Method for manufacturing interior permanent magnet rotor and device for manufacturing interior permanent magnet rotor

Abstract

This method for manufacturing an interior permanent magnet rotor comprises an orienting and molding step for filling slots formed in a rotor core (12) with a composition for forming anisotropic bonded magnets, magnetically orienting a magnet material contained in the composition filling the slots by applying magnetic flux to the magnet material using an orienting unit (50), and molding the composition. The orienting unit comprises: a plurality of magnetic flux generating members (52) that generate magnetic flux; a plurality of intermediate members (54); and a plurality of support members (56) provided to each of the plurality of magnetic flux generating members. Each of the support members has an arm part (58) extending toward the radially inward side of the orienting unit along a lateral surface of the magnetic flux generating member. When the rotor core is accommodated inside the plurality of magnetic flux generating members, the tips of the arm parts support a thinnest part between the outer circumferential surface of the rotor core and the slots from the radially outward side of the orienting unit.

Description

Manufacturing method and manufacturing device for interior magnet rotor CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based on and claims the benefit of priority from Japanese Patent Application No. 2024-093289, filed on June 7, 2024, the entire contents of which are incorporated herein by reference.

[0002] The technology disclosed herein relates to a manufacturing method and an apparatus for manufacturing an interior permanent magnet rotor.

[0003] Generally, in manufacturing an embedded magnet rotor, a composition for forming an anisotropic bonded magnet is filled into slots formed in a rotor core, and an orientation unit is used to apply magnetic flux to the magnetic material contained in the composition filled in the slots to magnetically orient the magnetic material, and the composition is then molded through an orientation / molding process to produce an embedded magnet rotor.

[0004] For example, the following is a known example of an orientation unit used in this type of manufacturing method for an interior permanent magnet rotor (see, for example, Japanese Patent No. 6870356). This known orientation unit includes a plurality of magnetic flux generating members arranged in a ring shape. A cylindrical sleeve is disposed inside the plurality of magnetic flux generating members, and the rotor core is housed inside the sleeve.

[0005] As a result of detailed studies by the inventors, the following problem was discovered. Specifically, when the slot shape is such that the thinnest portion occurs between the outer peripheral surface of the rotor core and the slot (for example, U-shaped), if the pressure of the composition when filling the slot with the composition (i.e., injection pressure) is high, stress may concentrate on the thinnest portion, causing the sleeve to deform radially outward from the location corresponding to the thinnest portion. In this case, the outer peripheral surface of the rotor core may deform in conjunction with the deformation of the sleeve, which may result in a decrease in the roundness of the outer peripheral surface of the rotor core.

[0006] The technology disclosed herein provides a method and apparatus for manufacturing an embedded magnet rotor that can manufacture an embedded magnet rotor while suppressing a decrease in the roundness of the outer surface of the rotor core.

[0007] A first aspect of the disclosed technology is a method for manufacturing an embedded magnet rotor, comprising an orientation / molding process in which a composition for forming an anisotropic bonded magnet is filled into slots formed in a rotor core, an orientation unit is used to apply magnetic flux to the magnetic material contained in the composition filled into the slots, thereby magnetically aligning the magnetic material, and molding the composition, wherein the orientation unit is arranged in a ring shape, houses the rotor core inside, and comprises a plurality of magnetic flux generating members that generate the magnetic flux, a plurality of intermediate members provided between the plurality of magnetic flux generating members, and a plurality of support members provided on each of the plurality of magnetic flux generating members, each of which has an arm extending radially inward of the orientation unit along the side of the magnetic flux generating member, and the tip of the arm supports the thinnest part between the outer peripheral surface of the rotor core and the slot from the radial outside of the orientation unit when the rotor core is housed inside the plurality of magnetic flux generating members.

