[0201] As shown in Figure 34(b), in the front / back determination process, the cooling channel 15 provided in a predetermined region when one end face of the stacked block 20 is viewed is used as the comparison target. The predetermined region is the region where the cooling channel 15 is provided, located radially outside the key 13 when the key 13, which is located above the one end face of the stacked block 20, is virtually rotated 54° clockwise. In Figure 34(b), the position of the virtually rotated key 13 is shown by a dashed line, and the cooling channel 15 located in the predetermined region is shown enclosed by a dashed line.

[0202] In the front / back determination process, first, the control unit 94 determines whether the cooling channel 15 in a predetermined area of ​​the captured image is the first cooling channel 15A to the third cooling channel 15C. If it is determined that the cooling channel 15 in the predetermined area is the first cooling channel 15A or the third cooling channel 15C, the control unit 94 determines that the imaging surface of the stacked block 20 is the front surface F. On the other hand, if it is determined that the cooling channel 15 in the predetermined area is the second cooling channel 15B, the control unit 94 determines that the imaging surface of the stacked block 20 is the back surface B. If it is determined that the imaging surface of the stacked block 20 is the back surface B, the control unit 94 determines that the correct / incorrect determination device 90 has not been transferred with a genuine stacked block 20 and stops the operation of the correct / incorrect determination device 90.

[0203] (Stacking order determination process) The stacking order determination step is a step in which the stacking order of the stacked blocks 20 is determined to be correct based on the determination result of the block determination step and the detection result of the groove detection step. The block determination step is a step in which the type of stacked block 20 is determined based on the captured image of the stacked block 20. The groove detection step is a step in which the presence or absence of welding grooves 33 in the stacked block 20 and the position of the welding grooves 33 are detected by a pair of displacement sensors 93A and 93B. The stacking order determination step is performed on stacked blocks 20 whose image surface is determined to be the front surface F in the front / back determination step.

[0204] The block determination process and groove detection process will be described in detail below. (Block determination process) In the block determination step, the control unit 94 determines the type of stacked block 20 by comparing the shape of the surface F of the stacked block 20 in the registered image with the shape of the surface F of the stacked block 20 in the captured image. More specifically, the control unit 94 determines the type of stacked block 20 by comparing the shape of the cooling channel 15 as viewed from the surface F between the registered image and the captured image.

[0205] Here, as shown in Figure 4(a), the shapes of the surfaces F of the first block 21, the second block 22, the fifth block 25, and the sixth block 26 are substantially the same. Therefore, it is difficult to determine the type of these stacked blocks 20 from the captured images. On the other hand, as shown in Figures 5 and 6, the shapes of the surfaces F of the third block 23 and the fourth block 24 are different from the shapes of the surfaces F of the other stacked blocks 20. Therefore, it is easy to determine the type of these stacked blocks 20 from the captured images.

[0206] As shown in Figure 35, in the block determination step, the control unit 94 determines whether the stacked block 20 is the third block 23 or the fourth block 24, or whether it is neither the third block 23 nor the fourth block 24.

[0207] (Groove detection process) As shown in Figure 14, in the groove detection step, a pair of displacement sensors 93A and 93B measure the indentation on the outer surface of the stacked block 20. The groove detection step is performed on stacked blocks 20 that have been determined in the block determination step to be neither the third block 23 nor the fourth block 24. That is, the groove detection step is performed on the first block 21, the second block 22, the fifth block 25, and the sixth block 26, but not on the third block 23 and the fourth block 24.

[0208] In the groove detection process, the control unit 94 determines that a recess of a predetermined depth formed on the outer surface of the laminated block 20 is a welding groove 33 when either of the pair of displacement sensors 93A or 93B detects it. The control unit 94 also determines the position of the welding groove 33 in the laminated block 20 by determining which of the pair of displacement sensors 93A or 93B detected the welding groove 33.

[0209] As shown in Figure 35, in a laminated block 20 where the groove detection process has been performed, if the displacement sensor 93A does not detect the weld groove 33, but the displacement sensor 93B detects the weld groove 33, the control unit 94 determines that the laminated block 20 is the first block 21. For convenience, in Figure 35, the displacement sensor 93A is labeled as the "upper sensor" and the displacement sensor 93B is labeled as the "lower sensor".

[0210] In a stacked block 20 on which the groove detection process has been performed, if the displacement sensor 93A detects a weld groove 33 but the displacement sensor 93B does not detect a weld groove 33, the control unit 94 determines that the stacked block 20 is the sixth block 26.

[0211] If, in a stacked block 20 on which the groove detection process has been performed, neither the displacement sensors 93A nor 93B detect a weld groove 33, the control unit 94 determines that the stacked block 20 is either the second block 22 or the fifth block 25.

[0212] In the stacking order determination process, the control unit 94 determines that the stacking order of a stacking block 20 is correct if the value of the number of determinations counted by the counter mentioned above matches the stacking number of the stacking block 20 whose type has been determined. The stacking number indicates which stacking block 20 a stacking block 20 is in the rotor core 11. Stacking numbers "1" to "6" are assigned to the first block 21 to the sixth block 26, respectively.

