CN112519064A

CN112519064A - Method and apparatus for manufacturing iron core product

Info

Publication number: CN112519064A
Application number: CN202010985365.XA
Authority: CN
Inventors: 生池一树; 加藤刚
Original assignee: Mitsui High Tec Inc
Current assignee: Mitsui High Tec Inc
Priority date: 2019-09-18
Filing date: 2020-09-18
Publication date: 2021-03-19
Also published as: JP2021048695A; JP7360286B2

Abstract

One example of a method for manufacturing an iron core product includes: arranging the iron core main body provided with the resin injection part on a resin injection device, and injecting molten resin into the resin injection part; cooling the core main body in a process of conveying the core main body by a conveying path extending between the resin injection device and a subsequent processing device; and when the temperature of the iron core main body in the conveying path is lower than the specified temperature, preserving the heat of the iron core main body.

Description

Method and apparatus for manufacturing iron core product

Technical Field

The present invention relates to a method and an apparatus for manufacturing an iron core product.

Background

International publication No. 2017/159348 discloses a method for manufacturing a rotor core used in an IPM (Interior Permanent Magnet) motor. The method comprises the following steps: inserting a permanent magnet into a magnet insertion hole of the iron core body; injecting molten resin into the magnet insertion hole; and solidifying the molten resin. In the resin injection step, the core body is preheated in order to fill the magnet insertion holes with the molten resin without omission.

Disclosure of Invention

Technical problem to be solved by the invention

The invention provides a method and an apparatus for manufacturing an iron core product, which can effectively utilize heat of an iron core body in a subsequent process.

Means for solving the problems

According to an aspect of the present invention, a method of manufacturing an iron core product includes: arranging a core main body provided with a resin injection part on a resin injection device so as to inject molten resin into the resin injection part; cooling the core main body while conveying the core main body by a conveyance path extending between the resin injection device and a subsequent processing device; and when the temperature of the iron core main body in the conveying process of the conveying path is lower than a specified temperature, preserving the temperature of the iron core main body.

According to another aspect of the present invention, an apparatus for manufacturing an iron core product includes: a resin injection device configured to inject a molten resin into a resin injection portion provided in the core body; a subsequent processing device of the resin injection device; a conveyance path configured to extend between the resin injection device and the processing device; a cooling unit configured to cool the inside of the conveyance path; a heat retaining unit configured to retain heat of the core body being conveyed on the conveyance path; a measuring unit configured to measure a temperature of the core body being conveyed through the conveying path; and a control unit configured to operate the heat retention unit when the temperature measured by the measurement unit is lower than a predetermined temperature.

Effects of the invention

According to the method for manufacturing an iron core product and the apparatus for manufacturing an iron core product according to the present invention, heat of the iron core body can be effectively used in the subsequent process.

Drawings

Fig. 1 is an exploded perspective view showing an example of a rotor.

Fig. 2 is a sectional view taken along line II-II of fig. 1.

Fig. 3 is a schematic view showing an example of a rotor manufacturing apparatus.

Fig. 4 is a cross-sectional view schematically showing an example of the resin injection device.

Fig. 5 is a cross-sectional view schematically showing an example of the welding apparatus.

Fig. 6 is a side view schematically showing an example of the transport device.

Fig. 7 is a plan view schematically showing the transport apparatus of fig. 6.

Fig. 8 is a side view showing a state in which the covering member covers the conveyance path in the conveyance device of fig. 6.

Detailed Description

Hereinafter, an example of an embodiment according to the present invention will be described in more detail with reference to the drawings. In the following description, the same reference numerals are used for the same elements or elements having the same functions, and redundant description is omitted.

[ Structure of rotor ]

First, the structure of the rotor 1 (core product) will be described with reference to fig. 1 and 2. The rotor 1(rotor) is combined with a stator (stator) to form a motor. The rotor 1 may be configured as an interior magnet type (IPM) motor, for example, or may be configured as a part of another type of motor. The rotor 1 includes a rotor laminated core 2, a pair of

end plates

3, 4, and a shaft 5.

The rotor laminated core 2 includes a laminated body 10 (core main body), a plurality of permanent magnets 12, and a plurality of cured resins 14.

As shown in fig. 1, the laminated body 10 has a cylindrical shape. A shaft hole 10a penetrating the stacked body 10 is provided in the central portion of the stacked body 10 so as to extend along the central axis Ax. The axial hole 10a extends in the height direction (vertical direction) of the stacked body 10. The stacked body 10 rotates around the central axis Ax, and therefore, the central axis Ax is also a rotation axis.

A pair of ribs 10b are formed on the inner peripheral surface of the shaft hole 10 a. The ribs 10b extend in the height direction from the upper end surface S1 to the lower end surface S2 of the stacked body 10. The pair of protrusions 10b face each other with the center axis Ax in between, and protrude from the inner circumferential surface of the shaft hole 10a toward the center axis Ax.

The laminated body 10 is formed with a plurality of magnet insertion holes 16 (resin injection portions). As shown in fig. 1, the magnet insertion holes 16 are arranged at predetermined intervals along the outer peripheral edge of the stacked body 10. As shown in fig. 2, the magnet insertion hole 16 penetrates the stacked body 10 so as to extend along the central axis Ax. That is, the magnet insertion holes 16 extend in the height direction.

The laminated body 10 is formed by laminating a plurality of punched members W. The blanking member W is a plate-like body obtained by blanking a metal plate MS (e.g., an electrical steel plate) described later into a predetermined shape, and has a shape corresponding to the laminated body 10. The laminate 10 may be formed by so-called spin lamination. The term "rotationally stacked" refers to stacking a plurality of punched members W so that the angles of the punched members W are offset relative to each other. The rotary lamination is mainly performed for the purpose of improving the flatness, parallelism, and squareness of the laminated body 10 by offsetting the thickness variation of the punched member W. The angle of the rotational lamination can be set to any value.

