Stator magnet mounting device, stator magnet mounting method, and stator manufacturing method

Abstract

A stator magnet mounting device for mounting magnets to a stator core includes: a holding mechanism including a holding member formed from a magnetic material, the holding member having a holding lower surface for attracting and holding the upper surface of a magnet by magnetic force; a movement mechanism for moving the holding member so that the magnet held by the holding member is arranged at a predetermined position facing a magnet mounting surface of the stator core with a gap therebetween in the vertical direction; and a separation mechanism for separating the magnet held in the predetermined position from the holding lower surface toward the magnet mounting surface.

Description

Stator magnet assembly device, stator magnet assembly method, and stator manufacturing method

[0001] This disclosure relates to a stator magnet assembly device, a stator magnet assembly method, and a stator manufacturing method. This application claims priority to Japanese Patent Application No. 2024-003676, filed with the Japan Patent Office on January 15, 2024, the contents of which are incorporated herein by reference.

[0002] Conventionally, stators incorporated in magnetic gear electric machines have been known. For example, a stator disclosed in Patent Document 1 includes a stator core extending in a circumferential direction. A plurality of magnets (stator magnets) are arranged in the circumferential direction on a plurality of teeth provided on the stator core.

[0003] Japanese Patent Application Laid-Open No. 2023-042363

[0004] It is preferable that the stator magnets be efficiently assembled into the stator core.

[0005] An object of the present disclosure is to provide a stator magnet assembling device, a stator magnet assembling method, and a stator manufacturing method that can efficiently assemble magnets into a stator core.

[0006] A stator magnet assembly device according to at least one embodiment of the present disclosure is a stator magnet assembly device for assembling a magnet to a stator core, and includes: a holding mechanism including a holding member formed of a magnetic material, the holding member having a holding lower surface for attracting and holding the upper surface of the magnet by magnetic force; a moving mechanism for moving the holding member so that the magnet held by the holding member is positioned at a predetermined position facing the magnet mounting surface of the stator core with a gap in the vertical direction; and a separating mechanism for moving the magnet held at the predetermined position away from the holding lower surface toward the magnet mounting surface.

[0007] A stator magnet assembling method according to at least one embodiment of the present disclosure is a stator magnet assembling method for assembling a magnet to a stator core, comprising: a holding step of attracting and holding the magnet to a lower holding surface of a holding member formed from a magnetic material; a moving step of moving the holding member so that the held magnet is positioned at a predetermined position facing the magnet mounting surface of the stator core with a gap in the vertical direction; and a separating step of separating the magnet held by the holding member from the lower holding surface toward the magnet mounting surface.

[0008] A method of manufacturing a stator according to at least one embodiment of the present disclosure is a method of manufacturing a stator in which a plurality of magnets are assembled to the stator core over the entire circumferential length of the stator core by repeating the stator magnet assembling method described above, wherein the plurality of magnets include: a first radial magnet magnetized on the radially outer side of the stator core; a second radial magnet magnetized on the radially inner side; a first circumferential magnet magnetized on one circumferential side of the stator core; and a second circumferential magnet magnetized on the other circumferential side, and the method of manufacturing the stator includes: a radial magnet arranging step of arranging the first radial magnets and the second radial magnets alternately at intervals in the circumferential direction of the stator core; After the radial magnet arranging step, there is a circumferential magnet arranging step of arranging the first circumferential magnet and the second circumferential magnet at an interval in the circumferential direction, in which the first circumferential magnet is arranged on one side in the circumferential direction of the first radial magnet and on the other side in the circumferential direction of the second radial magnet, and the second circumferential magnet is arranged on the other side of the first radial magnet and on one side in the circumferential direction of the second radial magnet.

[0009] According to the present disclosure, it is possible to provide a stator magnet assembling device, a stator magnet assembling method, and a stator manufacturing method that can efficiently assemble a stator magnet onto a stator core.

[0010] 9A . FIG. 9B is a schematic diagram showing the magnet assembling method following FIG. 9C . FIG. 9D is a schematic diagram showing the magnet assembling method following FIG. 9D . FIG. 9C is a schematic diagram showing the magnet assembling method following FIG. 9D . FIG. 9D is a schematic diagram showing the magnet assembling method following FIG. 9A . FIG. 9D is a schematic diagram showing the magnet assembling method following FIG. 9D . FIG. 9E is a schematic diagram showing the magnet assembling method following FIG. 9F . FIG. 9F is a schematic diagram showing the magnet assembling method following FIG. 9F . FIG. 9G is a schematic diagram showing the magnet assembling method following FIG. 9F . FIG. 9H is a schematic diagram showing the magnet assembling method following FIG. 9H ... FIG. 10 is a schematic diagram illustrating a circumferential magnet placement step according to one embodiment.

[0011] Several embodiments of the present disclosure will be described below with reference to the accompanying drawings. However, the dimensions, materials, shapes, relative arrangements, etc. of components described as embodiments or shown in the drawings are not intended to limit the scope of the present disclosure and are merely illustrative examples. For example, expressions expressing relative or absolute arrangements, such as "in a certain direction," "along a certain direction," "parallel," "orthogonal," "center," "concentric," or "coaxial," not only strictly express such arrangements, but also express relative displacements with a tolerance or angle or distance to the extent that the same function is achieved. For example, expressions expressing the equality of things, such as "same," "equal," and "homogeneous," not only express strict equality, but also express tolerance or differences to the extent that the same function is achieved. For example, expressions expressing shapes such as a square or cylindrical shape not only express shapes such as a square or cylindrical shape in the strict geometric sense, but also express shapes including concave and convex portions, chamfered portions, etc., to the extent that the same effect is achieved. On the other hand, the expressions "comprise," "include," or "have" one component are not exclusive expressions that exclude the existence of other components. Note that similar components may be assigned the same reference numerals and descriptions thereof may be omitted.

[0012] <Basic Configuration of Magnetic Gear Electric Machine 10> Referring to Fig. 1, a magnetic gear electric machine 10 equipped with a stator 20 will be outlined. The magnetic gear electric machine 10 is equipped with a rotating shaft 18 connected to an external device 9. In Fig. 1, the rotating shaft 18 is depicted as a single solid shaft member for the sake of simplicity, but the present disclosure is not limited to this. The rotating shaft 18 may be realized by a plurality of shaft members, and the plurality of shaft members may include a cylindrical shaft member.

[0013] In the following description, the "axial direction" refers to the axial direction of the axis S of the rotating shaft 18, the "circumferential direction" refers to the circumferential direction based on the axis S, and the "radial direction" refers to the radial direction based on the axis S. The "radial inner side" refers to the side approaching the axis S, and the "radial outer side" refers to the side moving away from the axis S. The axis S is the center of the stator 20. In this example, the axial direction refers to the horizontal direction, and the radial direction is a concept that includes the up and down directions.

[0014] The magnetic gear electric machine 10 includes a housing 17 that rotatably supports a rotating shaft 18, and a stator 20 fixed to the housing 17. The stator 20 includes a stator core 24, a plurality of stator coils 27 arranged in the stator core 24, and a plurality of magnets (stator magnets) 5 arranged on the inner circumferential surface of the stator core 24. The stator coil 27 is electrically connected to the power grid 16.

[0015] The magnetic gear electric machine 10 further includes a pole piece rotor 30. The pole piece rotor 30 includes an annular body 35 extending along the axis S radially inward of the stator 20, and a pair of connecting members 31 connecting the annular body 35 to the rotating shaft 18. The annular body 35 includes a plurality of magnetic pole pieces 36 and a plurality of non-magnetic bodies (not shown) arranged alternately along the circumferential direction. Each connecting member 31 is fixed to the rotating shaft 18, and the pole piece rotor 30 is configured to rotate integrally with the rotating shaft 18.

[0016] The magnetic gear electric machine 10 further includes a magnet rotor 40 connected to the rotating shaft 18 between the pair of connecting members 31. The magnet rotor 40 includes a plurality of inner magnets 41 arranged in the circumferential direction radially inside the annular body 35, and a rotor core 42 supporting the inner magnets 41. The rotor core 42 is connected to the rotating shaft 18 via a bearing, and the magnet rotor 40 is configured to rotate relatively to the rotating shaft 18.

[0017] The magnetic gear electric machine 10 according to one embodiment is a magnetic gear motor that receives power from a power grid 16 to drive an external device 9, and its operating principle is as follows: A rotating magnetic field generated by energizing the stator coil 27 causes the magnet rotor 40 to rotate. The relative positional relationship of the annular body 35 to the multiple inner magnets 41 and the multiple magnets 5 changes in the circumferential direction, and the magnetic flux between the magnet rotor 40 and the stator 20 is modulated by the multiple pole pieces 36, causing the pole piece rotor 30 to rotate. Torque is transmitted from the rotating shaft 18, which rotates together with the pole piece rotor 30, to the external device 9, thereby driving the external device 9.