[0213] For example, when the number of determinations is "1", the control unit 94 determines that the first block 21, whose stacking number is "1", is a valid stacking block 20. In this embodiment, the shapes of the second block 22 and the fifth block 25 are identical. Therefore, in the stacking order determination step, the stacking order of the stacked blocks 20 is determined without distinguishing between the second block 22 and the fifth block 25. Accordingly, for example, when the determination count is "2", the second block 22, which has a stacking number of "2", or the fifth block 25, which has a stacking number of "5", is determined to be the correct stacked block 20.

[0214] When the control unit 94 determines that the first block 21 to the sixth block 26 are in order to be regular stacked blocks 20, the value of the number of determinations is set to "1". In the stacking order determination process, for example, if the stacking block 20 that is determined to be correct or incorrect when the determination count is "1" is the second block 22 with stacking number "2", then it is determined that the stacking order of the stacking block 20 is incorrect. If it is determined that the stacking order of the stacking block 20 is incorrect, the control unit 94 stops the operation of the correct / incorrect determination device 90, as it determines that the correct stacking block 20 has not been transferred to the correct / incorrect determination device 90.

[0215] After the stacking order determination step, the control unit 94 may rotate the rotating stage 91 by 180° so that the first cooling channel 15A and the third cooling channel 15C are swapped. This allows the stacking of the stacked blocks 20 to be performed in the rotor core formation step described later.

[0216] In addition, in the stacking order determination step, it is possible to determine whether the stacking order of the first block 21 and the sixth block 26 is correct based solely on the detection results of the groove detection step. (Manufacturing line determination process) The manufacturing line determination process is a process of determining whether the manufacturing line of the stacked block 20 is correct by comparing the line identification unit 44 of the registered image with the line identification unit 44 of the captured image. In other words, the manufacturing line determination process is a process of determining whether the stacked block 20 was manufactured on a legitimate manufacturing line.

[0217] In the manufacturing line determination process, the control unit 94 compares the opening shape of the first cooling channel 15A in the registered image with the opening shape of the first cooling channel 15A in the captured image. The manufacturing line determination process is performed on the stacked block 20 whose image surface is determined to be the front surface F in the front / back determination process.

[0218] In the manufacturing line determination process, the control unit 94 compares the distance between protrusions of the first cooling channel 15A in the registered image with the distance between protrusions of the first cooling channel 15A in the captured image. For example, if the regular manufacturing line is the first manufacturing line M1, the control unit 94 determines whether the distance between protrusions in the captured image is the distance between protrusions d1 (see Figure 7).

[0219] If the distance between protrusions matches between the registered image and the captured image, the control unit 94 determines that the manufacturing line for the stacked block 20 is correct. If the distance between protrusions does not match between the registered image and the captured image, the control unit 94 determines that the manufacturing line for the stacked block 20 is incorrect.

[0220] If the manufacturing line determination process determines that the manufacturing line for the stacked block 20 is incorrect, the control unit 94 stops the operation of the correct / incorrect determination device 90, as it determines that the correct / incorrect stacked block 20 has not been transferred to the correct / incorrect determination device 90.

[0221] (Type determination process) The variety determination step is a step in which the variety identification unit 45 of the registered image and the variety identification unit 45 of the captured image are compared to determine whether the variety of the stacked block 20 is correct or not.

[0222] In the variety determination step, the control unit 94 compares the pair of magnet housing holes 14 in the registered image with the pair of magnet housing holes 14 in the captured image. The variety determination step is performed on the stacked block 20 whose image surface is determined to be the front surface F in the front / back determination step.

[0223] In the variety determination process, the control unit 94 compares the identification angle formed by the pair of magnet housing holes 14 in the registered image with the identification angle formed by the pair of magnet housing holes 14 in the captured image. For example, if the regular variety is the first variety V1, the control unit 94 determines whether the identification angle in the captured image is the identification angle θ1 (see Figure 4(a)).

[0224] If the identification angle matches between the registered image and the captured image, the control unit 94 determines that the type of stacked block 20 is correct. If the identification angle does not match between the registered image and the captured image, the control unit 94 determines that the type of stacked block 20 is incorrect.

[0225] If, during the variety determination process, the variety of the stacked block 20 is determined to be incorrect, the control unit 94 stops the operation of the correct / incorrect determination device 90, as it determines that the correct / incorrect stacked block 20 has not been transferred to the correct / incorrect determination device 90.

[0226] As described above, prior to the rotor core formation process, it is determined whether the stacking block 20 to be stacked on the stacking jig 101 is a regular stacking block 20 or not. In the correct / failure determination process of this embodiment, a front / back determination process, a stacking order determination process, a manufacturing line determination process, and a product type determination process are performed based on a single image of the aligned stacked block 20. This reduces the number of times the aligned stacked block 20 needs to be imaged to just one.

[0227] As shown in FIG. 36, the stacked block 20 determined to be a normal stacked block 20 in the pass / fail determination step is conveyed by the second transfer device 115 toward the stacking jig 101.