As shown in fig. 1 and 2, the blanking parts W adjacent in the stacking direction may be fastened to each other by a crimping portion 18. These punched parts W may be fastened to each other by various known methods instead of the crimping portion 18. For example, the plurality of blanking members W may be joined to each other by using an adhesive or a resin material, or may be joined to each other by welding. Alternatively, after providing the punching members W with temporary pressure bonding and fastening the plurality of punching members W by the temporary pressure bonding to obtain the laminated body 10, the temporary pressure bonding may be removed from the laminated body. The "temporary crimping" is a crimping for temporarily integrating the plurality of punched members W and is to be removed in the process of manufacturing the rotor laminated core 2.

As shown in fig. 1 and 2, the permanent magnets 12 are inserted into the magnet insertion holes 16 one by one. The shape of the permanent magnet 12 is not particularly limited, and may have a rectangular parallelepiped shape, for example. The type of the permanent magnet 12 may be determined depending on the application of the motor, required performance, and the like, and may be, for example, a sintered magnet or a bonded magnet.

The cured resin 14 is obtained by curing a resin material (molten resin) in a molten state filled in the magnet insertion holes 16 that accommodate the permanent magnets 12. The cured resin 14 may be configured to fix the permanent magnet 12 in the magnet insertion hole 16. The cured resin 14 may be configured to join the punched parts W adjacent to each other in the height direction.

As shown in fig. 1, the

end plates

3, 4 have a circular ring shape. That is,

shaft holes

3a and 4a penetrating the

end plates

3 and 4 are provided in the center portions of the

end plates

3 and 4, respectively. The outer diameters of the

end plates

3 and 4 may be set to be smaller than the outer diameter of the laminated body 10, for example, or may be set to be approximately the same as the outer diameter of the laminated body 10.

A pair of projections 3b are formed on the inner peripheral surface of the shaft hole 3 a. The pair of projections 3b face each other with the center axis Ax in between, and project from the inner peripheral surface of the shaft hole 3a toward the center axis Ax. A pair of projections 4b is also formed on the inner peripheral surface of the shaft hole 4a, similarly to the shaft hole 3 a. The size and shape of the

projections

3b, 4b may be substantially the same as those of the ridge 10b when viewed from above (in the central axis direction).

The

end plates

3 and 4 are disposed on the upper end surface S1 and the lower end surface S2 of the laminate 10, respectively, and are joined to the laminate 10 by welding. For example, as shown in fig. 2, the end plate 3 is joined to one or more punched members W located in the vicinity of the upper end of the laminated body 10 via a weld bead B1 provided so as to straddle the end plate 3 and the laminated body 10. Similarly, the end plate 4 is joined to one or more punched members W located in the vicinity of the lower end of the laminated body 10 by a weld bead B2 provided so as to straddle the end plate 4 and the laminated body 10. In this way, the rotor laminated core 2 and the

end plates

3 and 4 are integrated by welding, and thus one rotating body 6 is configured.

The shaft 5 has a cylindrical shape as a whole. A pair of grooves 5a are formed on the shaft 5. The groove 5a extends in the extending direction of the shaft 5 from one end to the other end of the shaft 5. The shaft 5 is inserted into the

shaft holes

3a, 4a, 10 a. At this time, the

projections

3b, 4b and the ridge 10b engage with the groove 5 a. This transmits a rotational force between the shaft 5 and the rotor laminated core 2.

[ apparatus for manufacturing rotor ]

Next, a manufacturing apparatus 100 of the rotor 1 will be described with reference to fig. 3 to 5. The manufacturing apparatus 100 is configured to manufacture the rotor 1 from a strip-shaped metal plate MS. As shown in fig. 3, the manufacturing apparatus 100 includes an unwinder 110, a feeder 120, a press working apparatus 130, a resin injection apparatus 140, a welding apparatus 150 (a subsequent working apparatus), a shaft attachment apparatus 160 (a subsequent working apparatus), conveying apparatuses 200A to 200C, and a controller Ctr (a control unit).

The unwinder 110 is configured to rotatably hold the coil 111. The coil 111 is formed by winding a metal sheet MS in a coil shape (spiral shape). The feeding device 120 includes a pair of

rollers

121 and 122 for sandwiching the metal plate MS from above and below. The pair of

rollers

121 and 122 rotate and stop based on an instruction signal from the controller Ctr, and intermittently and sequentially feed the metal plate MS toward the press working apparatus 130.

The press working device 130 operates based on an instruction signal from the controller Ctr. The press working device 130 is configured to sequentially perform a punching process on the metal plate MS intermittently fed by the feeding device 120 to form a punched member W. The press working apparatus 130 is configured to sequentially stack a plurality of punched members W obtained by punching to form the laminated body 10.

The resin injection device 140 operates based on an instruction signal from the controller Ctr. The resin injection device 140 is configured such that the permanent magnets 12 are disposed in the magnet insertion holes 16, respectively. The resin injection device 140 is configured to fill molten resin into the magnet insertion holes 16 that accommodate the permanent magnets 12. As shown in fig. 4 in particular, the resin injection device 140 includes a lower die 141, an upper die 142, and a plurality of plungers 143.