[0018] The magnetic gear electric machine 10 according to another embodiment is a magnetic gear generator that receives power from an external device 9 and supplies electricity to a power grid 16. The operating principle is as follows: When the external device 9 drives the rotating shaft 18, the pole piece rotor 30 rotates together with the rotating shaft 18. The relative position of the annular body 35 to the multiple inner magnets 41 and the multiple magnets 5 changes in the circumferential direction, causing the magnet rotor 40 to rotate. Electromagnetic induction occurs as the pole piece rotor 30 and the magnet rotor 40 rotate, generating a current in the stator coil 27, which supplies electricity to the power grid 16.

[0019] 1 illustrates a structure in which the rotating shaft 18 rotates together with the pole piece rotor 30, but the present disclosure is not limited to this. For example, a structure in which the rotating shaft 18 rotates together with the magnet rotor 40 may be employed. In this case, the pole piece rotor 30 is connected to the rotating shaft 18 via a bearing.

[0020] <Basic Configuration of Stator 20> Figure 2 is a schematic diagram of a stator 20 according to an embodiment of the present disclosure. The stator core 24 of the stator 20 is formed from a soft magnetic material. The stator core 24 includes a base 23 extending in the circumferential direction and a plurality of teeth 25 protruding radially inward from the base 23. The plurality of teeth 25 are spaced apart in the circumferential direction, and the plurality of stator coils 27 described above are disposed on the plurality of teeth 25. Each tooth 25 has a tip portion 252, and an interposing member 209 is disposed in an opening formed between two adjacent tip portions 252. The interposing member 209, which may be formed from, for example, a resin material, is held by the two tip portions 252.

[0021] The stator 20 further includes a plurality of protrusions 6 that protrude radially inward beyond the plurality of teeth 25. The protrusions 6 illustrated in FIG. 2 include a protrusion 7 that protrudes radially inward from a tip 252 of the tooth 25, and a protrusion 8 that protrudes radially inward from an intervening member 209. The protrusion 7 is integrally formed from the same soft magnetic material as the tip 252, and the protrusion 8 is integrally formed from the same resin material as the intervening member 209. The protrusions 7 and 8 have the same shape. Note that the intervening member 209 is not an essential component of the stator 20, and the protrusion 6 does not necessarily include the protrusion 8. In this case, the plurality of protrusions 6 is formed only from the plurality of protrusions 7. In the following description, the protrusions 7 and 8 may be referred to as "protrusions 6" without distinguishing between them.

[0022] The stator 20 further includes a plurality of magnets 5 arranged alternately with the plurality of protrusions 6 in the circumferential direction. The plurality of magnets 5 are arranged radially inward of the plurality of teeth 25, and each magnet 5 is sandwiched between two of the plurality of protrusions 6 that are adjacent in the circumferential direction. Note that adhesive may be interposed between the magnets 5 and the teeth 25, in which case protrusions 6 may not be arranged. Adhesive may also be interposed between two magnets 5 that are adjacent in the circumferential direction.

[0023] The multiple magnets 5 are arranged in a Halbach array. In this example, the Halbach array strengthens the magnetic flux caused by the magnets 5 radially inward relative to the multiple magnets 5 relative to the radially outward. The Halbach array is realized by arranging a group of four magnets 5 magnetized in different directions in the circumferential direction. As an example, the four magnets 5 constituting this group of magnets are surrounded by a two-dot chain line J in FIG. 2. Note that each magnet 5 extending in the axial direction is composed of multiple permanent magnets (not shown) stacked in the axial direction. For convenience of explanation in this specification, each magnet 5 extending in the axial direction is counted as one magnet.

[0024] The four magnets 5 that make up the magnet group include a first radial magnet 1 magnetized radially outward, a second radial magnet 2 magnetized radially inward, a first circumferential magnet 3 magnetized on one circumferential side, and a second circumferential magnet 4 magnetized on the other circumferential side. The first circumferential magnet 3 is located on one circumferential side of the first radial magnet 1, and the second circumferential magnet 4 is located on the other circumferential side of the first radial magnet 1. The magnetization direction of these four magnets 5 is indicated by a thick arrow on each magnet 5, and the end of each magnet 5 facing the direction of the arrow is the north pole.

[0025] In the following description, the first radial magnet 1, the second radial magnet 2, the first circumferential magnet 3, and the second circumferential magnet 4 may be referred to as "magnets 5" without distinction.

[0026] <Stator magnet assembly device 50A according to the first embodiment> An overview of the stator magnet assembly device 50 used when manufacturing the stator 20 will be given. The stator magnet assembly device 50 is configured to assemble the magnets 5 into the stator core 24. Fig. 3 is a schematic diagram showing the stator magnet assembly device 50A (50) according to the first embodiment. The stator 20 is formed in a cylindrical shape centered on the axis S, but only a portion of it is shown in the figure. Also, in the figure, multiple teeth 25 are not shown for the sake of simplicity.

[0027] In the following description, the surface of the inner circumferential surface of the stator core 24 (in other words, the inner circumferential surface of each of the multiple teeth 25) that is located below the axis S of the stator 20 (see Figure 1) may be referred to as the "magnet mounting surface 29."

[0028] As illustrated in Figure 3, the stator magnet assembly device 50A (50) includes a holding mechanism 55A (55) for holding the magnet 5, a separation mechanism 70A (70) for separating the magnet 5 from the holding mechanism 55A, and a movement mechanism 60A (70) for moving the holding mechanism 55A together with the separation mechanism 70A. In Figure 3, the holding mechanism 55A, the separation mechanism 70A, and the movement mechanism 60A are all exemplified as the first embodiment. A holding mechanism 55B, the separation mechanism 70B, and the movement mechanism 60B according to a second embodiment will be described later.

[0029] As shown in FIG. 5 , the holding mechanism 55A includes a holding member 53 made of a magnetic material, and a lower holding surface 54 of the holding member 53 magnetically attracts and holds the upper surface 5a of the magnet 5. More specifically, when the magnet 5 approaches the holding member 53, the holding member 53 is magnetized by the magnet 5. The magnet 5 is attracted to the lower holding surface 54 by the magnetic attraction force generated between the magnet 5 and the holding member 53. The lower holding surface 54 may directly abut against the upper surface 5a (not shown), or may indirectly abut against the upper surface 5a via another member such as a spacer 66 (described later). The upper surface 5a is the radially inner end surface of the magnet 5.

[0030] The holding member 53 is an L-shaped plate extending in the axial direction. More specifically, the holding member 53 has a horizontal plate 531 extending in the horizontal direction and a vertical plate 532 standing upright from the end of the horizontal plate 531. The lower holding surface 54 is the lower surface of the horizontal plate 531. Note that the holding member 53 may be a columnar body (not shown) extending in the axial direction, and the lower holding surface 54 may be the lower surface of the columnar body.

[0031] The spacing mechanism 70A illustrated in Fig. 5 is configured to space the magnets 5 held by the lower holding surface 54 downward. As a means for spacing the magnets 5, several means can be used, as will be described later in detail. The spacing mechanism 70A is attached to the holding member 53.

[0032] 3, the moving mechanism 60A movably supports the holding mechanism 55A, which allows the holding mechanism 55A to move together with the spacing mechanism 70A. The moving mechanism 60A moves the holding member 53 of the holding mechanism 55A, causing the magnet 5 held by the holding member 53 to reach a predetermined position.

[0033] Here, the predetermined position refers to a position where the magnet 5 faces the magnet mounting surface 29 with a gap in the vertical direction (see FIG. 9C ). The magnet 5 at the predetermined position faces the magnet mounting surface 29 with a gap in between over the entire axial length of the magnet 5. The magnet 5 at the predetermined position is held by the lower holding surface 54 by the magnetic attractive force between the holding member 53 and the magnet 5. Note that the magnet 5 at the predetermined position may also receive a magnetic attractive force from the stator core 24 made of a soft magnetic material. However, when the magnet 5 is disposed at the predetermined position, the attractive force caused by the holding member 53 is greater than the attractive force caused by the stator core 24.

[0034] The magnet 5 held by the holding member 53 is configured to be separated from the lower holding surface 54 toward the magnet mounting surface 29 by a separating mechanism 70A at a predetermined position. The separating mechanism 70A may separate the magnet 5 that is in direct contact with the lower holding surface 54 from the lower holding surface 54, or may separate the magnet 5 that is in indirect contact with the lower holding surface 54 via a spacer 66 from the lower holding surface 54 together with the spacer 66. If the magnet 5 in a predetermined position moves closer to the magnet mounting surface 29, the magnetic attraction force between the magnet 5 and the stator core 24 increases, and the magnet 5 is attracted to the magnet mounting surface 29 and comes into contact with it.