[0228] (Rotor Core Forming Step) The rotor core forming step is a step of forming the rotor core 11 by stacking a plurality of stacked blocks 20 while supporting them with the stacking jig 101.

[0229] The rotor core forming step includes a raising step, a fitting step, and a stacking step. (Raising Step) As shown in FIG. 37, in the raising step, the lifting mechanism 110 operates to raise the mounting table 106. The position of the upper surface of the mounting table 106 in the state where the mounting table 106 has risen is below the tapered portion 105 of the second post 103.

[0230] (Fitting Step) In the fitting step, the second transfer device 115 sequentially fits the first block 21 to the sixth block 26 conveyed from the pass / fail determination device 90 into the second post 103.

[0231] As described above, in the pass / fail determination step, alignment is performed between the key 13 of the stacked block 20 and the key groove 103a of the second post 103. Therefore, the second transfer device 115 can fit the stacked block 20 into the second post 103 by moving it vertically and horizontally. <​​​​​​

[0234] As shown in Figure 38, the pair of clamping parts 116 then release their grip on the first block 21, causing the first block 21 to fall along the second post 103. This causes the first block 21 to fit onto the second post 103 and be placed on the upper surface of the mounting base 106.

[0235] (Lamination process) As shown in Figure 39, in the lamination process, first, the pair of clamping portions 116 rise above the second post 103 and then move closer to each other. As a result, the lower surfaces of each of the pair of clamping portions 116 face the upper surface of the first block 21. Subsequently, the pair of clamping portions 116 descend toward the first block 21, pressing the upper surface of the first block 21 toward the mounting base 106.

[0236] When the pair of clamping parts 116 press against the upper surface of the first block 21, the mounting base 106 descends by the same distance that the pair of clamping parts 116 press against the first block 21. That is, the first block 21 is supported on its lower surface by the mounting base 106, while its upper surface is pressed against by the pair of clamping parts 116.

[0237] As shown in Figure 40, subsequently, in the same manner as with the first block 21, the pair of clamping parts 116 drop the second block 22 from above the stacking jig 101, thereby fitting the second block 22 into the second post 103.

[0238] As shown in Figure 41, the pair of clamping parts 116 then press against the upper surface of the second block 22 in the same manner as with the first block 21, and the mounting platform 106 is lowered. As shown in Figure 42, each time a stacked block 20 is fitted into the second post 103, the pair of clamping parts 116 press against the upper surface of the stacked block 20 and the mounting base 106 lowers. In this way, the first block 21 to the sixth block 26 are stacked in order, forming a rotor core 11 supported by the stacking jig 101.

[0239] As shown in Figure 15, when the pair of clamping parts 116 press the upper surface of the stacked block 20 toward the mounting base 106, the load acting on the pair of clamping parts 116 is measured by the load sensor 117. In the stacking process, if this load is determined to be greater than a predetermined load, the second transfer device 115 stops the operation of the pair of clamping parts 116.

[0240] (Crimping process) As shown in Figure 43, the crimping process involves applying pressure to the rotor core 11 to crimp the dowels 18 of adjacent first iron core pieces Wa in the laminated block 20.

[0241] In the crimping process, first, the lamination jig 101 is placed on the first mold 121. Then, the upper surface of the rotor core 11 supported by the lamination jig 101 is pressed by the second mold 122. As a result, the dowels 18 of adjacent first core pieces Wa in each lamination block 20 are crimped together. Consequently, the gaps between the first core pieces Wa in the rotor core 11 are reduced.

[0242] In the crimping process, while the rotor core 11 is pressed, the stacking thickness Tm of the rotor core 11 is indirectly measured based on the distance between the first type 121 and the second type 122, which is measured by a measuring instrument (not shown).

[0243] If the stacking thickness Tm of the rotor core 11 measured during the crimping process is not within a predetermined range, the number of layers N of the first core pieces Wa in the rotor core 11 is adjusted. More specifically, if the stacking thickness Tm of the rotor core 11 exceeds a predetermined range, for example, the operator removes at least one first core piece Wa from the rotor core 11. If the stacking thickness Tm of the rotor core 11 is less than a predetermined range, for example, the operator adds at least one first core piece Wa to the rotor core 11. The first core piece Wa added at this time does not necessarily have a dowel 18 formed on it. When a first core piece Wa is added, it is fixed to the other first core pieces Wa by the solidification of the resin during the molding process described later.

[0244] (Magnet Insertion Process) The magnet insertion process is a process in which magnets 30 are inserted into each of a plurality of magnet accommodation holes 14 of the rotor core 11 in which the caulking process has been performed.

[0245] In the magnet insertion process, according to the type of the rotor 10, the insertion station 161A and the pushing station 162A, or the insertion station 161B and the pushing station 162B operate. Hereinafter, as an example of the magnet insertion process, the case where the insertion station 161A and the pushing station 162A operate will be described.

[0246] As shown in FIG. 44, in the magnet insertion process, first, the position of the supply mechanism 131 is set to the take-out position by the sliding of the slide table 133. As shown in FIG. 45, next, the take-out mechanism 136 grips and takes out a plurality of magnets 30 from a plurality of magazines 132 of the supply mechanism 131 located at the take-out position. The take-out mechanism 136 takes out, for example, four magnets 30 from the plurality of magazines 132 at a time.