[0008] A second aspect of the disclosed technology is an embedded magnet rotor manufacturing device that includes an orientation / molding device that fills slots formed in a rotor core with a composition for forming an anisotropic bonded magnet, uses an orientation unit to apply magnetic flux to the magnetic material contained in the composition filled in the slots, thereby magnetically aligning the magnetic material, and molds the composition, wherein the orientation unit is arranged in a ring shape, houses the rotor core inside, and includes a plurality of magnetic flux generating members that generate the magnetic flux, a plurality of intermediate members provided between the plurality of magnetic flux generating members, and a plurality of support members provided on each of the plurality of magnetic flux generating members, each of which has an arm extending radially inward of the orientation unit along the side of the magnetic flux generating member, and the tip of the arm supports the thinnest part between the outer peripheral surface of the rotor core and the slot from the radial outside of the orientation unit when the rotor core is housed inside the plurality of magnetic flux generating members.

[0009] According to the technology disclosed herein, a method and an apparatus for manufacturing an embedded magnet rotor are provided that can manufacture an embedded magnet rotor while suppressing a decrease in the roundness of the outer surface of the rotor core.

[0010] 1 is a perspective view of a rotor according to one embodiment of the technology of the present disclosure; FIG. 2 is a plan view of a rotor according to one embodiment of the technology of the present disclosure; FIG. 3 is a longitudinal sectional view of an orientation / shaping device according to one embodiment of the technology of the present disclosure; FIG. 4 is an explanatory view illustrating a first half of the steps of a method for manufacturing a rotor according to one embodiment of the technology of the present disclosure; FIG. 5 is an explanatory view illustrating a second half of the steps of a method for manufacturing a rotor according to one embodiment of the technology of the present disclosure; FIG. 6 is an enlarged view of a main part of FIG. 6; FIG. 7 is a perspective view of a plurality of support members according to one embodiment of the technology of the present disclosure; FIG. 8 is a perspective view of one support member according to one embodiment of the technology of the present disclosure; FIG. 9 is an enlarged plan view of a main part of a rotor according to a first modified example; FIG. 10 is an enlarged plan view of a main part of a rotor according to a second modified example; FIG. 11 is an enlarged plan view of a main part of a rotor according to a third modified example; FIG. 12 is an enlarged plan view of a main part of a rotor according to a fourth modified example; FIG. 13 is an enlarged plan view of a main part of a rotor according to a fifth modified example; FIG. 14 is an enlarged perspective view of a main part including a partial cross section of an orientation unit according to a sixth modified example; FIG. 15 is an enlarged perspective view of a main part including a partial cross section of an orientation unit according to a seventh modified example; FIG. 16 is an enlarged perspective view of a main part including a partial cross section of an orientation unit according to an eighth modified example; FIG. 17 is a plan view illustrating a state in which a rotor is arranged inside an orientation unit according to a comparative example. 10 is a plan view showing a state in which a sleeve according to a comparative example is deformed. FIG.

[0011] An embodiment of the technology of the present disclosure will be described below.

[0012] As shown in Figure 1, a rotor 10 according to this embodiment is an interior permanent magnet (IPM) rotor and includes a rotor core 12 and a plurality of bonded magnets 14. The rotor 10 is an example of an "interior permanent magnet rotor" according to the technology of the present disclosure. The bonded magnets 14 are an example of an "anisotropic bonded magnet" according to the technology of the present disclosure.

[0013] The rotor core 12 has a plurality of core sheets 16. Each core sheet 16 is formed in a disk shape. The rotor core 12 is formed of a laminate in which a plurality of core sheets 16 are stacked. The core sheets 16 are formed of, for example, electromagnetic steel sheets.

[0014] The outer peripheral surface of the rotor core 12 is formed in a circular shape when viewed in the axial direction of the rotor core 12. An insertion hole 18 is formed in the center of the rotor core 12. The insertion hole 18 penetrates the rotor core 12 in the axial direction. A shaft is press-fitted into the insertion hole 18.