The lower mold 141 includes a base member 141a and a through post 141b provided to the base member 141 a. The base member 141a is configured to be able to mount the stacked body 10. The insertion post 141b is located at a substantially central portion of the base member 141a, and protrudes upward from the upper surface of the base member 141 a. The insertion column 141b has a cylindrical shape and has an outer shape corresponding to the shaft hole 10a of the laminate 10. A heat source similar to the heat source 142b described later may be disposed inside the lower mold 141.

The upper die 142 is configured to be capable of sandwiching the stacked body 10 in the height direction together with the lower die 141. The upper die 142 includes a base member 142a and a heat source 142 b.

The base member 142a is a plate-like member having a rectangular shape. The base member 142a is provided with one through hole 142c and a plurality of receiving holes 142 d. The through hole 142c is located at a substantially central portion of the base member 142 a. The through hole 142c has a shape (substantially circular shape) corresponding to the insertion column 141b, and the insertion column 141b can be inserted through the through hole 142 c.

The plurality of receiving holes 142d penetrate the base member 142a and are arranged at predetermined intervals along the periphery of the through hole 142 c. When the laminate 10 is sandwiched between the lower mold 141 and the upper mold 142, the receiving holes 142d are located at positions corresponding to the magnet insertion holes 16 of the laminate 10. Each accommodation hole 142d has a cylindrical shape and is capable of accommodating at least one resin particle P.

The heat source 142b is, for example, a heater built in the base member 142 a. When the heat source 142b operates, the base member 142a is heated, the stacked body 10 in contact with the base member 142a is heated, and the resin particles P accommodated in the respective accommodation holes 142d are heated. Thereby, the resin particles P are melted and changed into a molten resin.

A plurality of plungers 143 are positioned above the upper die 142. Each plunger 143 is configured to be insertable into and removable from the corresponding receiving hole 142d by a drive source not shown.

The welding device 150 operates based on an instruction signal from the controller Ctr. The welding device 150 is configured to weld the rotor laminated core 2 and the

end plates

3 and 4. As shown in fig. 5, the welding device 150 includes

protective plates

151, 152 and

welding torches

153, 154.

The

protection plates

151, 152 have a circular plate shape. The outer diameters of the

protective plates

151 and 152 may be set to be larger than the outer diameters of the

end plates

3 and 4 and the stacked body 10, or may be set to be approximately the same as the outer diameters of the

end plates

3 and 4 and the stacked body 10.

The protective plate 151 is disposed above the rotor laminated core 2 and the end plate 3. The protective plate 152 is disposed below the rotor laminated core 2 and the end plate 4. The

protective plates

151 and 152 are configured to be able to sandwich the rotor laminated core 2 and the

end plates

3 and 4.

Heat sources

151a and 152a are respectively incorporated in the

protection plates

151 and 152. The

heat sources

151a and 152a are configured to heat the

end panels

3 and 4 in a state where the

protection plates

151 and 152 are in contact with the

end panels

3 and 4, respectively. The

heat sources

151a, 152a may be, for example, heaters.

The welding torches 153 and 154 are configured to weld the

end plates

3 and 4 and the rotor laminated core 2 (laminated body 10), respectively. The welding torches 153, 154 may be, for example, laser welding machines. The welding torch 153 is disposed so that the tip end thereof faces the end plate 3 exposed from the protective plate 151 and the peripheral edge of the rotor laminated core 2 (laminated body 10). The welding torch 154 is disposed so that the tip end thereof faces the end plate 4 exposed from the protective plate 152 and the peripheral edge of the rotor laminated core 2 (laminated body 10).

The shaft mounting device 160 operates based on an instruction signal from the controller Ctr. The shaft mounting device 160 is configured to mount the shaft 5 to the rotating body 6 formed by integrating the rotor laminated core 2 and the

end plates

3 and 4 by welding. For example, the shaft mounting device 160 may be configured to heat press-fit the shaft 5 to the

shaft holes

3a, 4a, and 10a while heating the rotor laminated core 2 and the

end plates

3 and 4.

As shown in fig. 3, the conveying device 200A is configured to extend between the press working device 130 and the resin injection device 140. The conveyor 200A is configured to operate based on an instruction from the controller Ctr, and convey the laminate 10 discharged from the press working apparatus 130 to the resin injection apparatus 140. The conveyor 200A may include various conveyors (e.g., a roller conveyor, a belt conveyor, etc.).

The conveying device 200B is configured to extend between the resin injection device 140 and the welding device 150. The conveying device 200B is configured to operate based on an instruction from the controller Ctr, and convey the rotor laminated core 2 discharged from the resin injection device 140 to the welding device 150. The details of the conveyance device 200B will be described later.

The conveying device 200C is disposed so as to extend between the welding device 150 and the shaft attachment device 160. The conveying device 200C is configured to operate based on an instruction from the controller Ctr, and convey the rotary body 6 discharged from the welding device 150 to the shaft mounting device 160. The conveying apparatus 200C may have the same configuration as the conveying apparatus 200B.

The controller Ctr is configured to generate instruction signals for operating the feeding device 120, the press working device 130, the resin injection device 140, the welding device 150, and the conveying devices 200A to 200C, respectively, based on a program stored in a storage medium (not shown), an operation input from an operator, or the like, for example. The controller Ctr is configured to send the instruction signal to each of these apparatuses.

[ details of the conveying apparatus 200B ]

Next, details of the conveyance device 200B will be described with reference to fig. 6 to 8. As shown in fig. 6 and 7, the conveying device 200B includes a conveying path 202, a conveyor 204, a cooler 206 (cooling unit), a temperature sensor 208 (measuring unit), a heat-retaining device 210 (heat-retaining unit), a discharge device 212 (discharge unit), and a heating device 214 (heating unit).