[0247] Next, the take-out mechanism 136 places one magnet 30 on each of a plurality of placement parts 141 of the alignment mechanism 140 located at the placement position. After that, the take-out mechanism 136 moves toward the magazine 132 to take out the next magnet 30.

[0248] As shown in FIG. 44, next, the alignment mechanism 140 slides from the placement position to the supply position, and the pitch changer 142 sets the interval between the placement parts 141 to a predetermined interval. The interval between the placement parts 141 is predetermined according to the type of the rotor 10.

[0249] As shown in FIG. 46, the rotor core 11 supported by the lamination jig 101 is conveyed to the insertion station 161A. At the insertion station 161A, a guide jig 170 is placed on the upper surface of the rotor core 11. The guide jig 170 is pre-positioned so that the guide hole 171 and the magnet accommodation hole 14 communicate with each other.

[0250] Next, the insertion mechanism 145 grasps all the magnets 30 placed on the mounting section 141 and moves toward the insertion station 161A. Once all the magnets 30 placed on the mounting section 141 are grasped by the insertion mechanism 145, the alignment mechanism 140 moves from the supply position to the mounting position.

[0251] As shown in Figure 47, the insertion mechanism 145 then inserts the magnets 30 into the magnet housing holes 14 of the rotor core 11 via the guide jig 170. Although not shown in the figure, the insertion mechanism 145 inserts all the magnets 30 held by the multiple chucks 146 into each of the multiple magnet housing holes 14 at once.

[0252] The insertion mechanism 145 repeatedly grips the magnet 30 on the mounting section 141 and inserts the magnet 30 into the magnet housing hole 14. As a result, magnets 30 are inserted into all of the magnet housing holes 14 of the rotor core 11. After insertion by the insertion mechanism 145, one end of the magnet 30 protrudes from the guide hole 171 of the guide jig 170.

[0253] Next, the rotor core 11, with one end of the magnet 30 protruding from the guide hole 171, is transported to the pressing station 162A together with the stacking jig 101. As shown in Figure 48, in the pushing station 162A, the pushing jig 172, positioned above the guide jig 170, descends, pushing the multiple magnets 30 protruding from the guide hole 171 into the magnet housing hole 14 all at once. As a result, the magnets 30 are housed inside each magnet housing hole 14.

[0254] Next, after the pushing jig 172 and the guide jig 170 are retracted from the rotor core 11, the rotor core 11, supported by the stacking jig 101, is transported to the outside of the magnet insertion device 130. (Residue reduction treatment) The magnet insertion device 130 temporarily stops operating when a product changeover occurs to switch the type of rotor 10 being manufactured. At this time, magnets 30 may remain in at least one of the extraction mechanism 136, the alignment mechanism 140, and the insertion mechanism 145. Therefore, the control unit 156 of the magnet insertion device 130 performs a residue suppression process when a product changeover occurs. The residue suppression process is a process that prevents magnets 30 of the type manufactured before the product changeover from remaining inside the magnet insertion device 130.

[0255] When the residue suppression process is performed, if magnets 30 are present in the extraction mechanism 136, alignment mechanism 140, and insertion mechanism 145 during a product changeover, the magnets 30 are collected in the collection container 150.

[0256] The procedure for residue reduction treatment will be explained with reference to the flowchart shown in Figure 49. The residue suppression process is executed when a command signal for product type change is input to the control unit 156. The command signal is input to the control unit 156 when, for example, a product type change switch (not shown) provided on the magnet insertion device 130 is operated by an operator.

[0257] As shown in Figure 49, in the residue suppression process, the control unit 156 determines whether the third sensor 148 of the insertion mechanism 145 is ON or OFF (step S201). If the third sensor 148 is ON (step S201: YES), that is, if it is determined that the insertion mechanism 145 is gripping the magnet 30, the insertion mechanism 145 puts the gripped magnet 30 into the collection container 150 (step S202). If the third sensor 148 is NOT ON (step S201: NO), that is, if it is determined that the insertion mechanism 145 is not gripping the magnet 30, the control unit 156 executes step S203, which will be described later.

[0258] Following step S202, the control unit 156 determines whether the second sensor 143 of the alignment mechanism 140 is ON or OFF (step S203). If the second sensor 143 is ON (step S203: YES), that is, if it is determined that the magnet 30 is placed on the mounting section 141, the insertion mechanism 145 inserts the magnet 30 from the mounting section 141 into the collection container 150 (step S204). Note that if the second sensor 143 is ON in step S203, the position of the alignment mechanism 140 is set to the supply position. If the second sensor 143 is NOT ON (step S203: NO), that is, if it is determined that the magnet 30 is not placed on the mounting section 141, the control unit 156 executes step S205, which will be described later.