[0015] A plurality of slots 20 are formed radially outward of the insertion holes 18 in the rotor core 12. The plurality of slots 20 are formed around the insertion holes 18. The plurality of slots 20 are formed side by side in the circumferential direction of the rotor core 12. Each slot 20 penetrates the rotor core 12 in the axial direction. A bonded magnet 14 is housed in each slot 20.

[0016] 2 , the slots 20 are formed in a U-shape when viewed in the axial direction of the rotor core 12. The slots 20 are oriented such that the lower part of the U-shape is located on the insertion hole 18 side and the upper part of the U-shape is located on the outer peripheral surface side of the rotor core 12.

[0017] Because the slots 20 are formed in a U-shape, the distance between the outer peripheral surface of the rotor core 12 and the slots 20 varies depending on the location of the slots 20. In other words, the distance between the outer peripheral surface of the rotor core 12 and the slots 20 is shortest at the top of the U-shape of the slots 20, and the distance between the outer peripheral surface of the rotor core 12 and the slots 20 is longest at the bottom of the U-shape of the slots 20. Hereinafter, the location of the rotor core 12 where the distance between the outer peripheral surface of the rotor core 12 and the slots 20 is shortest will be referred to as the thinnest portion 22. Because the slots 20 are formed in a U-shape, a pair of thinnest portions 22 is formed for each slot 20 in the rotor core 12.

[0018] As shown in Figure 3, the rotor manufacturing method according to this embodiment uses a rotor manufacturing apparatus S. The rotor manufacturing method is an example of an "embedded magnet rotor manufacturing method" according to the technology of the present disclosure. The rotor manufacturing apparatus S is an example of an "embedded magnet rotor manufacturing apparatus" according to the technology of the present disclosure. The rotor manufacturing apparatus S includes an orientation / molding apparatus 30. The orientation / molding apparatus 30 includes an injection facility 32 and a mold 34.

[0019] The mold 34 has a first mold 36 and a second mold 38. As an example, the first mold 36 is an upper mold, and the second mold 38 is a lower mold. A boundary 40 indicates the boundary between the first mold 36 and the second mold 38. The second mold 38 has an orientation unit 50. The orientation unit 50 has a cavity 42 into which the rotor core 12 is inserted. The cavity 42 is formed by a space similar to the outer shape of the rotor core 12. The configuration of the orientation unit 50 will be described in detail later.

[0020] The first die 36 has a sprue 46 and a runner 48. The sprue 46 and the runner 48 are configured as separate bodies from the die body of the first die 36. The runner 48 is formed in an annular shape along the circumferential direction of the rotor core 12. The sprue 46 is connected to the runner 48. The injection equipment 32 is connected to the sprue 46. The sprue 46 communicates with the runner 48 and the injection equipment 32. The runner 48 communicates with the slot 20 via a gate.

[0021] As shown in Figures 4 and 5, the rotor manufacturing method according to this embodiment includes a preparation process A, an insert process B, a mold clamping process C, an orientation / molding process D, a mold opening process E, and a removal process F.

[0022] In the preparation step A, the first die 36 and the second die 38 are opened. In the insertion step B, the rotor core 12 is inserted into the orientation unit 50. In the die clamping step C, the first die 36 and the second die 38 are clamped.

[0023] In the orientation / molding process D, the composition for forming the bonded magnet 14 (i.e., the magnet material) is injected from the injection equipment 32. The composition injected from the injection equipment 32 is filled into each slot 20 through the sprue 46, runner 48, and gate. The magnetic material contained in the composition filled into each slot 20 is magnetically oriented by the action of magnetic flux from the orientation unit 50. Also, in the orientation / molding process D, the composition filled into each slot 20 is molded by injection molding. Then, the binder resin contained in the composition solidifies, and the bonded magnet 14 is molded from the composition.

[0024] In a mold-opening step E, the first mold 36 and the second mold 38 are opened. In a removal step F, the rotor core 12 is removed from the orientation unit 50. Through the above steps, the rotor 10 shown in FIG. 1 is manufactured.