The transfer path 202 extends to connect the outlet of the resin injection device 140 and the inlet of the welding device 150. The conveyance path 202 may be, for example, a quadrangular prism-shaped space surrounded by a bottom wall, a pair of side walls, and an upper wall. The side wall may have a net shape to allow air to circulate. The portion of the upper wall where the cooler 206 is disposed may also have a mesh shape to allow air to flow.

The conveyor 204 is provided in the bottom wall of the conveyance path 202. The conveyor 204 is configured to operate in response to an instruction from the controller Ctr, and convey the stacked rotor laminated core 2 from the resin injection device 140 to the welding device 150. The conveyor 204 may also be any of a variety of conveyors (e.g., a roller conveyor, a belt conveyor, etc.).

The cooling machine 206 is configured to operate based on an instruction from the controller Ctr, and to cool the rotor laminated core 2 conveyed by the conveyor 204. The cooler 206 may be a blower that blows ambient air to the rotor laminated core 2, or may be a cooler that blows cool air to the rotor laminated core 2.

The cooler 206 is provided in the conveyance path 202. The location where the cooler 206 is provided may be an upper wall portion of the conveyance path 202, or may be other portions (e.g., a bottom wall, a side wall, etc.). The number of the coolers 206 provided in the conveyance path 202 may be one or more. The plurality of coolers 206 may be arranged at predetermined intervals in the longitudinal direction of the conveyance path 202. The number of coolers 206, the amount of air blown, the temperature of the air blown, and the like may be set so that the temperature of the rotor laminated core 2 reaching the welding apparatus 150 is not lower than a prescribed temperature (first threshold).

The temperature sensor 208 is configured to measure the temperature of the rotor laminated core 2 conveyed by the conveyor 204 and transmit the measured temperature data to the controller Ctr. The temperature sensor 208 may be a contact sensor or a non-contact sensor.

The temperature sensor 208 is provided in the conveyance path 202. The position where the temperature sensor 208 is disposed may be the downstream side in the conveyance path 202, or may be another position (for example, the upstream side, the center, or the like). The number of the temperature sensors 208 provided in the conveyance path 202 may be one or more. The plurality of temperature sensors 208 may be arranged at predetermined intervals in the longitudinal direction of the conveyance path 202.

The heat retaining device 210 is configured to retain the temperature of the rotor laminated core 2 conveyed through the conveyance path 202. The thermal device 210 includes a cover member 216 and a drive mechanism 218.

The covering member 216 is configured to cover at least a part of the conveyance path 202. The position where the covering member 216 is provided may be the side of the conveyance path 202 as shown in fig. 6 to 8, or may be other positions (for example, above and below the conveyance path 202). The covering member 216 may be provided at least on the upstream side of the conveyance path 202 in the longitudinal direction of the conveyance path 202.

The covering member 216 may be a plate-like body provided with no opening or the like. A heat insulating material may be provided in a portion of the covering member 216 facing the conveyance path 202. The number of the covering members 216 provided in the conveyance path 202 may be one or more. The plurality of coating members 216 may be arranged at predetermined intervals in the longitudinal direction of the conveyance path 202, or may be arranged adjacent to each other without any gap.

The drive mechanism 218 is configured to be operable based on an instruction from the controller Ctr, and drives the cover member 216 between a cover position (see fig. 8) at which the cover member 216 covers the conveyance path 202 and a retracted position (see fig. 6) at which the cover member 216 does not overlap the conveyance path 202. When the cover member 216 is in the covering position, the delivery path 202 is at least partially covered by the cover member 216, and therefore air in the delivery path 202 becomes less likely to flow. Therefore, the temperature decrease in the conveyance path 202 is suppressed. On the other hand, when the cover member 216 is located at the retracted position, air can freely flow inside and outside the conveyance path 202. Therefore, the temperature decrease in the conveyance path 202 is promoted.

When the cover member 216 is disposed on the side of the conveyance path 202, the drive mechanism 218 can drive the cover member 216 between the cover position and the retracted position by moving the cover member 216 up and down. When the heat-insulating device 210 includes a plurality of the covering members 216, the driving mechanism 218 may be connected to each covering member 216, or one driving mechanism 218 may drive 2 or more covering members 216.

As shown in fig. 7, the discharge device 212 is configured to operate in response to an instruction from the controller Ctr, and to push out the rotor laminated core 2 conveyed by the conveyor 204 from the conveyance path 202 to the heating device 214. The discharge device 212 may be, for example, a hydraulic actuator, a pneumatic actuator, an electric actuator, an electromagnetic solenoid, or the like.

The heating device 214 is configured to heat the rotor laminated core 2 pushed out from the conveyance path 202 by the discharge device 212. The heating device 214 may be used to reheat the rotor laminated core 2 having an excessively low temperature so that the rotor laminated core 2 becomes a temperature suitable for processing in a subsequent device (the welding device 150 or the shaft attachment device 160).

[ method for manufacturing rotor ]

Next, a method for manufacturing the rotor 1 will be described with reference to fig. 3 to 8. First, as shown in fig. 3, a metal plate MS is sequentially punched out by the press working apparatus 130, and a plurality of punched-out members W are stacked to form a stacked body 10. The laminate 10 discharged from the press working apparatus 130 is conveyed to the resin injection apparatus 140 by the conveying apparatus 200A.

Next, as shown in fig. 4, the laminate 10 is placed on the lower mold 141. Next, the permanent magnets 12 are inserted into the respective magnet insertion holes 16. The permanent magnets 12 may be inserted into the magnet insertion holes 16 manually or by a robot arm (not shown) provided in the resin injection device 140 in response to an instruction from the controller Ctr.