[0259] Following step S204, the control unit 156 determines whether the first sensor 138 of the extraction mechanism 136 is ON or OFF (step S205). If the first sensor 138 is ON (step S205: YES), that is, if it is determined that the extraction mechanism 136 is gripping the magnet 30, the extraction mechanism 136 transports the gripped magnet 30 to the mounting section 141 (step S206). Note that if the first sensor 138 is ON in step S205, the position of the alignment mechanism 140 is set to the mounting position. If the first sensor 138 is NOT ON (step S205: NO), that is, if it is determined that the extraction mechanism 136 is not gripping the magnet 30, the control unit 156 executes step S208, which will be described later.

[0260] Following step S206, the insertion mechanism 145 places the magnet 30 of the mounting section 141 into the collection container 150 (step S207). Prior to step S207, the position of the alignment mechanism 140 is set to the supply position.

[0261] As steps S201 to S207 are executed, all of the magnets 30 remaining in the extraction mechanism 136, alignment mechanism 140, and insertion mechanism 145 are collected in the collection container 150.

[0262] Next, the control unit 156 determines whether the first sensor 138, the second sensor 143, and the third sensor 148 are OFF (step S208). If the first sensor 138, the second sensor 143, and the third sensor 148 are OFF (step S208: YES), the locking mechanism 155 unlocks the collection container 150 (step S209). This allows the collection container 150 to slide from the collection position to the discharge position. If the first sensor 138, the second sensor 143, and the third sensor 148 are not OFF (step S208: NO), the control unit 156 executes the process in step S201.

[0263] Next, the supply mechanism 131 moves from the extraction position to the replacement position (step S210). This allows, for example, an operator to replace the magazine 132. The replaced magazine 132 contains the magnet 30 of the new product type.

[0264] Next, the control unit 156 determines whether the collection container 150 has opened the opening 160a of the housing 160 based on the detection result of the opening / closing sensor 153 (step S211). If the opening / closing sensor 153 is OFF, that is, if it is determined that the collection container 150 has opened the opening 160a (step S211: YES), the control unit 156 proceeds to step S212. If it is determined that the collection container 150 has not opened the opening 160a (step S211: NO), the control unit 156 repeats the process of step S211.

[0265] In step S212, the control unit 156 determines whether the collection container 150 is blocking the opening 160a based on the detection result of the opening / closing sensor 153 (step S212). If the opening / closing sensor 153 is ON, that is, if it is determined that the collection container 150 is blocking the opening 160a (step S212: YES), the locking mechanism 155 locks the collection container 150 in the collection position (step S213). If it is determined that the collection container 150 is not blocking the opening 160a (step S212: NO), the control unit 156 repeats the process in step S212.

[0266] If, after steps S201 to S208 have been executed, the magnet 30 has been collected in the collection container 150, then, after step S209, for example, an operator slides the collection container 150 from the collection position to the discharge position to remove the magnet 30 from the collection container 150. At this time, the collection container 150 opens its opening 160a, so the processing of the control unit 156 proceeds from step S211 to step S212.

[0267] Next, for example, after the worker removes the magnet 30, they slide the collection container 150 from the discharge position to the collection position. At this time, the collection container 150 closes the opening 160a. As a result, the control unit 156 proceeds from step S212 to step S213.

[0268] Based on the above, the control unit 156 controls the locking mechanism 155 to lock the collection container 150 in the collection position when the collection container 150 moves from the discharge position to the collection position during a product changeover. Furthermore, the control unit 156 controls the insertion mechanism 145 so as not to insert the magnet 30 into the magnet housing hole 14 until the above lock is complete. More specifically, the control unit 156 does not operate the insertion mechanism 145 until the above lock is complete.

[0269] (Molding process) As shown in Figure 50, the molding process involves filling each of the multiple magnet housing holes 14 of the rotor core 11 with resin material 31 and allowing it to solidify, thereby fixing the multiple magnets 30 to the rotor core 11.

[0270] In the molding process, first, a cal plate 182 is placed on the upper surface of the rotor core 11, which is supported by a lamination jig 101. The rotor core 11 already contains multiple magnets 30.

[0271] Next, the lamination jig 101, rotor core 11, and calplate 182 are placed in a heating device (not shown) and preheated to a predetermined temperature. The molding device 180 is also preheated to a predetermined temperature.

[0272] Next, the lamination jig 101 is placed on the fixed mold 181 of the molding device 180. Then, the movable mold 186 descends and makes contact with the upper surface of the calplate 182. As shown in Figure 21, the resin pellets P, held by a robot hand (not shown), are then placed in the supply path 188. The resin pellets P placed in the supply path 188 are melted by the heat of the preheating.

[0273] As shown in Figure 50, the plunger 189 then descends, applying pressure to the molten resin material 31 from the resin pellets P. This fills the magnet housing hole 14 with resin material 31 through the supply port 183 of the calplate 182. The resin material 31 filled inside the magnet housing hole 14 solidifies as it is heated by the heat from the preheating. This fixes each stacked block 20 to each other and fixes the magnets 30 to the rotor core 11.

[0274] At this time, a portion of the resin material 31 remains in each supply port 183 of the Calplate 182 without being filled into the magnet housing hole 14. As a result, solidified resin material R remains in each supply port 183 of the Calplate 182.