[0025] As shown in FIG. 6 , the orientation unit 50 is configured in an annular shape and includes a plurality of magnetic flux generating members 52, a plurality of intermediate members 54, and a plurality of support members 56. The plurality of magnetic flux generating members 52 are arranged in an annular shape. The rotor core 12 is housed inside the plurality of magnetic flux generating members 52. The plurality of magnetic flux generating members 52 include a plurality of first magnetic flux generating members 52A and a plurality of second magnetic flux generating members 52B. Each of the first magnetic flux generating members 52A is a portion that generates magnetic flux directed radially inward of the orientation unit 50, and each of the second magnetic flux generating members 52B is a portion that generates magnetic flux directed radially outward of the orientation unit 50.

[0026] Each intermediate member 54 is provided between the plurality of magnetic flux generating members 52. The first magnetic flux generating members 52A and the second magnetic flux generating members 52B are alternately arranged in the circumferential direction of the orientation unit 50 via the intermediate members 54. The first magnetic flux generating members 52A and the second magnetic flux generating members 52B include, for example, magnets oriented in the radial direction of the orientation unit 50. The intermediate members 54 include, for example, magnets oriented in the circumferential direction of the orientation unit 50, or are formed of a non-magnetic material.

[0027] The plurality of support members 56 are provided for each of the plurality of magnetic flux generating members 52. The plurality of support members 56 are configured independently of one another. Each support member 56 has the same configuration. Each support member 56 is made of, for example, a non-magnetic material.

[0028] 7 to 9 , the support member 56 is formed in a frame shape having a pair of arms 58, a front end connecting portion 60, and a rear end connecting portion 62. The pair of arms 58 extend radially inward of the alignment unit 50 along the side surfaces 53 on both sides of the magnetic flux generating member 52. Each arm 58 extends straight radially inward of the alignment unit 50 along the side surfaces 53 of the magnetic flux generating member 52. The side surfaces 53 on both sides of the magnetic flux generating member 52 are surfaces of the outer circumferential surface of the magnetic flux generating member 52 that extend radially of the alignment unit 50.

[0029] Each arm 58 is formed in a plate shape extending in the radial direction of the alignment unit 50. Each arm 58 has a leading end 58A and a trailing end 58B. The leading end 58A of each arm 58 is the end of the arm 58 located on the radially inner side of the alignment unit 50, and the trailing end 58B of each arm 58 is the end of the arm 58 located on the radially outer side of the alignment unit 50.

[0030] The tip end 58A of each arm portion 58 is positioned to support the thinnest portion 22 from the radially outer side of the alignment unit 50. In other words, the tip end 58A of each arm portion 58 is positioned to correspond to the thinnest portion 22 between the outer peripheral surface of the rotor core 12 and the upper part of the U-shape of the slot 20, and supports the thinnest portion 22 from the radially outer side of the alignment unit 50 when the rotor core 12 is housed inside the multiple magnetic flux generating members 52. An air gap 64 is provided between one arm portion 58 of one of adjacent support members 56 and the other arm portion 58 of the other support member 56.

[0031] The tip connecting portion 60 is formed in a plate shape extending in the circumferential direction of the orientation unit 50, and is disposed radially inward of the orientation unit 50 relative to the magnetic flux generating members 52. The tip connecting portion 60 connects the tip portions 58A of the pair of arms 58. When the rotor core 12 is housed inside the multiple magnetic flux generating members 52, the tip connecting portion 60 supports the outer peripheral surface of the rotor core 12 from the radially outside of the orientation unit 50.

[0032] The rear end connecting portion 62 is formed in a plate shape extending in the circumferential direction of the alignment unit 50, and is disposed radially outward of the alignment unit 50 with respect to the magnetic flux generating member 52. The rear end connecting portion 62 connects the rear ends 58B of the pair of arms 58 together. Each support member 56 is fixed to the magnetic flux generating member 52, for example, by screwing the rear end connecting portion 62 to the magnetic flux generating member 52.