[0035] According to the above configuration, after the moving mechanism 60A moves the holding member 53 so that the magnet 5 is disposed in a predetermined position, the separating mechanism 70A moves the magnet 5 downward from the lower holding surface 54 toward the magnet mounting surface 29, whereby the magnet 5 is attracted to the stator core 24 and mounted on the magnet mounting surface 29. Since the magnet 5 can be mounted on the magnet mounting surface 29 without any delay, a stator magnet assembly device 50A (50) is realized that can efficiently assemble the magnet 5 to the stator core 24.

[0036] The moving mechanism 60A (60), the separating mechanism 70A (70), and the holding mechanism 55A (55) according to the first embodiment will be described in detail below.

[0037] <Moving Mechanism 60A According to First Embodiment> The moving mechanism 60A (60) according to the first embodiment will be described in detail with reference to Figures 3 and 4. Note that in Figure 4, the holding mechanism 55A is not shown.

[0038] The movement mechanism 60A includes a pair of support columns 64 spaced apart in the axial direction, an axial guide 65A (65) supported by the pair of support columns 64, and a slider 69 attached to the axial guide 65A. The axial guide 65A extends in the axial direction so as to pass inside the stator 20, and is located, for example, below the axis S (see FIG. 4) of the stator 20. The slider 69 is configured to move along the axial guide 65A.

[0039] The holding member 53 of the holding mechanism 55A is connected to the slider 69. Therefore, the holding member 53 supported by the axial guide 65A can move in the axial direction together with the spacing mechanism 70A.

[0040] As shown in Fig. 4, the axial guide 65A (65) has a first guide portion 61 disposed within the axial range of the stator core 24, and a second guide portion 62 disposed at a position axially away from the axial range of the stator core 24 to one side. The first guide portion 61 and the second guide portion 62 are integrally formed from the same material, and the slider 69 (see Fig. 3) moves linearly between the first guide portion 61 and the second guide portion 62. The axial length (dimension L2) of the second guide portion 62 is equal to or greater than the axial length (dimension L1) of the first guide portion 61.

[0041] Returning to FIG. 3 , the movement mechanism 60A may further include a vertical movement mechanism 67 for moving the holding member 53 in the vertical direction. The vertical movement mechanism 67 has a base 161 connected to the slider 69, a vertical rail 162 installed on the base 161 and extending in the vertical direction, and a movable support 163 connected to the vertical rail 162 via a bearing. The movable support 163 is movable along the vertical rail 162 and is therefore movable in the vertical direction relative to the slider 69. The holding member 53 is fixed to the movable support 163 by a fastening member (not shown). Therefore, the holding member 53 is movable axially together with the slider 69 and vertically together with the movable support 163.

[0042] The magnet 5 is attached to the lower holding surface 54 (see FIG. 5 ), for example, as follows. First, the magnet 5 is attached to the lower holding surface 54 with the holding member 53 supported by the second guide portion 62 (see FIG. 3 ). At this time, the holding member 53 is located, for example, at the upper end of its vertical movable range (however, the present disclosure is not limited to the holding member 53 being located at the upper end of its movable range; it is sufficient that the holding member 53 is located so that the magnet 5 is located above the magnet mounting surface 29). After the magnet 5 is attached, the holding member 53 moves toward the other side in the axial direction, and the magnet 5 moves to directly above the magnet mounting surface 29. Then, the holding member 53 moves downward, and the magnet 5 reaches a predetermined position.

[0043] In this example, the holding member 53 moves in both the axial direction and the vertical direction when the operator manually pushes the holding member 53. However, the present disclosure is not limited to this, and the moving mechanism 60A may further include at least one driving source (not shown). The driving source may be a motor, a solenoid, an air cylinder, a hydraulic cylinder, or a combination thereof.

[0044] By configuring the moving mechanism 60A with the axial guide 65A, the magnet 5 can be attached to the holding member 53 at a position axially separated from the predetermined position. The holding member 53 can then be stably moved in the axial direction so that the magnet 5 is positioned at the predetermined position. This facilitates the attachment of the magnet 5 to the magnet attachment surface 29. Note that one of the pair of support columns 64 of the moving mechanism 60A does not need to be provided. In this case, the axial guide 65A is cantilevered by the single support column 64. Even in this case, it is possible to obtain the above-mentioned technical advantages.

[0045] With a configuration in which the axial length of the second guide portion 62 is equal to or greater than the axial length of the first guide portion 61, the magnet 5 can be attached to the lower holding surface 54 with the holding member 53 supported by the second guide portion 62. Because the magnet 5 is attached at a position away from the axial range of the stator core 24 to one side, the magnetic attraction between the magnet 5 and the stator core 24 does not interfere with the attachment of the magnet 5. This makes it easy to attach the magnet 5.

[0046] By configuring the movement mechanism 60A to include the vertical movement mechanism 67, the magnet 5 can be attached to the lower holding surface 54 at a position above the magnet mounting surface 29. The magnetic attraction between the magnet 5 and the stator core 24 does not interfere with the attachment of the magnet 5, making the attachment of the magnet 5 easy. Note that the movement mechanism 60A does not need to include the vertical movement mechanism 67. In this case, the holding member 53 is attached directly to the slider 69 (see FIGS. 9A to 9E).

[0047] 5 and 6, the spacing mechanism 70A (70) according to the first embodiment will be described in detail. The spacing mechanism 70A includes a biasing unit 80 for spacing the magnet 5 held by the holding member 53 from the lower holding surface 54 toward the magnet mounting surface 29.

[0048] The biasing unit 80 has a biasing rod 82 whose axial direction is the vertical direction. The biasing rod 82 is inserted into a holding hole 57 of the holding member 53. Here, the holding hole 57 is a through-hole that penetrates the holding member 53 in the vertical direction, and in this example, opens at the holding lower surface 54, which is the lower surface of the horizontal plate 531. In this example, the biasing rod 82 is inserted into each of a plurality of holding holes 57 that are arranged at intervals in the axial direction. The biasing rod 82 is configured to be displaceable in the vertical direction.

[0049] More specifically, the retaining hole 57 is a threaded hole having an inner circumferential surface 58 on which a female thread is formed, and the biasing rod 82 has a threaded shank 83 that screws into the female thread of the inner circumferential surface 58. The threaded shank 83 may be the shank of a screw 37 such as a butterfly screw. When an operator rotates the screw 37, the biasing rod 82 is displaced downward. When the lower end of the threaded shank 83 protrudes downward from the retaining hole 57, it directly or indirectly abuts against the magnet 5. As the screw 37 rotates further, the threaded shank 83 biases the magnet 5 downward, and the magnet 5 is moved away from the lower retaining surface 54 toward the magnet mounting surface 29. The magnet 5 that has detached from the magnet mounting surface 29 is attached to the magnet mounting surface 29 by the magnetic attractive force it receives from the stator 20.

[0050] When the separating mechanism 70A includes the biasing unit 80, the magnet 5 can be displaced to the magnet mounting surface 29 even if the magnet 5 experiences a magnetic repulsive force from the magnet mounting surface 29 when the separating mechanism 70A separates the magnet 5 from the lower holding surface 54 toward the magnet mounting surface 29. More specifically, when the magnets 5 are sequentially mounted on the magnet mounting surface 29 so that the magnets 5 are arranged in a Halbach array, the magnets 5 held by the holding member 53 may experience a repulsive force from the magnets 5 already mounted on the magnet mounting surface 29 (further details will be described later with reference to FIG. 15 ). In this regard, with this configuration, the biasing unit 80 can displace the magnet 5 in a predetermined position toward the magnet mounting surface 29, thereby preventing the repulsive force from interfering with the mounting process. This allows the magnet 5 to be mounted accurately and easily. The biasing unit 80 may include an ejection unit that ejects air toward the magnet 5 instead of the biasing rod 82. Even in this case, the jetted air urges the magnet 5 at a predetermined position toward the magnet mounting surface 29, so the above-mentioned technical advantage can be obtained.

[0051] If the biasing unit 80 has a biasing rod 82 configured to be displaceable in the up and down direction, the biasing rod 82 biases the magnet 5 downward, thereby reliably displacing the magnet 5 toward the magnet mounting surface 29. Note that the biasing rod 82 does not have to include the threaded shaft portion 83. For example, even if the biasing rod 82 is the shaft portion of an air cylinder or a solenoid, the biasing rod 82 can still bias the magnet 5 downward, thereby achieving the above-mentioned technical advantage.

[0052] With a configuration in which the biasing rod 82 has a threaded shaft portion 83 that threads into the inner circumferential surface 58 of the retaining hole 57, when the operator rotates the screw 37, the rotating biasing rod 82 gradually displaces downward together with the magnet 5. This reduces the speed at which the magnet 5 approaches the magnet mounting surface 29 from a predetermined position, thereby reducing the collision force that occurs between the magnet 5 and the magnet mounting surface 29 when the magnet 5 reaches the magnet mounting surface 29 due to magnetic attraction. This allows the magnet 5 to be more properly mounted on the magnet mounting surface 29. Note that an actuator such as a motor may rotate the biasing rod 82 instead of the operator. Even in this case, the above-mentioned technical advantages can be obtained.