[0275] Next, after the movable type 186 is raised, the calplate 182 placed on the upper surface of the rotor core 11 is removed to the outside by the conveying device 195. Next, although not shown in the diagram, the mounting base 106 is pressed upward by multiple pressing parts that penetrate the second base plate 102 and press the lower surface of the mounting base 106 upward. As a result, the mounting base 106, together with the rotor core 11, separates from the second base plate 102. In this way, the rotor core 11 is removed from the lamination jig 101.

[0276] (Removal process) The removal process involves removing the solidified resin material R remaining in each of the multiple supply ports 183 of the Calplate 182 by using an extrusion jig 190 to push out the solidified resin material R.

[0277] As shown in Figure 51, in the removal process, first, the conveying device 195 supports the calplate 182 with a pair of support parts 196 and conveys the calplate 182 above the extrusion jig 190.

[0278] Next, as the conveying device 195 descends, the multiple extrusion sections 192 of the extrusion jig 190 come into contact with the multiple solidified materials R remaining on the calplate 182. More specifically, only the multiple first extrusion sections 193 come into contact with the multiple solidified materials R remaining on the calplate 182.

[0279] As shown in Figure 52, as the conveying device 195 descends further, the upper surface of the calplate 182 is pressed by a pair of pressing parts 197. As a result, the solidified material R is pressed against the first extrusion part 193, and multiple solidified materials R are pushed out from the calplate 182 by multiple first extrusion parts 193.

[0280] As shown in Figure 53, the conveying device 195 then descends further, pressing the remaining solidified material R on the calplate 182 against the second extrusion unit 194. As a result, the multiple second extrusion units 194 push the multiple solidified material R out of the calplate 182.

[0281] The solidified material R extruded from the Calplate 182 is located inside the supply port 183, with its contact with the Calplate 182 released. The solidified material R extruded from the Calplate 182 is removed from the Calplate 182 by adsorption by an adsorption device (not shown).

[0282] (Welding process) As shown in Figure 54, the welding process involves welding the rotor core 11 to the end plate 32.

[0283] In the welding process, the end plates 32 are first positioned on both end faces of the rotor core 11 in the axial direction. Next, the welding torch 211 welds the rotor core 11 to the end plate 32. This forms weld beads 33a inside the multiple welding grooves 33.

[0284] The rotor 10 is manufactured in the manner described above. The operation and effects of this embodiment will now be described. (1) In the lifting process, the mounting table 106 is raised. In the insertion process, the stacking block 20 is fitted into the second post 103 using a second transfer device 115 which has a pair of clamping parts 116 that clamp the outer surface of the stacking block 20 and which transfers the stacking block 20 to the stacking jig 101. In the stacking process, each time a stacking block 20 is fitted into the second post 103, the mounting table 106 is lowered while the top surface of the stacking block 20 is pressed toward the mounting table 106 by the pair of clamping parts 116, thereby stacking multiple stacking blocks 20. In the stacking process, if the load acting on the pair of clamping parts 116 when the pair of clamping parts 116 press the stacking block 20 toward the mounting table 106 is greater than a predetermined load, the operation of the second transfer device 115 is stopped.

[0285] According to this method, during the fitting process, the laminated block 20 fitted into the second post 103 is placed on the mounting base 106. This suppresses the horizontal tilt of the laminated block 20. Then, during the lamination process, the mounting base 106 is lowered while the upper surface of the laminated block 20 is pressed by a pair of clamping parts 116. As a result, the laminated block 20 is lowered while its posture is maintained, allowing the laminated block 20 to be smoothly fitted into the second post 103.

[0286] Furthermore, according to the above method, if the load acting on the pair of clamping parts 116 during the stacking process is greater than a predetermined load, the operation of the second transfer device 115 will stop. Therefore, for example, it is possible to prevent the stacked block 20 from being continuously pressed while it is caught on the second post 103. Thus, it is possible to determine whether or not the stacked blocks 20 have been stacked correctly by stopping the operation of the second transfer device 115.

[0287] Based on the above, the stacking blocks 20 can be stacked on the stacking jig 101 using a simple method. (2) In the insertion process, with only the tapered portion 105 positioned inside the central hole 12 of the laminated block 20, the clamping of the laminated block 20 by the pair of clamping portions 116 is released and the laminated block 20 is dropped, thereby fitting the laminated block 20 into the second post 103.

[0288] According to this method, the laminated block 20 falls with only the tapered portion 105 of the second post 103 positioned inside the central hole 12 of the laminated block 20. At this time, the laminated block 20 is guided toward the columnar portion 104 by the tapered portion 105, so the laminated block 20 can be easily fitted into the second post 103. This reduces the time required for the fitting process compared to the case where the laminated block 20 is fitted to the columnar portion 104 of the second post 103 while the pair of clamping portions 116 are clamping the laminated block 20. Therefore, the productivity of the rotor core 11 can be increased.

[0289] <Example of changes> This embodiment can be implemented with the following modifications. This embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0290] During the insertion process, the clamping of the laminated block 20 by the pair of clamping parts 116 may be released and the laminated block 20 may be dropped while the second post 103 is not positioned inside the central hole 12 of the laminated block 20.