[0033] If the thickness of the arm portion 58 is thickness t1, the thickness of the tip connecting portion 60 is thickness t2, and the thickness of the rear end connecting portion 62 is thickness t3, the thickness t2 of the tip connecting portion 60 is thinner than the thickness t1 of the arm portion 58 and the thickness t3 of the rear end connecting portion 62. The thickness t1 of the arm portion 58 is also thinner than the thickness t3 of the rear end connecting portion 62. The thickness t1 of each arm portion 58 is uniform, and the thickness t1 of a pair of arms 58 is the same. The thickness t2 of the tip connecting portion 60 is also uniform, and the thickness t3 of the rear end connecting portion 62 is also uniform.

[0034] Next, the effects of this embodiment will be described.

[0035] First, to clarify the effects of this embodiment, a comparative example will be described. As shown in FIG. 18 , an orientation unit 150 is used in the comparative example. The orientation unit 150 according to the comparative example includes a plurality of magnetic flux generating members 152, a plurality of intermediate members 154, and a sleeve 156. The plurality of magnetic flux generating members 152 and the plurality of intermediate members 154 have the same configuration as in this embodiment. The sleeve 156 is formed in a cylindrical shape and is disposed inside the plurality of magnetic flux generating members 152. The sleeve 156 is formed from a non-magnetic material. The rotor core 12 is housed inside the sleeve 156.

[0036] 19 , in the orientation unit 150 according to the comparative example, if the pressure of the composition when filling the slots 20 with the composition (i.e., the injection pressure) is high, stress may be concentrated in the thinnest part 22, and the sleeve 156 may deform radially outward from the location corresponding to the thinnest part 22. In this case, the outer peripheral surface of the rotor core 12 may deform due to the deformation of the sleeve 156, and the roundness of the outer peripheral surface of the rotor core 12 may decrease.

[0037] Furthermore, in the orientation unit 150 according to the comparative example, it is possible to increase the thickness of the sleeve 156 in order to suppress deformation of the outer peripheral surface of the rotor core 12. However, in this case, the distance between the magnetic flux generating member 152 and the slot 20 increases, and the magnetic force imparted by the magnetic flux generating member 152 to the magnetic material contained in the composition filled in the slot 20 decreases, which may result in a decrease in the magnetic force emitted from the bonded magnet 14.

[0038] 6 to 9 , a support member 56 is provided for each of the plurality of magnetic flux generating members 52, and each support member 56 has a pair of arms 58 extending radially inward of the orientation unit 50 along both side surfaces 53 of the magnetic flux generating member 52. When the rotor core 12 is housed inside the plurality of magnetic flux generating members 52, the tip end 58A of each arm 58 supports the thinnest portion 22 between the outer peripheral surface of the rotor core 12 and the upper U-shaped portion of the slot 20 from the radially outer side of the orientation unit 50.

[0039] Therefore, even if the pressure of the composition when filling the slots 20 (i.e., the injection pressure) is high, the tip portions 58A of the arms 58 support the thinnest portions 22 from the radially outer side of the orientation unit 50, thereby preventing the rotor core 12 from deforming radially outward from the thinnest portions 22. This prevents the outer peripheral surface of the rotor core 12 from deforming, thereby preventing a decrease in the roundness of the outer peripheral surface of the rotor core 12.

[0040] Furthermore, by having tip portions 58A of each arm portion 58 support thinnest portion 22 from the radially outer side of alignment unit 50, sleeve 156 can be eliminated. This allows the distance between magnetic flux generating member 52 and slot 20 to be shorter compared to when sleeve 156 is used, as in the comparative example. This ensures the magnetic force imparted by magnetic flux generating member 52 to the magnetic material contained in the composition filled in slot 20, thereby preventing a decrease in the magnetic force emitted from bond magnet 14.

[0041] Furthermore, each support member 56 has a tip connecting portion 60 that connects the tip ends 58A of the pair of arm portions 58, and the thickness t2 of the tip connecting portion 60 is thinner than the thickness t1 of the arm portion 58 and the thickness t3 of the rear end connecting portion 62. Therefore, even if the tip connecting portion 60 is provided, it is possible to prevent the distance between the magnetic flux generating member 52 and the slot 20 from increasing.