[0053] <Retention Mechanism 55A According to First Embodiment> The retention mechanism 55A (55) according to the first embodiment will be described in detail with reference to FIG. 6 . The retention mechanism 55A further includes a pair of retention protrusions 51 spaced apart along the lower retention surface 54 in a direction perpendicular to the axial direction. Each retention protrusion 51 protrudes downward from the lower retention surface 54. Each retention protrusion 51 is separate from the retention member 53 and is made of a non-magnetic material. Each retention protrusion 51 is fixed to the lower retention surface 54 by, for example, a fastening member. Each retention protrusion 51 extends in the axial direction. The axial length of the retention protrusion 51 may be equal to or greater than the axial length of the magnet 5. Each retention protrusion 51 has an inner surface 51a. The pair of inner surfaces 51a face each other in a direction perpendicular to the axial direction. Each retention protrusion 51 is shorter than the magnet 5 in the vertical direction.

[0054] Furthermore, the holding mechanism 55A includes a spacer 66 interposed between the upper surface 5a and the lower holding surface 54 of the magnet 5. The spacer 66 is a plate extending axially between the pair of holding protrusions 51 and has a thickness in the vertical direction. In this example, the spacer 66 abuts against each inner surface 51a. The spacer 66 is made of a non-magnetic material with excellent lubricity and wear resistance.

[0055] Furthermore, the spacer 66 of this example has a flat lower surface 661 and a recess 662 formed in the lower surface 661. The recess 662 extends in the axial direction. The upper end of the magnet 5 is fitted into the recess 662, and a bottom surface 662a formed in the recess 662 is adapted to directly abut against the upper surface 5a of the magnet 5. Note that, while this is merely an example, the vertical dimension (i.e., depth dimension) of the recess 662 is ½ or less, more specifically ¼ or less, of the vertical dimension of the magnet 5.

[0056] The spacer 66 is attached to the lower holding surface 54 as follows. The worker inserts the spacer 66 between the pair of holding protrusions 51 and abuts it against the lower holding surface 54. At this time, the holding hole 57 is blocked from below by the spacer 66. While pressing the spacer 66 against the lower holding surface 54, the worker inserts the magnet 5 between the pair of holding protrusions 51 and fits it into the recess 662. Due to the attractive force between the magnet 5 and the holding member 53, the spacer 66 and the magnet 5 are attached to the lower holding surface 54. Thereafter, the biasing rod 82 protrudes downward from the holding hole 57 and biases the spacer 66 downward, allowing the spacer 66 and magnet 5 to be displaced downward along the pair of holding protrusions 51 and separate from the lower holding surface 54.

[0057] With the configuration in which the holding mechanism 55A includes a pair of holding protrusions 51, the pair of holding protrusions 51 can guide the vertical displacement of the magnet 5 when the magnet 5 is attached to the lower holding surface 54 and when the magnet 5 is separated from the lower holding surface 54 together with the spacer 66. This facilitates the installation of the magnet 5. Note that the lower surface 661 of the spacer 66 does not need to be formed with the recess 662 into which the magnet 5 fits. Even in this case, it is possible to obtain the above-mentioned technical advantages.

[0058] According to the configuration in which the holding mechanism 55A includes the spacer 66, the biasing unit 80 can bias the magnet 5 toward the magnet mounting surface 29 via the spacer 66. This prevents the biasing force from concentrating on a specific portion of the magnet 5, allowing the magnet 5 to leave the lower holding surface 54 in a position substantially parallel to the axial direction. Furthermore, because the spacer 66 abuts against the pair of inner surfaces 51a, tilting of the spacer 66 in the axial and circumferential directions can be prevented. This allows the magnet 5 to be positioned even more substantially parallel to the axial and circumferential directions. Furthermore, the vertical distance from the lower holding surface 54 to the magnet 5 when the holding member 53 holds the magnet 5 can be optimized by adjusting the thickness of the spacer 66. This optimizes the magnetic attraction between the lower holding surface 54 and the magnet 5, allowing the magnet 5 to be smoothly transferred from the lower holding surface 54 to the magnet mounting surface 29.

[0059] 3 and 7, the stator magnet assembly device 50A (50) may further include a rotation support mechanism 90 configured to rotate the stator 20. When the stator 20 rotates in the circumferential direction, the relative position of the stator core 24 with respect to the holding member 53 is changed.

[0060] As illustrated in Figure 3, the rotation support mechanism 90 includes a pair of support wall portions 94 spaced apart in the axial direction, a plurality of support shafts 95 supported by each of the pair of support wall portions 94, rotating bodies 96 each supported by the plurality of support shafts 95, a stator support 92 supporting the stator core 24, and a pin 98 extending in the axial direction.

[0061] The pair of support wall portions 94 are wall portions extending in a direction perpendicular to the axial direction and are disposed between the pair of support columns 64 described above. Each support shaft 95 extends in the axial direction and supports a rotating body 96 via a bearing. Therefore, each rotating body 96 is rotatable around its corresponding support shaft 95. One example of the rotating body 96 is a roller. In the example of FIG. 7 , multiple rotating bodies 96 are disposed on each support wall portion 94. However, the present disclosure is not limited to this, and the number of rotating bodies 96 disposed between the pair of support wall portions 94 may be one.

[0062] The stator support 92 in this example is a pair of rings that sandwich the stator core 24 in the axial direction. Each ring extends in the circumferential direction. Each ring is supported by a plurality of rotating bodies 96, so that the stator support 92 rotates in the circumferential direction together with the stator core 24. The stator support 92 has a plurality of insertion holes 93 that are spaced apart along the circumferential direction. Each insertion hole 93 is open in the axial direction. The pin 98 is inserted into one of the plurality of insertion holes 93 and a hole 94 a formed in the support wall portion 94.

[0063] The magnets 5 are assembled using the rotary support mechanism 90 as follows: The worker removes the pins 98 and rotates the stator support 92 together with the stator core 24 in the circumferential direction. At this time, the multiple rotating bodies 96 all rotate in conjunction with the rotation of the stator support 92. When the desired portion of the magnet mounting surface 29 reaches directly below the axis S (see FIG. 4 ), the worker stops the rotation of the stator support 92 and inserts the pins 98 into the holes 94 a and the insertion holes 93. With the stator core 24 fixed, the worker can mount the magnets 5 on the magnet mounting surface 29.

[0064] Since the stator magnet assembly device 50A is configured to include the rotation support mechanism 90, the relative position of the stator core 24 with respect to the holding member 53 is changed by the rotation of the stator core 24. This allows the desired magnet mounting surface 29 to be positioned directly below the magnet 5 held by the holding member 53. This allows the magnet 5 to be mounted accurately.

[0065] The rotation support mechanism 90 is not limited to the above embodiment. The stator support 92 may be a single ring instead of a pair of rings. Gear teeth extending continuously in the circumferential direction may be formed on the outer circumferential surface of the single ring. In this case, the rotating body 96 is a gear (pinion) that meshes with the gear teeth instead of a roller, and the lower part of the rotating body 96 meshes with a rack extending linearly in the horizontal direction. If the rack moves linearly due to power applied from a driving source such as a motor, the stator support 92 can rotate together with the stator core 24. In this case, if the rotation support mechanism 90 includes a stopper that stops the rack at a predetermined position, the insertion hole 93, hole 94a, and pin 98 described above are all unnecessary. Alternatively, the rack may be stopped by using the holding torque of the motor. In this case, the stopper is not necessary. Even in this embodiment, the relative position of the stator core 24 with respect to the holding member 53 changes as the stator core 24 rotates, thereby achieving the above-described technical advantages.

[0066] <Method of Assembling Stator Magnet (First Embodiment)> A method of assembling the magnet 5 (stator magnet) according to the first embodiment will be described with reference to Figures 8 and 9A to 9D. This assembling method utilizes the stator magnet assembling device 50A according to the first embodiment. Below, an example of an assembling method in an embodiment in which the movement mechanism 60A does not include the up-down movement mechanism 67 (see Figure 3) will be described. Hereinafter, "step" may be abbreviated as "S."

[0067] First, a holding step (S11) is performed in which the magnet 5 is attracted to and held by the lower holding surface 54. For example, as shown in Figures 9A and 9B, the worker moves the holding member 53 to the second guide part 62 and attaches the magnet 5 to the lower holding surface 54 via the spacer 66. As a result, the magnet 5 is held by the lower holding surface 54 at a position away from the axial range of the stator core 24 to one side in the axial direction.

[0068] Next, a rotation step (S13) is performed in which stator core 24 is rotated to a predetermined rotation position and stopped. S13 is performed using rotation support mechanism 90. By rotating stator core 24 (arrow A in FIG. 9B ), a desired portion of magnet mounting surface 29 is positioned directly below axis S.