Next, the upper die 142 is placed on the laminate 10. Therefore, the laminate 10 is sandwiched between the lower mold 141 and the upper mold 142 in the lamination direction. Next, the resin particles P are put into the accommodation holes 142 d. When the resin pellets P are brought into a molten state by the heat source 142b of the upper die 142, the molten resin is injected into each magnet insertion hole 16 by the plunger 143. After that, when the molten resin is solidified, the solidified resin 14 is formed in the magnet insertion hole 16. When the lower mold 141 and the upper mold 142 are detached from the laminated body 10, the rotor laminated core 2 is completed.

The controller Ctr instructs the conveyor 204 to convey the stacked body 10 discharged from the resin injection device 140 toward the welding device 150. The controller Ctr instructs the cooler 206 to blow air to the rotor laminated core 2 conveyed by the conveyor 204. Thereby, the rotor laminated core 2 is cooled to such an extent that the temperature of the rotor laminated core 2 fed to the welding apparatus 150 becomes a temperature suitable for welding.

At this time, the controller Ctr compares the temperature data of the rotor laminated core 2 sent from the temperature sensor 208 with a predetermined temperature (first threshold value), and determines whether or not the temperature data is lower than the predetermined temperature. When determining that the temperature data is not lower than the predetermined temperature (first threshold value), the controller Ctr continues the conveyance of the rotor laminated core 2 to the welding apparatus 150 by the conveyor 204.

On the other hand, when determining that the temperature data is lower than the predetermined temperature (1 st threshold), the controller Ctr instructs the cooling machine 206 to stop the operation of the cooling machine 206 and instructs the heat retaining device 210 to move the cover member 216 to the cover position by the drive mechanism 218. This stops the air blowing toward the rotor laminated core 2 and suppresses the flow of air in the conveyance path 202. Therefore, the heat retained by the laminated rotor core 2 is unlikely to escape from the conveyance path 202, and the laminated rotor core 2 can be kept warm.

When the temperature data is lower than a predetermined lower limit value set to be lower than a predetermined temperature (first threshold), the temperature of the rotor laminated core 2 is too low. Therefore, even if the laminated core 2 is thermally insulated by the heat insulator 210, the welding quality may be affected. Therefore, the controller Ctr may determine whether or not the temperature data is lower than a predetermined lower limit value.

When determining that the temperature data is lower than the predetermined lower limit value, the controller Ctr may instruct the discharge device 212 to convey the rotor laminated core 2 from the conveyance path 202 to the heating device 214 and instruct the heating device 214 to reheat the rotor laminated core 2. Thereafter, when the rotor laminated core 2 is reheated by the heating device 214 to such an extent that the temperature of the rotor laminated core 2 becomes a temperature suitable for welding, the controller Ctr may instruct a conveying device, not shown, or the like to convey the rotor laminated core 2 from the heating device 214 to the welding device 150.

Next, as shown in fig. 5, the

end plates

3 and 4 are disposed on the upper end surface S1 and the lower end surface S2 of the rotor laminated core 2 conveyed to the welding device 150, respectively. In this state, the rotor laminated core 2 and the

end plates

3 and 4 are sandwiched between the

protective plates

151 and 152 heated to a predetermined temperature by the

heat sources

151a and 152 a. Thereby, the

end plates

3, 4 are heated to a temperature suitable for welding. On the other hand, the temperature of the laminated rotor core 2 is maintained at a predetermined temperature suitable for welding or higher by the heat retaining device 210.

Next, the controller Ctr instructs the welding torches 153 and 154 to weld the

end plates

3 and 4 to the rotor laminated core 2 (laminated body 10). This forms a rotating body 6 in which the

end plates

3 and 4 are joined to the rotor laminated core 2. The rotary body 6 discharged from the welding apparatus 150 is conveyed toward the shaft mounting apparatus 160 by the conveying apparatus 200C. The controller Ctr can control the transport apparatus 200C in the same manner as the above-described transport apparatus 200B.

Next, shaft mounting device 160 mounts shaft 5 to rotating body 6. The shaft 5 can be shrink-fitted to the rotating body 6, for example. Thus, the rotor 1 is completed.

[ Effect ]

According to the above example, in the case of continuing to produce the rotor 1, the rotor laminated core 2 is appropriately cooled to a temperature suitable for welding or mounting of the shaft 5 between the resin injection device 140 and the subsequent welding device 150 or shaft mounting device 160. On the other hand, when the production of the rotor 1 is interrupted or the like, the cooling of the rotor laminated core 2 is stopped, and the rotor laminated core 2 is kept warm. Therefore, the case where the rotor laminated core 2 is excessively cooled when the production of the rotor 1 is restarted is greatly suppressed. Therefore, the heat of the rotor laminated core 2 can be effectively utilized in the subsequent process.

In the above example, the laminated rotor core 2 can be heat-insulated by the heat-insulating device 210 at least during the conveyance on the upstream side of the conveyance path 202. In this case, a rapid decrease in the temperature of the laminated rotor core 2 immediately after being discharged from the resin injection device 140 is suppressed. Therefore, the temperature of the rotor laminated core 2 can be easily controlled.

In the above example, the heat of the rotor laminated core 2 can be preserved by at least partially covering the conveyance path 202 with the covering member 216. In this case, the heat of the laminated rotor core 2 can be easily and simply maintained.

In the above example, the controller Ctr can drive the heat retaining device 210 when the temperature of the rotor laminated core 2 being conveyed on the downstream side of the conveyance path 202 is lower than a predetermined temperature, using temperature data from the temperature sensor 208 disposed on the downstream side of the conveyance path 202. In this case, the start of the heat retention is determined based on the temperature of the laminated rotor core 2 that is located on the downstream side and whose temperature is decreasing. Therefore, the start of the heat retention can be determined more accurately.