[0042] Furthermore, by connecting the tip ends 58A of a pair of arm portions 58 to each other by the tip connecting portion 60, the support rigidity of the arm portions 58 with respect to the thinnest portion 22 can be increased, thereby more effectively suppressing deformation of the thinnest portion 22 radially outward from the rotor core 12.

[0043] Furthermore, when the rotor core 12 is housed inside the plurality of magnetic flux generating members 52, the tip connecting portion 60 supports the outer peripheral surface of the rotor core 12 from the radially outer side of the orientation unit 50. This makes it possible to more effectively prevent the outer peripheral surface of the rotor core 12 from being deformed.

[0044] Furthermore, by connecting the rear end portions 58B of the pair of arm portions 58 together by the rear end connecting portion 62, the support rigidity of the arm portions 58 with respect to the thinnest portion 22 can be increased, and deformation of the thinnest portion 22 radially outward from the rotor core 12 can be more effectively suppressed.

[0045] Furthermore, the pair of arms 58 extend straight toward the radially inner side of the orientation unit 50 along both side surfaces 53 of the magnetic flux generating member 52. This increases the tension force of the arms 58 against the thinnest portion 22, making it possible to more effectively prevent the thinnest portion 22 from deforming radially outward of the rotor core 12.

[0046] Furthermore, the plurality of support members 56 are configured to be independent of one another, which makes it possible to prevent magnetic flux from leaking between adjacent magnetic flux generating members 52.

[0047] Furthermore, an air gap 64 is provided between one arm 58 of one of the adjacent support members 56 and the other arm 58 of the other support member 56. This makes it possible to prevent magnetic flux from leaking between one arm 58 of one of the adjacent support members 56 and the other arm 58 of the other support member 56.

[0048] Next, a modification of this embodiment will be described.

[0049] In the above embodiment, the slots 20 are formed in a U-shape, so that the thinnest part 22 is formed between the outer peripheral surface of the rotor core 12 and the slots 20, but the shape of the slots 20 may be any shape as long as the thinnest part 22 is formed.

[0050] For example, as shown in FIG. 10 , the slot 20 may be V-shaped. As shown in FIG. 11 , the slot 20 may be W-shaped. As shown in FIG. 12 , the slot 20 may be rectangular U-shaped. As shown in FIG. 13 , the slot 20 may be V-shaped and have a bridge portion 66 in the center of the V. Although not shown, the slot 20 may be U-shaped and have a bridge portion in the center of the U. As shown in FIG. 14 , the slot 20 may have a configuration in which multiple U-shaped portions are arranged in layers.

[0051] 15 to 17, a pair of arm portions 58 may be formed with a reinforcing rib 70. In the example shown in FIG. 15, the reinforcing rib 70 extending in the axial direction of the alignment unit 50 is formed from one end to the other end in the height direction of the arm portion 58. In the example shown in FIG. 16, the reinforcing rib 70 extending in the radial direction of the alignment unit 50 is formed from the center of the length direction of the pair of arm portions 58 to the tip end 58A. In the example shown in FIG. 17, the reinforcing rib 70 extending in the radial direction of the alignment unit 50 is formed from the tip end 58A to the rear end 58B of the pair of arm portions 58. The reinforcing rib 70 may connect the pair of arm portions 58. When the reinforcing rib 70 is formed in the pair of arm portions 58 in this manner, the rigidity of the arm portions 58 can be increased.

[0052] Furthermore, in the above embodiment, each support member 56 has a pair of arms 58 , but it may have a single arm 58 .

[0053] Furthermore, in the above embodiment, each arm portion 58 extends straight, but may be curved or bent.

[0054] Furthermore, in the above embodiment, each support member 56 has a tip connecting portion 60, but the tip connecting portion 60 may be omitted.