[0069] Next, an adhesive step (S15) is performed in which adhesive is applied to at least one of the lower surface 5b of the magnet 5 and the magnet mounting surface 29 located directly below the axis S. The adhesive is applied by a worker, an industrial robot, or a combination of these. The lower surface 5b is the surface opposite the upper surface 5a of the magnet 5.

[0070] Next, a moving step (S17) is executed in which the holding member 53 is moved so that the magnet 5 held by the holding member 53 is positioned at a predetermined position. The holding member 53 moves along the second guide portion 62 and the first guide portion 61. As the holding member 53 moves along the axial direction, the magnet 5 reaches a predetermined position (see FIG. 9C ). At this time, the holding member 53 is supported by the first guide portion 61 over the entire axial length of the holding member 53.

[0071] Next, a separating step (S19) is performed in which the magnet 5 held by the holding member 53 is moved away from the lower holding surface 54 toward the magnet mounting surface 29. S19 is performed by the biasing unit 80 of the separating mechanism 70A described above. More specifically, the magnet 5 held by the holding member 53 is biased toward the magnet mounting surface 29 so as to move away from the lower holding surface 54 (see FIG. 9D ). More specifically, the operator uses the biasing rod 82 inserted through the holding hole 57 to bias the magnet 5 and spacer 66 toward the magnet mounting surface 29 so as to move the magnet 5 together with the spacer 66 away from the lower holding surface 54.

[0072] The magnet 5, which is displaced downward from the predetermined position, is attracted to the magnet mounting surface 29 by the attractive force received from the stator core 24. As a result, the magnet 5 is mounted on the magnet mounting surface 29 (see FIG. 9E), and the spacer 66 is removed. This assembly method is completed.

[0073] The moving mechanism 60A may include the vertical moving mechanism 67 (see FIG. 1) described above. In this case, after moving the holding member 53 to a position where it is supported by the first guide portion 61 in S17, the holding member 53 is moved downward so that the magnet 5 is positioned in a predetermined position. The order of S11, S13, and S15 may be any combination. Furthermore, these three steps may be performed simultaneously.

[0074] According to a configuration in which the adhesion step (S15) is performed, the separation step (S19) is performed to prevent the magnet 5 from floating up from the magnet mounting surface 29 due to the influence of other magnets 5 after the magnet 5 is attached to the magnet mounting surface 29.

[0075] <Modifications of the Separation Mechanism 70A (70)> Fig. 10A is a schematic diagram showing a separation mechanism 70A according to a first modification. The separation mechanism 70A may further include an electromagnet 72 disposed on the holding member 53. The electromagnet 72 is disposed on the upper surface of the horizontal plate 531, for example. The electromagnet 72 has an energized coil (not shown) that extends spirally in the vertical direction. When a current flows through the energized coil, the electromagnet 72 is turned on, and when the current flow stops, the electromagnet 72 is turned off.

[0076] An example of how the electromagnet 72 is used is as follows: When the electromagnet 72 is turned on, the magnetic field generated in the current-carrying coil can attract the magnet 5 to the lower holding surface 54. If the electromagnet 72 is turned off after the magnet 5 reaches a predetermined position, the magnetic force caused by the electromagnet 72 disappears, and the magnet 5 can be easily displaced downward from the lower holding surface 54.

[0077] By changing the winding method of the energized coil, the magnetic field generated when the electromagnet 72 is in the ON state can also apply a downward magnetic force to the magnet 5. In this case, if the electromagnet 72 is switched from the OFF state to the ON state after the magnet 5 has reached a predetermined position, the magnet 5 will be displaced away from the lower holding surface 54 and toward the magnet mounting surface 29. Therefore, in the separating step (S19), the electromagnet 72 may be switched from the ON state to the OFF state, or from the OFF state to the ON state.

[0078] According to the above configuration, the separating mechanism 70A can separate the magnet 5 from the lower holding surface 54 by switching the state of the electromagnet 72 .

[0079] As described above, the magnets 5 according to one embodiment of the present disclosure include the first radial magnet 1, the second radial magnet 2, the first circumferential magnet 3, and the second circumferential magnet 4. When a specific magnet 5 out of these four types of magnets 5 is mounted on the magnet mounting surface 29, it is also possible to use the electromagnet 72.

[0080] 10B is a schematic diagram showing a spacing mechanism 70A according to a second modification. The spacing mechanism 70A may further include a mounting magnet 74 that is detachably attached to the holding member 53. The mounting magnet 74 is, for example, a permanent magnet disposed on the upper surface of the horizontal plate 531. The mounting magnet 74 attracts the magnet 5, thereby more strongly attracting the magnet 5 to the lower holding surface 54. In this case, the mounting magnet 74 is removed in the spacing step (S19).

[0081] According to the above configuration, by removing the mounting magnet 74 from the holding member 53, the separating mechanism 70A can separate the magnet 5 from the lower holding surface 54. Note that the present disclosure is not limited to the mounting magnet 74 being removed upward from the holding member 53. The mounting magnet 74 may be removed from the holding member 53 while sliding axially or circumferentially relative to the horizontal plate 531.

[0082] As described above, the magnets 5 according to one embodiment of the present disclosure include the first radial magnet 1, the second radial magnet 2, the first circumferential magnet 3, and the second circumferential magnet 4. Multiple types of mounting magnets 74 may be used depending on these four types of magnets 5.

[0083] <Stator magnet assembling device 50B according to second embodiment> A stator magnet assembling device 50B (50) according to the second embodiment will be described with reference to Figures 8, 11, and 12A to 12C. Note that among the components of the stator magnet assembling device 50B, the same components as those in the first embodiment are given the same reference numerals in the drawings, and their description may be omitted or simplified below.

[0084] As illustrated in FIG. 11, the stator magnet assembly device 50B (50) includes a holding mechanism 55B (55), a moving mechanism 60B (60), and a separating mechanism 70B (70).

[0085] The holding mechanism 55B includes a rod-shaped jig 45 having a longitudinal direction. The rod-shaped jig 45 has the above-mentioned holding member 53 formed on a first longitudinal side and a non-magnetic member 44 made of a non-magnetic material formed on a second longitudinal side. The holding member 53 and the non-magnetic member 44 are connected to each other and extend continuously and linearly in the longitudinal direction. The rod-shaped jig 45 may be detachable from an axial guide 65B (65) described below. The first longitudinal side of the rod-shaped jig 45 is the side indicated by arrow Q1, and the second longitudinal side is the side indicated by arrow Q2.

[0086] The axial guide 65B (65) of the movement mechanism 60B includes a third guide portion 63 that is disposed on the other axial side of the axial range of the stator core 24. The third guide portion 63 is integrally formed from the same material as the first guide portion 61. When the rod-shaped jig 45 is attached to the axial guide 65B, the longitudinal direction of the rod-shaped jig 45 is parallel to the axial direction, and the second longitudinal side is one axial side. The attached rod-shaped jig 45 can move along the axial guide 65B.

[0087] The spacing mechanism 70B includes a protrusion 49 fixed to the end face 24a of the stator core 24 on the other axial side. The protrusion 49 protrudes toward the axis S (i.e., toward the center of the stator 20) beyond the magnet mounting surface 29 located directly below the axis S.

[0088] The method of using the stator magnet assembly device 50B is as shown in the flowchart of Figure 8. To avoid repetition of explanation, only steps that are different from those in the first embodiment will be explained below.

[0089] In the holding step (S11), the rod-shaped jig 45 is attached to the axial guide 65B, and the magnet 5 is attached to the holding member 53 (see FIG. 11). At this time, the holding member 53 is supported by the second guide portion 62.

[0090] In the moving step (S17), the worker moves the rod-shaped jig 45 along the axial guide 65B so that the magnet 5 is positioned at a predetermined position. When the magnet end face 5c of the magnet 5 on the other axial side abuts against the protrusion 49, S17 ends (see FIG. 12A).

[0091] In the separation step (S19), the operator moves the rod-shaped jig 45 further toward the other axial direction while the magnet end face 5c remains in contact with the protrusion 49. The magnet 5 in contact with the protrusion 49 remains stationary. The rod-shaped jig 45 slides against the magnet 5 and moves toward the other axial direction. The end of the magnet 5 on one axial side comes into contact with the non-magnetic member 44 instead of the holding member 53 (see FIG. 12B). As a result, the end of the magnet 5 moves toward the magnet mounting surface 29 due to the magnetic attractive force it receives from the magnet mounting surface 29. Even after the magnet 5 assumes a position tilted relative to the axial direction, the rod-shaped jig 45 continues to move. Eventually, the end of the magnet 5 on the other axial side receives a stronger attractive force from the magnet mounting surface 29 than the attractive force it receives from the holding member 53, and moves from the holding member 53 to the magnet mounting surface 29. As a result, the magnet 5 is attached to the magnet mounting surface 29 (see FIG. 12C).