[0291] During the insertion process, with the columnar portion 104 of the second post 103 positioned inside the central hole 12 of the laminated block 20, the clamping of the laminated block 20 by the pair of clamping portions 116 may be released, allowing the laminated block 20 to fall.

[0292] • A reversing device for inverting the stacked blocks 20 may be connected to the downstream side of the press device 60 in the transport direction. For example, the reversing device may invert the stacked blocks 20 by dropping them under their own weight as they are transported by a roller conveyor. This causes the dowels 18 on the stacked blocks 20 to face upwards. Alternatively, the reversing device may form a stacked body 11A by stacking other stacked blocks 20 on top of the inverted stacked block 20, with the 6th block 26 to the 1st block 21 stacked on top of it. In this case, it is preferable that the reversing device discharges the stacked body 11A to the outside each time the stacked body 11A is formed. With this configuration, when stacking multiple stacked blocks 20 on a support jig 85 during the transport process, the operator can easily perform the stacking work by supporting the stacked body 11A discharged from the reversing device on the support jig 85.

[0293] The detection unit 83 may be provided integrally with the regulating unit 81. In this modified example, the detection unit 83 is configured to be able to move up and down together with the regulating unit 81. Therefore, in the first transfer step, when the detection unit 83 rises from the lower end to the upper end of the stacked body 11A, the detection unit 83 and the regulating unit 81 rise together. Subsequently, the detection unit 83 and the regulating unit 81 both descend, and the regulating unit 81 grips the second block 20A.

[0294] The manufacturing line determination step may be a step in which the multiple stacked blocks 20 constituting the rotor core 11 are determined to be manufactured on the same manufacturing line by comparing the registered image and the captured image of the stacked block 20. In this case, first, the control unit 94 determines whether the manufacturing line of the first block 21 is the first manufacturing line M1 or the second manufacturing line M2 by comparing the line identification unit 44 of the registered image with the line identification unit 44 of the captured image. Then, the control unit 94 determines whether the manufacturing lines of the second block 22 to the sixth block 26, which are sequentially transferred to the correctness determination device 90 following the first block 21, match the manufacturing line of the first block 21. In other words, the manufacturing line determination step determines whether the manufacturing lines of the second block 22 to the sixth block 26 are correct in relation to the manufacturing line of the first block 21. Furthermore, if the manufacturing lines for the second block 22 to the sixth block 26 are different from the manufacturing line for the first block 21, the control unit 94 will determine that the correct stacked block 20 has not been transferred to the correct / incorrect device 90 and will stop the operation of the correct / incorrect device 90.

[0295] In the above embodiment, the front / back determination step, stacking order determination step, manufacturing line determination step, and product type determination step were performed based on the captured image of the stacked block 20 aligned using the rotating stage 91, but the embodiment is not limited to this. For example, the front / back determination step, manufacturing line determination step, and product type determination step may be performed based on the captured image of the stacked block 20 before alignment, and the stacking order determination step may be performed based on the captured image of the aligned stacked block 20. In this case, the control unit 94 recognizes the rotation phase of the stacked block 20 from the position of the key 13 in the captured image of the stacked block 20, and then compares the registered image with the captured image. This allows the front / back determination step, manufacturing line determination step, and product type determination step to be performed. If the front / back determination step, manufacturing line determination step, and product type determination step determine that the stacked block 20 is a normal stacked block 20, the control unit 94 rotates the rotating stage 91 so that the position of the key 13 is in a predetermined position. This rotation causes the welding groove 33 to face either of the pair of displacement sensors 93A and 93B if the stacked block 20 has a welding groove 33. This allows the control unit 94 to perform the groove detection step in the stacking order determination step. The control unit 94 may also determine whether the alignment of the stacked block 20 by the rotating stage 91 has been performed correctly before the stacking order determination step. In this case, the control unit 94 can determine whether the position of the key 13 is in a predetermined position based on the image captured of one end face of the stacked block 20 after the rotation of the rotating stage 91.

[0296] - When the lamination jig 101 is placed on the first mold 121 during the crimping process, the lamination jig 101 may be positioned by positioning pins protruding from the first mold 121. In this case, it is preferable that the second base plate 102 of the lamination jig 101 is provided with positioning holes into which the positioning pins are inserted. Since the rotor core 11 is supported in a position relative to the lamination jig 101, the positioning of the lamination jig 101 by the positioning pins positions the rotor core 11 and the crimping device 120. As a result, when the upper surface of the rotor core 11 is pressed by the second mold 122, interference between the rotor core 11 and the lamination jig 101 and deformation of the rotor core 11 can be suppressed.

[0297] The rotor core 11, supported by the stacking jig 101, may be transported to the pushing stations 162A and 162B without being transported to the insertion stations 161A and 161B. In this case, the insertion mechanism 145 inserts the magnets 30 into each guide hole 171 of the guide jig 170 placed on the insertion stations 161A and 161B. Subsequently, the guide jig 170 with the magnets 30 inserted is transported to the pushing stations 162A and 162B, thereby connecting the guide holes 171 of the guide jig 170 with the magnet housing holes 14 of the rotor core 11. Then, the magnets 30 are pushed into the magnet housing holes 14 by the pushing jig 172.