In the above example, the controller Ctr can stop the cooling machine 206 and drive the heat retaining device 210 when the temperature of the rotor laminated core 2 being conveyed in the conveyance path 202 is lower than a predetermined temperature, using the temperature data from the temperature sensor 208. In this case, the case where the rotor laminated core 2 is excessively cooled at the start of production of the rotor laminated core 2 or the like is greatly suppressed. Therefore, the heat of the rotor laminated core 2 can be more effectively used in the subsequent process.

In the above example, when the temperature of the rotor laminated core 2 being conveyed on the downstream side of the conveyance path 202 is lower than the predetermined lower limit value, the controller Ctr can push out the rotor laminated core 2 to the heating device 214 by the output device 212 and can reheat the rotor laminated core 2 by the heating device 214. In this case, the rotor laminated core 2 that has been excessively cooled during conveyance in the conveyance path 202 is reheated without being conveyed to the subsequent welding device 150 or shaft attachment device 160. Therefore, only the rotor laminated core 2 that does not need to be reheated is conveyed to the welding device 150 or the shaft mounting device 160, and therefore, the production time of the rotor 1 can be shortened. Further, since the rotor laminated core 2 that needs to be reheated is processed in the welding device 150 or the shaft attachment device 160 after being reheated, the rotor laminated core 2 can be used without waste. As a result, productivity of the rotor 1 can be improved.

[ modified examples ]

The disclosure of the present specification is to be considered in all respects as illustrative and not restrictive. Various omissions, substitutions, changes, and the like may be made to the above examples without departing from the scope of the claims and their spirit.

(1) When the temperature of the laminated rotor core 2 is lower than a predetermined temperature (1 st threshold), the covering member 216 can be manually attached to and detached from the conveyance path 202.

(2) The controller Ctr may detect the conveying speed of the laminated core 2 by the conveyor 204, compare the speed data with a predetermined speed (2 nd threshold), and determine whether the speed data is lower than the predetermined speed. When determining that the speed data is lower than the predetermined speed (2 nd threshold), the controller Ctr may instruct the cooling machine 206 to stop the operation of the cooling machine 206 and instruct the heat retainer 210 to move the cover member 216 to the cover position by the drive mechanism 218. In this case, even if the conveying speed of the rotor laminated core 2 in the conveying path 202 is relatively slow, the cooling of the rotor laminated core 2 is stopped, and the rotor laminated core 2 is further kept warm, so that the rotor laminated core 2 is suppressed from being excessively cooled. Therefore, the heat of the rotor laminated core 2 can be more effectively used in the subsequent process.

(3) When the apparatus 100 is stopped, that is, when the transport speed of the laminated rotor core 2 is 0, the controller Ctr can instruct the heat retaining device 210 to move the cover member 216 to the cover position by the drive mechanism 218, regardless of the temperature data from the temperature sensor 208.

(4) The controller Ctr can control the drive mechanism 218 to increase or decrease the area covered by the covering member 216 on the conveyance path 202, based on the temperature of the rotor laminated core 2, the conveyance speed, the outside air temperature, and the like.

(5) When determining that the temperature data from the temperature sensor 208 is lower than the predetermined temperature (1 st threshold), the controller Ctr may instruct the heat retainer 210 to move the cover member 216 to the cover position by the drive mechanism 218 without stopping the operation of the cooling machine 206. In this case, since the conveyance path 202 is covered with the cover 216, even if the cooler 206 is operated, the air blow from the cooler 206 is difficult to be discharged to the outside of the conveyance path 202. Therefore, the cooling capability of the cooler 206 for the rotor laminated core 2 is weakened, and the rotor laminated core 2 can be kept warm. In the case where the apparatus 100 includes a plurality of cooling machines 206, some of the plurality of cooling machines 206 may be operated, and the remaining cooling machines 206 may be stopped.

(6) The step of keeping the laminated core 2 warm may include heating the laminated core 2 by a heating device (heater, air heater, or the like) provided in the conveyance path 202.

(7) The permanent magnets 12 may be resin-encapsulated in the magnet insertion holes 16 after the shaft 5 is mounted to the laminated body 10. Alternatively, the shaft 5 may be attached to the rotor laminated core 2, and then the

end plates

3 and 4 may be welded to the rotor laminated core 2.

(8) In the welding process, the welding torches 153 and 154 may be moved in the vertical direction to weld a plurality of positions on the outer peripheral surface of the multilayer body 10 in the stacking direction.

(9) The welding device 150 may also comprise a welding torch. In this case, the welding torch may weld the end plate 3 to the stacked body 10 first, and then move (descend) in the height direction to weld the end plate 4 to the stacked body 10. Alternatively, in this case, for example, the end plates 3 are first welded to the stacked body 10, and then the joined end plates 3 are turned over together with the rotor laminated core 2, set in the welding device 150, and stood upright, and the end plates 4 are welded to the stacked body 10.

(10) An end plate may be disposed on at least one end surface of the laminate 10. Alternatively, the rotor 1 may be free of end plates. In this case, for example, the stacked body 10 may be welded to join the plurality of punched members W. Specifically, a weld bead extending in the height direction from the upper end to the lower end of the laminated body 10 is formed on the peripheral surface of the laminated body 10 to join all of the punched members W. Alternatively, a bead may be formed on the peripheral surface of the laminated body 10 so as to join the plurality of punched members W at the upper end and/or the lower end of the laminated body 10. In these cases, curling of the punched member W at the upper end and/or the lower end can be suppressed. In particular, in the latter case, since the weld bead is formed in a part of the upper end portion and/or the lower end portion, it is possible to suppress a decrease in the magnetic properties of the rotor 1 due to welding.