[0092] According to the above configuration, the magnet 5 can be attached to the magnet attachment surface 29 simply by moving the rod-shaped jig 45 toward the other side in the axial direction, so that the magnet 5 can be efficiently assembled to the stator core 24.

[0093] <Method of Manufacturing Stator> A method of manufacturing the stator 20 will be described with reference to Figures 13 to 15. In the method of manufacturing the stator 20, the stator magnet assembling method (S11 to S19) illustrated in Figure 8 is repeated to assemble the multiple magnets 5 into the stator core 24 over the entire circumferential length of the stator core 24. As a result, the multiple magnets 5 are arranged in a Halbach array in the stator core 24.

[0094] The manufacturing method of the stator 20 includes a radial magnet arrangement step (S21) in which the first radial magnets 1 and the second radial magnets 2 are arranged alternately at intervals in the circumferential direction of the stator core 24, and a circumferential magnet arrangement step (S23) after S21 in which the first circumferential magnets 3 and the second circumferential magnets 4 are arranged at intervals in the circumferential direction.

[0095] In S21, either the first radial magnets 1 or the second radial magnets 2 are arranged through S11 to S19 shown in Fig. 8. By repeatedly executing S11 to S19, the multiple first radial magnets 1 and the multiple second radial magnets 2 are assembled sequentially to the stator core 24 (see Fig. 14).

[0096] S23 is the same as S21. That is, through S11 to S19 shown in FIG. 8, either the first circumferential magnet 3 or the second circumferential magnet 4 is arranged. By repeatedly executing S11 to S19, the multiple first circumferential magnets 3 and the multiple second circumferential magnets 4 are sequentially assembled to the stator core 24 (see FIG. 15). The worker arranges the first circumferential magnet 3 on one circumferential side of the first radial magnet 1 and the other circumferential side of the second radial magnet 2, and arranges the second circumferential magnet 4 on the other circumferential side of the first radial magnet 1 and one circumferential side of the second radial magnet 2.

[0097] When the first circumferential magnet 3 and the second circumferential magnet 4 are assembled, the first radial magnet 1 and the second radial magnet 2 are already assembled to the stator core 24. Therefore, due to the influence of the magnetic fields generated by the first radial magnet 1 and the second radial magnet 2, the first radial magnet 1 and the second circumferential magnet 4 are attached to the stator core 24 while being subjected to a magnetic repulsive force. Therefore, in the separation step (S19) shown in FIG. 8 , it is preferable to use the biasing unit 80 (see FIG. 9D ) to bias the first circumferential magnet 3 and the second circumferential magnet 4 toward the magnet mounting surface 29. This allows the first circumferential magnet 3 and the second circumferential magnet 4 to reach the magnet mounting surface 29 while resisting the repulsive force.

[0098] Furthermore, even after the first circumferential magnet 3 and the second circumferential magnet 4 are mounted on the magnet mounting surface 29, they may be biased radially inward due to the influence of the magnetic field caused by the first radial magnet 1 and the second radial magnet 2, and may lift off from the magnet mounting surface 29. In this regard, by performing the bonding step (S15), the first circumferential magnet 3 and the second circumferential magnet 4 are bonded to the magnet mounting surface 29, and therefore the first circumferential magnet 3 and the second circumferential magnet 4 can be prevented from lifting off.

[0099] <Summary> The contents described in the above-described embodiments can be understood, for example, as follows.

[0100] 1) A stator magnet assembly device (50) according to at least one embodiment of the present disclosure is a stator magnet assembly device for assembling a magnet (5) to a stator core (24), comprising: a holding mechanism (55) including a holding member (53) formed of a magnetic material, the holding member having a holding lower surface (54) for attracting and holding an upper surface (5a) of the magnet by magnetic force; a moving mechanism (60) for moving the holding member so that the magnet held by the holding member is positioned at a predetermined position facing a magnet mounting surface (29) of the stator core with a gap in the vertical direction; and a separating mechanism (70) for moving the magnet held at the predetermined position away from the holding lower surface toward the magnet mounting surface.

[0101] According to the configuration of 1) above, after the moving mechanism moves the holding member so that the magnet is placed in the predetermined position, the separating mechanism moves the magnet away from the lower holding surface toward the magnet mounting surface, whereby the magnet is attracted to the stator core and mounted on the magnet mounting surface. Since the magnet can be mounted on the magnet mounting surface without any obstructions, a stator magnet assembly device is realized that can efficiently assemble the magnet into the stator core.

[0102] 2) In some embodiments, in the stator magnet assembly device described in 1) above, the movement mechanism further includes an axial guide (65) that extends in the axial direction of the stator core and movably supports the holding member.

[0103] According to the configuration 2), the magnet can be attached to the holder at a position axially separated from the predetermined position. The holder can then be moved axially stably so that the magnet is positioned at the predetermined position. This makes it easy to attach the magnet to the magnet mounting surface.

[0104] 3) In some embodiments, in the stator magnet assembly device described in 2) above, the axial guide includes a first guide portion (61) arranged in the axial range of the stator core, and a second guide portion (62) arranged at a position away from the axial range of the stator core to one side, and the axial length of the second guide portion is equal to or greater than the axial length of the first guide portion.

[0105] According to the configuration 3), the magnet can be attached to the lower holding surface while the holding member is supported by the second guide portion. Since the magnet is attached to one side of the axial range of the stator core, the magnetic attraction between the magnet and the stator core does not interfere with the magnet attachment. This makes the magnet attachment process easy.

[0106] 4) In some embodiments, in the stator magnet assembly device described in 2) or 3) above, the movement mechanism includes a vertical movement mechanism (60) for moving the holding member in the vertical direction.

[0107] According to the configuration of 4) above, the magnet can be attached to the lower holding surface at a position above the magnet mounting surface. Since the magnetic attraction between the magnet and the stator core does not interfere with the magnet attachment, the magnet attachment work can be easily performed.

[0108] 5) In some embodiments, in the stator magnet assembly device described in any one of 1) to 4) above, the holding mechanism further includes a pair of holding protrusions (51) formed of a non-magnetic material and protruding downward from the holding lower surface, the pair of holding protrusions being spaced apart along the holding lower surface in a direction perpendicular to the axial direction of the stator core.

[0109] According to the configuration of 5) above, when the magnet is attached to the lower holding surface and when the magnet is released from the lower holding surface, the pair of holding protrusions can guide the magnet's vertical displacement, thereby facilitating the magnet installation work.

[0110] 6) In some embodiments, in the stator magnet assembly device described in any one of 1) to 5) above, the spacing mechanism includes a biasing unit (80) for biasing the magnet held by the holding member so as to space the magnet from the lower holding surface toward the magnet mounting surface.

[0111] According to the configuration of 6) above, even if the magnet is subjected to a magnetic repulsive force from the magnet mounting surface when the separating mechanism separates the magnet from the lower holding surface toward the magnet mounting surface, the biasing unit can displace the magnet toward the magnet mounting surface, thereby enabling accurate and easy magnet mounting.

[0112] 7) In some embodiments, in the stator magnet assembly device described in 6) above, the holding member has a holding hole (57) that opens on the lower holding surface, the biasing unit has a biasing rod (82) that is inserted into the holding hole, and the biasing rod is configured to be displaceable up and down.

[0113] According to the configuration 7) above, the biasing rod biases the magnet downward, so that the magnet can be reliably displaced toward the magnet mounting surface.

[0114] 8) In some embodiments, in the stator magnet assembly device described in 7) above, the retaining hole is a threaded hole having an inner circumferential surface (58) on which a female thread is formed, and the biasing rod has a threaded shaft portion (83) that screws into the inner circumferential surface.

[0115] According to the configuration of 8) above, by rotating the biasing rod, the biasing rod gradually displaces downward together with the magnet. This reduces the speed at which the magnet approaches the magnet mounting surface, thereby reducing the collision force that occurs between the magnet and the magnet when they reach the magnet mounting surface. This allows the magnet to be more properly mounted on the magnet mounting surface.

[0116] 9) In some embodiments, in the stator magnet assembly device described in any one of 6) to 8) above, the holding mechanism further includes a spacer (66) interposed between the magnet and the holding lower surface, extending in the axial direction of the stator core and made of a non-magnetic material.

[0117] According to the configuration of 9) above, the biasing unit can bias the magnet toward the magnet mounting surface via the spacer. This prevents the biasing force from concentrating on a specific portion of the magnet, allowing the magnet to leave the lower holding surface in a position approximately parallel to the axial direction. Furthermore, the distance from the lower holding surface to the magnet when the holding member holds the magnet can be optimized by adjusting the thickness of the spacer. This optimizes the magnetic attraction force between the lower holding surface and the magnet, allowing the magnet to be smoothly transferred from the lower holding surface to the magnet mounting surface. Furthermore, in an embodiment in which the spacer abuts against the inner surfaces of each of the pair of holding protrusions, tilting of the spacer in the axial and circumferential directions as it displaces toward the magnet mounting surface can be prevented, allowing the magnet to be positioned even more approximately parallel to the axial and circumferential directions.