[0055] Furthermore, in the above embodiment, each support member 56 has the rear end connecting portion 62, but the rear end connecting portion 62 may be omitted.

[0056] The above describes one embodiment of the technology of the present disclosure, but the present invention is not limited to the above, and it goes without saying that the present invention can be implemented in various modifications within the scope of the gist of the present disclosure.

[0057] The following are supplementary notes regarding the technology of the present disclosure. (Supplementary Note 1) The method includes an orientation / molding process in which a composition for forming an anisotropic bonded magnet (14) is filled into slots (20) formed in a rotor core (12), and an orientation unit (50) is used to apply magnetic flux to the magnetic material contained in the composition filled into the slots, thereby magnetically orienting the magnetic material, and molding the composition, wherein the orientation unit includes: a plurality of magnetic flux generating members (52) arranged in an annular shape, which house the rotor core inside and generate the magnetic flux, a plurality of intermediate members (54) provided between the plurality of magnetic flux generating members, and a plurality of support members (56) provided on each of the plurality of magnetic flux generating members, each of which has an arm portion (58) extending radially inward of the orientation unit along a side surface (53) of the magnetic flux generating member, A method for manufacturing an interior permanent magnet rotor, wherein the tip ends (58A) of the arms support the thinnest parts (22) between the outer peripheral surface of the rotor core and the slots from the radially outer side of the alignment unit when the rotor core is housed inside the plurality of magnetic flux generating members. (Supplementary Note 2) A method for manufacturing an interior permanent magnet rotor according to Supplementary Note 1, wherein each of the support members has a pair of arms extending radially inward of the alignment unit along both side surfaces of the magnetic flux generating member, and a tip connecting portion (60) connecting the tip ends of the pair of arms. (Supplementary Note 3) A method for manufacturing an interior permanent magnet rotor according to Supplementary Note 2, wherein the tip connecting portion supports the outer peripheral surface of the rotor core from the radially outer side of the alignment unit when the rotor core is housed inside the plurality of magnetic flux generating members. (Supplementary Note 4) A method for manufacturing an interior permanent magnet rotor according to Supplementary Note 2 or Supplementary Note 3, wherein the thickness (t2) of the tip connecting portion is thinner than the thickness (t1) of the arms. (Supplementary Note 5) The manufacturing method of an interior permanent magnet rotor according to any one of Supplementary Note 2 to Supplementary Note 4, wherein each of the support members has a rear end connecting portion (62) that connects the rear ends of the pair of arm portions together. (Supplementary Note 6) The manufacturing method of an interior permanent magnet rotor according to Supplementary Note 5, wherein a thickness (t2) of the front end connecting portion is thinner than a thickness (t3) of the rear end connecting portion.(Supplementary Note 7) The method for manufacturing an interior permanent magnet rotor according to any one of Supplementary Notes 1 to 6, wherein the arm portion extends straight toward the radially inner side of the alignment unit along a side surface of the magnetic flux generating member. (Supplementary Note 8) The method for manufacturing an interior permanent magnet rotor according to any one of Supplementary Notes 1 to 7, wherein the plurality of support members are configured independently of one another. (Supplementary Note 9) The method for manufacturing an interior permanent magnet rotor according to any one of Supplementary Notes 1 to 8, wherein an air gap (64) is provided between the arm portion of one of the adjacent support members and the arm portion of the other support member. (Appendix 10) The invention comprises an orientation / molding device (30) that fills slots formed in a rotor core with a composition for forming an anisotropic bonded magnet, applies magnetic flux to the magnetic material contained in the composition filled in the slots using an orientation unit to magnetically align the magnetic material, and molds the composition, wherein the orientation unit comprises: a plurality of magnetic flux generating members (52) arranged in an annular shape, accommodating the rotor core inside and generating the magnetic flux; a plurality of intermediate members (54) provided between the plurality of magnetic flux generating members; and a plurality of support members (56) provided on each of the plurality of magnetic flux generating members, each of the support members having an arm portion (58) extending radially inward of the orientation unit along a side surface (53) of the magnetic flux generating member, and a tip end portion (58A) of the arm portion supporting the thinnest portion (22) between the outer circumferential surface of the rotor core and the slot from the radially outer side of the orientation unit when the rotor core is accommodated inside the plurality of magnetic flux generating members. Manufacturing equipment for embedded magnet rotors (S).