(11) A plurality of permanent magnets 12 may be inserted into one magnet insertion hole 16. In this case, the plurality of permanent magnets 12 may be arranged adjacently in the height direction in one magnet insertion hole 16, or may be arranged in a direction intersecting the height direction in one magnet insertion hole 16.

(12) The core body may be configured by a component other than the laminated body 10. For example, the core body may be a member formed by compression molding ferromagnetic powder, or may be a member formed by injection molding a resin material containing ferromagnetic powder.

(13) The present technique can be applied to a core product other than the rotor 1 (for example, a laminated stator core). Specifically, the present technology can also be applied when a resin film for insulating the stator laminated core from the winding is provided on the inner peripheral surface (resin injection portion) of the slot of the stator laminated core. The laminated stator core may be a split-type laminated stator core in which a plurality of core pieces are combined, or may be a non-split-type laminated stator core. In these laminated cores, the present technology can be applied to a case where a plurality of punched members are joined by filling molten resin into through holes (resin injection portions) that penetrate in the height direction.

[ other examples ]

Example 1 an example of a method of manufacturing an iron core product (2) may include: a step of disposing the core body (10) provided with the resin injection part (16) in a resin injection device (140) and injecting molten resin into the resin injection part (16); a step of cooling the core body (10) while conveying the core body (10) by a conveyance path (200B) extending between the resin injection device (140) and the subsequent processing devices (150, 160); and a step of keeping the temperature of the core body (10) conveyed in the conveying path (202) at a temperature lower than a predetermined temperature. In the case of continuing to produce the core product, the core main body is appropriately cooled until it becomes a temperature suitable for processing in the processing apparatus, between the resin injection apparatus and the subsequent processing apparatus. On the other hand, in the case where the production of the core product is interrupted or the like, the core body is kept warm. Therefore, the core main body is suppressed from being excessively cooled when the production of the core product is restarted. Therefore, the heat of the core body can be effectively utilized in the subsequent process.

Example 2 in the method of example 1, the step of keeping the core body (10) warm may include: and a step of keeping the temperature of the core body (10) when the temperature of the core body (10) being conveyed in the conveying path (202) is lower than a predetermined temperature and the conveying speed of the core body (10) in the conveying path (202) is lower than a predetermined speed. In this case, even if the conveying speed of the core body in the conveying path is relatively slow, the core body is kept warm, and therefore, the core body can be prevented from being excessively cooled. Therefore, the heat of the core body can be more effectively used in the subsequent process.

Example 3. in the method of example 1 or example 2, the step of keeping the core body (10) warm includes a step of keeping at least the core body (10) being conveyed on the upstream side of the conveyance path (202) warm. In this case, a rapid drop in the temperature of the core body immediately after discharge from the resin injection device is suppressed. Therefore, temperature control of the core body can be easily performed.

Example 4 in any of the methods of examples 1 to 3, the step of insulating the core main body (10) may include a step of at least partially covering the conveyance path (201) with a covering member (216). In this case, the heat insulation of the core body can be easily and easily performed.

Example 5 in any one of the methods of examples 1 to 4, the step of maintaining the temperature of the core body (10) may include: and a step of keeping the temperature of the core body (10) conveyed on the downstream side of the conveyance path (202) at a temperature lower than a predetermined temperature. In this case, the start of the heat retention is determined based on the temperature of the core main body located on the downstream side and whose temperature is decreasing. Therefore, the start of the heat retention can be determined more accurately.

Example 6 in any one of the methods of examples 1 to 5, the step of maintaining the temperature of the core body (10) may include: and a step of stopping cooling of the core body (10) and keeping the core body (10) warm when the temperature of the core body (10) being conveyed in the conveyance path (202) is lower than a predetermined temperature. In this case, in the case where the production of the core product is interrupted or the like, the cooling of the core main body is stopped, and the core main body is further kept warm. Therefore, the case where the core main body is excessively cooled when the production of the core product is restarted is greatly suppressed. Therefore, the heat of the core body can be more effectively used in the subsequent process.

Example 7 the method of any of examples 1-6 may further include: and a step of removing the core body (10) from the conveyance path (202) and reheating the core body when the temperature of the core body (10) being conveyed in the conveyance path (202) is lower than a predetermined lower limit value. In this case, the core body that has been excessively cooled during conveyance in the conveyance path is reheated without being conveyed to a subsequent processing device. Therefore, only the core body that does not need reheating is conveyed in the processing apparatus, and therefore, the production time of the core product can be shortened. Further, since the core body that needs to be reheated is processed in the processing device after being reheated, the core body can be used without waste. As a result, productivity of the core product can be improved.

Example 8 an example of the manufacturing apparatus (100) of the iron core product (1) may include: a resin injection device (140) configured to inject molten resin into a resin injection portion (16) provided in the core body (10); and processing devices (150, 160) subsequent to the resin injection device (140). An example of the apparatus (100) for manufacturing the iron core product (1) may further include: a conveyance path (202) extending between the resin injection device (140) and the processing devices (150, 160); and a cooling unit (206) configured to cool the inside of the conveyance path (202). An example of the manufacturing apparatus (100) for the iron core product (1) may further include: a heat-retaining unit (210) configured to retain heat of the core body (10) being conveyed through the conveyance path (202); and a measuring unit (208) configured to measure the temperature of the core body (10) being conveyed in the conveying path (202). In addition, an example of the manufacturing apparatus (100) of the iron core product (1) may also include a control unit (Ctr) configured to operate the heat-retaining unit (210) when the temperature measured by the measuring unit (208) is lower than a predetermined temperature. In this case, the same operational effects as those of the method of example 1 can be obtained.