[0118] 10) In some embodiments, in the stator magnet assembly device according to any one of 1) to 9) above, the spacing mechanism further includes an electromagnet disposed on the holding member.

[0119] According to the configuration of 10) above, the separating mechanism can separate the magnet from the lower holding surface by switching the state of the electromagnet.

[0120] 11) In some embodiments, in the stator magnet assembly device described in any one of 1) to 10) above, the spacing mechanism further includes an attachment magnet (74) that is removably attached to the holding member.

[0121] According to the configuration of 11) above, when the attached magnet is removed from the holding member, the separating mechanism can separate the magnet from the lower holding surface.

[0122] 12) In some embodiments, in the stator magnet assembly device described in any one of 2) to 4) above, the holding mechanism further includes a rod-shaped jig (45) having a longitudinal direction, and the rod-shaped jig has: the holding member formed on a first side in the longitudinal direction; and a non-magnetic member (44) made of a non-magnetic material formed on a second side in the longitudinal direction; the axial guide is configured to movably support the rod-shaped jig so that the longitudinal direction is parallel to the axial direction and the second side is one side of the axial direction; and the spacing mechanism includes a protrusion (49) that protrudes toward the center of the stator core and is configured to abut against a magnet end face (5c) on the other side of the magnet in the predetermined position.

[0123] According to the configuration of 12) above, the rod-shaped jig is installed in the axial guide and the magnet can be attached to the holding member. When the rod-shaped jig is moved toward the other side in the axial direction, the end face of the magnet abuts the protruding portion. The rod-shaped jig continues to move toward the other side, and the magnet abutting the protruding portion remains stationary. The end of the magnet on one side in the axial direction abuts the non-magnetic member instead of the holding member, and is displaced to the magnet mounting surface by the magnetic attractive force received from the magnet mounting surface. The rod-shaped jig continues to move thereafter. Eventually, the end of the magnet on the other side in the axial direction receives an attractive force from the magnet mounting surface that is stronger than the attractive force received from the holding member, and moves from the holding member to the magnet mounting surface. This attaches the magnet to the magnet mounting surface. In this way, the magnet can be attached to the magnet mounting surface simply by moving the rod-shaped jig toward the other side in the axial direction, allowing the magnet to be efficiently assembled to the stator core.

[0124] 13) In some embodiments, the stator magnet assembly device according to any one of 1) to 12) above further comprises a rotation support mechanism (90) configured to change the relative position of the stator core with respect to the holding member by rotating the stator core.

[0125] According to the configuration of 13) above, the relative position of the stator core with respect to the holding member is changed by rotating the stator core. This allows the desired magnet mounting surface to be positioned directly below the magnet held by the holding member. This allows the magnet to be mounted accurately.

[0126] 14) A stator magnet assembling method according to at least one embodiment of the present disclosure is a stator magnet assembling method for assembling a magnet (5) to a stator core (24), comprising: a holding step (S11) of attracting and holding the magnet to a holding lower surface (54) of a holding member (53) formed of a magnetic material; a moving step (S17) of moving the holding member so that the held magnet is positioned at a predetermined position facing the magnet mounting surface (29) of the stator core with a gap in the vertical direction; and a separating step (S19) of separating the magnet held by the holding member from the holding lower surface toward the magnet mounting surface.

[0127] According to the configuration 14) above, the same technical advantages as those of the configuration 1) above can be obtained.

[0128] 15) In some embodiments, the stator magnet assembling method described in 14) above further comprises, before the separating step, an adhering step (S15) of applying adhesive to at least one of the lower surface (5b) of the magnet or the magnet mounting surface.

[0129] According to the configuration of 15) above, after the magnet is attached to the magnet attachment surface by performing the separating step, the magnet can be prevented from floating up from the magnet attachment surface due to the influence of the magnetic force of other magnets.

[0130] 16) In some embodiments, the stator magnet assembly method described in 14) or 15) above is such that in the holding step, the magnet is held on the lower holding surface at a position away from one side of the axial range of the stator core, and in the moving step, the holding member holding the magnet is moved along the axial direction of the stator core.

[0131] The configuration 16) above provides the same technical advantages as the configuration 3).

[0132] 17) In some embodiments, in the stator magnet assembly method described in 16) above, in the moving step, after moving the holding member in the axial direction, the holding member is moved downward so that the magnet is positioned at the predetermined position.

[0133] The configuration 17) above provides the same technical advantages as the configuration 4).

[0134] 18) In some embodiments, in the stator magnet assembly method described in any one of 14) to 17) above, in the separating step, the magnet held by the holding member is urged toward the magnet mounting surface so as to move away from the lower holding surface.

[0135] The configuration 18) above provides the same technical advantages as the configuration 6) above.

[0136] 19) In some embodiments, in the stator magnet assembly method described in 18) above, the holding member has a holding hole (57) that opens in the holding lower surface, and in the separating step, a biasing rod (82) that is inserted into the holding hole and is displaceable in the vertical direction is used to bias the magnet toward the magnet mounting surface so as to move away from the holding lower surface.

[0137] The configuration 19) above provides the same technical advantages as the configuration 7) above.

[0138] 20) In some embodiments, in the stator magnet assembly method described in any one of 14) to 19) above, in the separating step, an electromagnet (72) arranged on the holding member is turned on or off.

[0139] According to the configuration 20) above, the same technical advantages as those of the configuration 10) above can be obtained.

[0140] 21) In some embodiments, the stator magnet assembling method according to any one of 14) to 20) above, wherein in the separating step, the mounting magnet (74) attached to the holding member is removed.

[0141] According to the configuration 21) above, the same technical advantages as those of the configuration 11) above can be obtained.

[0142] 22) In some embodiments, the stator magnet assembling method described in 14) above is provided, wherein in the holding step, the magnet is held by a holding member of a rod-shaped jig (45) having a longitudinal direction, the holding member being formed on a first side in the longitudinal direction and a non-magnetic member made of a non-magnetic material being formed on a second side in the longitudinal direction; in the moving step, an axial guide (65) is used to support the rod-shaped jig so that the longitudinal direction is parallel to the axial direction of the stator core and the second side is on one side of the axial direction of the stator core, and the rod-shaped jig is moved along the axial guide so that the magnet is disposed at the predetermined position; and in the separating step, a protrusion (49) protruding toward the center of the stator core is abutted against a magnet end face (5c) on the other side in the axial direction of the magnet that has moved in conjunction with the execution of the moving step, and the rod-shaped jig is further moved along the axial guide to the other side.

[0143] The configuration 22) above provides the same technical advantages as the configuration 12) above.

[0144] 23) In some embodiments, the stator magnet assembling method according to any one of 14) to 22) above further comprises a rotation step (S13) of rotating the stator core to a predetermined rotation position and stopping the same before executing the moving step.

[0145] According to the configuration 23) above, the same technical advantages as those of the configuration 13) above can be obtained.

[0146] 24) A stator manufacturing method according to at least one embodiment of the present disclosure is a stator manufacturing method in which a plurality of magnets are assembled to the stator core over the entire circumferential length of the stator core by repeating the stator magnet assembling method described in 14) above, wherein the plurality of magnets include: a first radial magnet (1) magnetized on the radially outer side of the stator core; a second radial magnet (2) magnetized on the radially inner side; a first circumferential magnet (3) magnetized on one circumferential side of the stator core; and a second circumferential magnet (4) magnetized on the other circumferential side, and the stator manufacturing method includes: a radial magnet arranging step (S21) of arranging the first radial magnets and the second radial magnets alternately at intervals in the circumferential direction of the stator core; and a circumferential magnet arranging step (S23) of arranging the first circumferential magnet and the second circumferential magnet at an interval in the circumferential direction after the radial magnet arranging step, in which the first circumferential magnet is arranged on one side in the circumferential direction of the first radial magnet and on the other side in the circumferential direction of the second radial magnet, and the second circumferential magnet is arranged on the other side of the first radial magnet and on the one side in the circumferential direction of the second radial magnet.

[0147] According to the configuration 24) above, the same technical advantages as those of the configuration 1) above can be obtained.

[0148] 25) In some embodiments, in the method for manufacturing a stator described in 24) above, in the separating step, the first circumferential magnet or the second circumferential magnet held by the holding member is urged toward the magnet mounting surface so as to move away from the holding lower surface.

[0149] According to the configuration of 25) above, even if the first circumferential magnet or the second circumferential magnet receives a magnetic repulsive force from the first radial magnet and the second radial magnet when the circumferential magnet placement step is performed, these circumferential magnets can be attached to the magnet mounting surface.