Claims

1. The method comprises an orientation and molding process in which a composition for forming an anisotropic bonded magnet (14) is filled into slots (20) formed in a rotor core (12), and an orientation unit (50) is used to apply magnetic flux to the magnetic material contained in the composition filled into the slots, thereby magnetically orienting the magnetic material, and molding the composition; the orientation unit comprises: a plurality of magnetic flux generating members (52) arranged in an annular shape, which house the rotor core inside and generate the magnetic flux; a plurality of intermediate members (54) provided between the plurality of magnetic flux generating members; and a plurality of support members (56) provided on each of the plurality of magnetic flux generating members, each of which has an arm portion (58) extending radially inward of the orientation unit along a side surface (53) of the magnetic flux generating member; a tip end (58A) of the arm portion supporting a thinnest portion (22) between the outer peripheral surface of the rotor core and the slot from the radially outside of the orientation unit when the rotor core is housed inside the plurality of magnetic flux generating members.

2. A manufacturing method for an embedded magnet rotor as described in claim 1, wherein each of the support members has a pair of arm portions extending radially inward of the orientation unit along both side surfaces of the magnetic flux generating member, and a tip connecting portion (60) connecting the tip ends of the pair of arm portions to each other.

3. A manufacturing method for an embedded magnet rotor as described in claim 2, wherein the tip connecting portion supports the outer surface of the rotor core from the radially outside of the orientation unit when the rotor core is housed inside the multiple magnetic flux generating members.

4. A method for manufacturing an interior permanent magnet rotor according to claim 2 or 3, wherein the thickness (t2) of the tip connecting portion is thinner than the thickness (t1) of the arm portion.

5. A manufacturing method for an interior permanent magnet rotor according to any one of claims 2 to 4, wherein each of the support members has a rear end connecting portion (62) that connects the rear ends of the pair of arm portions together.

6. The manufacturing method of an interior permanent magnet rotor according to claim 5, wherein the thickness (t2) of the leading end connecting portion is thinner than the thickness (t3) of the trailing end connecting portion.

7. A method for manufacturing an embedded magnet rotor according to any one of claims 1 to 6, wherein the arm portion extends straight along the side surface of the magnetic flux generating member toward the radially inner side of the orientation unit.

8. A method for manufacturing an interior permanent magnet rotor according to any one of claims 1 to 7, wherein the plurality of support members are configured independently of one another.

9. A manufacturing method for an embedded magnet rotor as set forth in any one of claims 1 to 8, wherein an air gap (64) is provided between the arm portion of one of the adjacent support members and the arm portion of the other support member.

10. An orientation / molding device (30) that fills slots formed in a rotor core with a composition for forming an anisotropic bonded magnet, applies magnetic flux to the magnetic material contained in the composition filled in the slots using an orientation unit to magnetically align the magnetic material, and molds the composition, wherein the orientation unit comprises: a plurality of magnetic flux generating members (52) arranged in an annular shape, accommodating the rotor core inside and generating the magnetic flux; a plurality of intermediate members (54) provided between the plurality of magnetic flux generating members; and a plurality of support members (56) provided on each of the plurality of magnetic flux generating members, each of which has an arm portion (58) extending radially inward of the orientation unit along a side surface (53) of the magnetic flux generating member, and a tip end portion (58A) of the arm portion supporting the thinnest portion (22) between the outer peripheral surface of the rotor core and the slot from the radially outer side of the orientation unit when the rotor core is accommodated inside the plurality of magnetic flux generating members. Manufacturing equipment for embedded magnet rotors (S).

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