Example 9. in the apparatus (100) of example 8, the control unit (Ctr) may be configured to operate the heat retaining unit (210) when the temperature measured by the measuring unit (208) is lower than a predetermined temperature and the conveying speed of the core body (10) in the conveying path (202) is lower than a predetermined speed. In this case, the same operational effects as those of the method of example 2 can be obtained.

Example 10 in the apparatus (100) according to example 8 or 9, the heat retaining unit (210) may be configured to retain heat of at least the core body (10) being conveyed on the upstream side of the conveyance path (202). In this case, the same operational effects as those of the method of example 3 can be obtained.

Example 11. in the devices (100) of examples 8 to 10, the heat retaining section (210) may include a covering member (216) that at least partially covers the conveyance path (202). In this case, the same operational effects as those of the method of example 4 can be obtained.

Example 12 in any one of the devices (100) of examples 8 to 11, the control unit (Ctr) may be configured to operate the heat retention unit (210) when the temperature measured by the measurement unit (208) is lower than a predetermined temperature. In this case, the same operational effects as those of the method of example 5 can be obtained.

Example 13 in any one of the devices (100) of examples 8 to 12, the control unit (Ctr) may be configured to stop the cooling unit (206) and operate the heat retention unit (210) when the temperature measured by the measurement unit (208) is lower than a predetermined temperature. In this case, the same operational effects as those of the method of example 6 can be obtained.

Example 14. the apparatus (100) according to any one of examples 8 to 13 may further include: a heating unit (214) configured to heat the core body (10); and a discharge unit (212) configured to discharge the core body (10) from the conveyance path (202) to the heating unit (214). The control unit (Ctr) may be configured to cause the discharge unit (212) to discharge the core body (10) from the conveyance path (202) to the heating unit (214) when the temperature measured by the measurement unit (208) is lower than a predetermined lower limit value. In this case, the same operational effects as those of the method of example 7 can be obtained.

Claims

1. A method of manufacturing an iron core article, comprising:

arranging a core main body provided with a resin injection part on a resin injection device so as to inject molten resin into the resin injection part;

cooling the core main body while conveying the core main body by a conveyance path extending between the resin injection device and a subsequent processing device; and

and when the temperature of the iron core main body in the conveying process of the conveying path is lower than a specified temperature, the iron core main body is kept warm.

2. The method of claim 1,

to the iron core main part keeps warm includes: and when the temperature of the iron core body in the conveying process of the conveying path is lower than the specified temperature and the conveying speed of the iron core body in the conveying path is lower than the specified speed, the iron core body is kept warm.

3. The method of claim 1 or 2,

to the iron core main part keeps warm includes: and holding at least the core body being conveyed on the upstream side of the conveyance path.

4. The method according to any one of claims 1 to 3,

to the iron core main part keeps warm includes: at least a part of the conveyance path is covered with a covering member.

5. The method according to any one of claims 1 to 4,

to the iron core main part keeps warm includes: and holding the core body while being conveyed downstream of the conveyance path when the temperature of the core body is lower than the predetermined temperature.

6. The method according to any one of claims 1 to 5,

to the iron core main part keeps warm includes: when the temperature of the core body being conveyed through the conveyance path is lower than the predetermined temperature, the cooling of the core body is stopped, and the core body is kept warm.

7. The method according to any one of claims 1 to 6,

further comprising: when the temperature of the core body during conveyance through the conveyance path is lower than a predetermined lower limit value, the core body is removed from the conveyance path and heated.

8. An apparatus for manufacturing an iron core product, comprising:

a resin injection device configured to inject a molten resin into a resin injection portion provided in the core body;

a subsequent processing device of the resin injection device;

a conveyance path configured to extend between the resin injection device and the processing device;

a cooling unit configured to cool the inside of the conveyance path;

a heat retaining unit configured to retain heat of the core body being conveyed on the conveyance path;

a measuring unit configured to measure a temperature of the core body being conveyed through the conveying path; and

and a control unit configured to operate the heat retention unit when the temperature measured by the measurement unit is lower than a predetermined temperature.

9. The apparatus of claim 8,

the control unit is configured to: and a temperature keeping unit configured to operate the temperature keeping unit when the temperature measured by the measuring unit is lower than the predetermined temperature and the conveying speed of the core body in the conveying path is lower than a predetermined speed.

10. The apparatus of claim 8 or 9,

the heat retaining unit is configured to retain heat of at least the core body being conveyed on an upstream side of the conveyance path.

11. The apparatus according to any one of claims 8 to 10,

the heat-insulating portion includes a covering member that covers at least a part of the conveyance path.

12. The apparatus according to any one of claims 8 to 11,

the control unit is configured to: and a temperature keeping unit that operates when the temperature of the core body being conveyed downstream of the conveyance path, as measured by the measuring unit, is lower than the predetermined temperature.

13. The apparatus according to any one of claims 8 to 12,

the control unit is configured to stop the cooling unit and operate the heat retention unit when the temperature measured by the measurement unit is lower than the predetermined temperature.

14. The apparatus of any one of claims 8-13, further comprising:

a heating unit configured to heat the core main body; and

a discharge unit configured to discharge the core main body from the conveyance path to the heating unit,

the control unit is configured to discharge the core main body from the conveyance path to the heating unit by the discharge unit when the temperature measured by the measurement unit is lower than a predetermined lower limit value.