[0298] In the molding process, the lamination jig 101 may be placed on the fixed mold 181 only if the elapsed time after the completion of preheating of the rotor core 11 and the lamination jig 101 is within a predetermined time. In this case, it is preferable that the temperature of the rotor core 11 is measured during preheating, and that preheating is completed when the temperature reaches a predetermined temperature. This suppresses the temperature drop of the resin material 31 during the molding process. If the elapsed time exceeds the predetermined time, the rotor core 11 and the lamination jig 101 may be preheated again.

[0299] The robot hand that places the resin pellets P in the supply path 188 of the movable type 186 may grip the resin pellets P supplied from the supply device and place them in the supply path 188. An example of a supply device is a parts feeder in which a bowl with a spiral transport path is formed and vibrates to align the resin pellets P on the transport path and transport them to the supply path. In this case, it is preferable that the supply device be placed in a housing adjusted so that the ambient temperature is below a predetermined temperature. This makes it possible to suppress the softening of the resin pellets P by chemical reaction before they are gripped by the robot hand.

[0300] During the molding process, the resin material 31 may leak and solidify between the upper surface of the mounting table 106 and the lower surface of the rotor core 11. In this case, air may be blown onto the lower surface of the rotor core 11 after it has been removed from the lamination jig 101 to remove the excess resin material 31 adhering to the lower surface of the rotor core 11. It is preferable to use dry air, for example, from which a certain amount of moisture has been removed from factory air, as the air used. This suppresses rusting of the rotor core 11 due to moisture contained in the air.

[0301] If the coefficients of thermal expansion of the rotor core 11 and the end plate 32 are different, there is a risk that the rotor core 11 and the end plate 32 may separate as the temperature rises during use of the rotating electric machine M. To avoid such separation, it is preferable that the rotor core 11 and the end plate 32 be welded together in the welding process while the temperature of the rotor core 11 is maintained within a predetermined temperature range. However, although the rotor core 11 is at a high temperature after the molding process, its temperature tends to vary. In this case, it is preferable to weld the rotor core 11 and the end plate 32 using a welding apparatus 210 equipped with, for example, first to third heat retention stations and a heat rise station. Each heat retention station and heat rise station is configured, for example, to clamp and heat the rotor core 11 from above and below with a pair of hot plates. In this modified example, first, the temperature of the rotor core 11 removed from the lamination jig 101 after the molding process is measured. Next, if the measured temperature is within a predetermined temperature range, the rotor core 11 is transported to the first heat retention station and heated for a certain period of time to maintain its temperature. After that, the rotor core 11 is transported to the second or third heat retention station and heated for a certain period of time to maintain its temperature. Then, the rotor core 11 transported to the second or third heat retention station and the end plate 32 are welded together. On the other hand, if the measured temperature is lower than the predetermined temperature range, the rotor core 11 is transported to the heating station and heated for a certain period of time to raise its temperature to within the predetermined temperature range. After that, the rotor core 11 is transported to the second or third heat retention station and heated for a certain period of time to maintain its temperature. Then, the rotor core 11 transported to the second or third heat retention station and the end plate 32 are welded together. From the above, even if there is variation in the temperature of the rotor core 11 after the molding process, the temperature of the rotor core 11 during welding can be kept within the predetermined temperature range. [Explanation of Symbols]

[0302] Wa... First iron core piece 11…Rotor core 12...Center hole 20…Laminated blocks 101... Lamination jig 103... Second post 104...Columnar part 105...Tapered section 106… Mounting platform 115…Second transfer device 116...Holding part 117... Load sensor

Claims

1. A method for manufacturing a laminated iron core, comprising stacking multiple cylindrical laminated blocks, each consisting of multiple iron core pieces, while supporting them with a stacking jig, thereby manufacturing a laminated iron core. The stacking jig comprises a post inserted into the central hole of each of the plurality of stacking blocks, and a mounting base configured to be able to move up and down in the axial direction of the stacking block relative to the post, on which the stacking block is placed. A lifting step of raising the aforementioned mounting platform, Following the lifting step, a fitting step is performed in which the stacked block is fitted into the post using a transfer device that has a pair of clamping parts for clamping the outer surface of the stacked block and for transferring the stacked block to the stacking jig, The stacking process includes stacking the plurality of stacking blocks by lowering the aforementioned mounting base while pressing the upper surface of the stacking block toward the aforementioned mounting base with the pair of clamping parts each time the aforementioned stacking block is fitted into the post, In the stacking process, if the load acting on the pair of clamping parts when they press the stacked block toward the aforementioned support base is greater than a predetermined load, the operation of the transfer device is stopped. A method for manufacturing laminated iron cores.

2. The post has a columnar portion extending in the axial direction and a tapered portion provided at the tip of the columnar portion. In the insertion step, with only the tapered portion of the post positioned inside the central hole of the laminated block, the clamping of the laminated block by the pair of clamping portions is released, causing the laminated block to fall, thereby fitting the laminated block into the post. A method for manufacturing a laminated iron core according to claim 1.

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