[0150] 1: First radial magnet 2: Second radial magnet 3: First circumferential magnet 4: Second circumferential magnet 5: Magnet 5a: Upper surface 5b: Lower surface 5c: Magnet end surface 6-8: Protrusion 9: External device 10: Magnetic gear electric machine 16: Power system 17: Housing 18: Rotating shaft 20: Stator 23: Base 24: Stator core 24a: End surface 25: Teeth 27: Stator coil 29: Magnet mounting surface 30: Pole piece rotor 31: Connecting member 35: Annular body 36: Pole piece 37: Screw 40: Magnet rotor 41: Inner magnet 42: Rotor core 44: Non-magnetic member 45: Rod-shaped jig 49: Protrusion 50 : Stator magnet assembly device 51 : Holding protrusion 51a : Inner surface 53 : Holding member 54 : Lower holding surface 55 : Holding mechanism 57 : Holding hole 58 : Inner peripheral surface 60 : Moving mechanism 61 : First guide portion 62 : Second guide portion 63 : Third guide portion 64 : Support 65 : Axial guide 66 : Spacer 67 : Up / down moving mechanism 69 : Slider 70 : Separating mechanism 72 : Electromagnet 74 : Mounting magnet 80 : Urging unit 82 : Urging rod 83 : Screw shaft portion 90 : Rotation support mechanism 92 : Stator support 93 : Insertion hole 94 : Support wall portion 94a : Hole 95 : Support shaft 96 : Rotating body 98 : Pin 161 : Base 162: Vertical rail 163: Movable support 209: Interposition member 252: Tip 531: Horizontal plate 532: Vertical plate 661: Lower surface 662: Recess 662a: Bottom surface A, Q1, Q2: Arrows L1, L2: Dimensions S: Axis

Claims

1. A stator magnet assembling device for assembling a magnet to a stator core, comprising: a holding mechanism including a holding member formed of a magnetic material, the holding member having a holding lower surface for attracting and holding the upper surface of the magnet by magnetic force; a moving mechanism for moving the holding member so that the magnet held by the holding member is disposed at a predetermined position facing the magnet mounting surface of the stator core with a gap therebetween in the vertical direction; and a separating mechanism for separating the magnet held at the predetermined position from the holding lower surface toward the magnet mounting surface.

2. The stator magnet assembling device according to claim 1, wherein the moving mechanism further includes an axial guide extending in the axial direction of the stator core and supporting the holding member movably.

3. The axial guide includes: a first guide portion disposed within the axial range of the stator core; and a second guide portion disposed at a position separated from one side of the axial range of the stator core, wherein the axial length of the second guide portion is equal to or greater than the axial length of the first guide portion. The stator magnet assembling device according to claim 2.

4. The stator magnet assembling device according to claim 2 or 3, wherein the moving mechanism includes a vertical moving mechanism for moving the holding member in the vertical direction.

5. The holding mechanism includes a pair of holding protrusions formed of a non-magnetic material and protruding downward from the holding lower surface, the pair of holding protrusions being arranged at intervals along the holding lower surface in a direction orthogonal to the axial direction of the stator core. The stator magnet assembling device according to any one of claims 1 to 3.

6. The separating mechanism includes a biasing unit for biasing the magnet held by the holding member to be separated from the holding lower surface toward the magnet mounting surface. The stator magnet assembling device according to any one of claims 1 to 3.

7. The holding member has a holding hole opening at the holding lower surface, the biasing unit has a biasing rod inserted through the holding hole, and the biasing rod is configured to be displaced vertically. The stator magnet assembling device according to claim 6.

8. The holding hole is a threaded hole having an inner peripheral surface formed with a female thread, and the biasing rod has a threaded shaft portion that is screwed into the inner peripheral surface. The stator magnet assembling device according to claim 7.

9. The holding mechanism further includes a spacer interposed between the magnet and the holding lower surface, the spacer extending in the axial direction of the stator core and being formed of a non-magnetic material. The stator magnet assembling device according to claim 6.

10. The separating mechanism further includes an electromagnet disposed on the holding member. The stator magnet assembling device according to any one of claims 1 to 3.

11. The separating mechanism further includes an attachment magnet detachably attached to the holding member. The stator magnet assembling device according to any one of claims 1 to 3.

12. The holding mechanism further includes a rod-shaped jig having a longitudinal direction, the rod-shaped jig having: the holding member formed on the first side in the longitudinal direction; and a non-magnetic member made of a non-magnetic material formed on the second side in the longitudinal direction. The axial guide is configured to movably support the rod-shaped jig such that the longitudinal direction is parallel to the axial direction and the second side is on one side in the axial direction. The separating mechanism includes a protruding portion that protrudes toward the center side of the stator core and is configured to contact a magnet end surface on the other side of the magnet at the predetermined position. The stator magnet assembling device according to claim 2 or 3.

13. The stator magnet assembling device according to any one of claims 1 to 3 further includes a rotation support mechanism configured to change a relative position of the stator core with respect to the holding member by rotating the stator core.

14. A stator magnet assembling method for assembling a magnet to a stator core, the method including: a holding step of attracting and holding the magnet on a holding lower surface of a holding member formed of a magnetic material; a moving step of moving the holding member such that the held magnet is disposed at a predetermined position where a gap is provided in the vertical direction with respect to a magnet mounting surface of the stator core; and a separating step of separating the magnet held by the holding member from the holding lower surface toward the magnet mounting surface.

15. The stator magnet assembling method according to claim 14, further comprising an adhesion step of applying an adhesive to at least one of the lower surface of the magnet or the magnet mounting surface before the separation step.

16. In the holding step, the magnet is held on the holding lower surface at a position separated from one side within the axial range of the stator core. In the moving step, the holding member holding the magnet is moved along the axial direction of the stator core. The stator magnet assembling method according to claim 14 or 15.

17. In the moving step, after moving the holding member in the axial direction, the holding member is moved downward so that the magnet is disposed at the predetermined position. The stator magnet assembling method according to claim 16.

18. In the separation step, the magnet held by the holding member is biased toward the magnet mounting surface so as to be separated from the holding lower surface. The stator magnet assembling method according to claim 14 or 15.

19. The holding member has a holding hole that opens on the holding lower surface. In the separation step, an urging rod that is inserted into the holding hole and is displaceable in the vertical direction is used to bias the magnet toward the magnet mounting surface so as to be separated from the holding lower surface. The stator magnet assembling method according to claim 18.

20. In the separation step, the electromagnet disposed on the holding member is turned on or off. The stator magnet assembling method according to claim 14 or 15.

21. In the separation step, the mounting magnet attached to the holding member is removed. The stator magnet assembling method according to claim 14 or 15.

22. In the holding step, a bar-shaped jig having a longitudinal direction is used. A holding member is formed on the first side in the longitudinal direction, and a non-magnetic member made of a non-magnetic material is formed on the second side in the longitudinal direction. The magnet is held by the holding member of the bar-shaped jig. In the moving step, an axial guide for supporting the bar-shaped jig is used such that the longitudinal direction is parallel to the axial direction of the stator core and the second side is on one side in the axial direction of the stator core. The bar-shaped jig is moved along the axial guide so that the magnet is disposed at the predetermined position. In the separating step, a protruding portion protruding toward the center side of the stator core is brought into contact with the magnet end face on the other side in the axial direction of the magnet that has moved with the execution of the moving step, and the bar-shaped jig is further moved to the other side along the axial guide. The method for assembling a stator magnet according to claim 14.

23. The method for assembling a stator magnet according to claim 14 or 15, further comprising a rotating step of rotating the stator core to a predetermined rotational position and stopping it before the execution of the moving step.

24. A method for manufacturing a stator in which a plurality of the magnets are assembled to the stator core over the entire circumferential length of the stator core by repeating the method for assembling the stator magnet according to claim 14, wherein the plurality of magnets include: a first radially magnetized magnet magnetized on the outer side in the radial direction of the stator core; a second radially magnetized magnet magnetized on the inner side in the radial direction; a first circumferentially magnetized magnet magnetized on one side in the circumferential direction of the stator core; and a second circumferentially magnetized magnet magnetized on the other side in the circumferential direction. The method for manufacturing the stator includes a radially magnet arrangement step of alternately arranging the first radially magnetized magnet and the second radially magnetized magnet at intervals in the circumferential direction of the stator core, and a circumferentially magnet arrangement step of arranging the first circumferentially magnetized magnet and the second circumferentially magnetized magnet at intervals in the circumferential direction after the radially magnet arrangement step, wherein the first circumferentially magnetized magnet is arranged on the one side in the circumferential direction of the first radially magnetized magnet and on the other side in the circumferential direction of the second radially magnetized magnet, and the second circumferentially magnetized magnet is arranged on the other side of the first radially magnetized magnet and on the one side in the circumferential direction of the second radially magnetized magnet.

25. The method for manufacturing a stator according to claim 24, wherein in the separation step, the first circumferentially magnetized magnet or the second circumferentially magnetized magnet held by the holding member is biased toward the magnet mounting surface so as to be separated from the holding lower surface.

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