JP2015076982A - Core member of rotating electric machine, and manufacturing method and manufacturing device thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a core member of a rotating electric machine, which is suitable to prevent resin from sneaking to the inner diameter side, and a manufacturing method and manufacturing device thereof.SOLUTION: A cylindrical core member 10 which has a plurality of teeth 12 arranged on a circular inner or outer peripheral surface thereof and has, between the teeth 12, slot spaces 13 in which coil wire rods 14A are disposed is taken as a mold object. The manufacturing device of the core member 10 of a rotating electric machine injects resin 52 into a pair of molds 30 and 40 in which a cavity C for housing the core member 10, to mold the core member 10 with the resin 52. After or while the coil wire rods 14A are urged to the inner radial side of the core member 10 in the slot spaces 13, the cavity C is filled with the resin 52.

Description

  The present invention relates to a core member molded with a resin such as a stator or a rotor around which a coil of a rotating electrical machine such as a motor or a generator is wound, a manufacturing method thereof, and a manufacturing apparatus.

  Conventionally, resin molding has been performed in order to ensure insulation and strength of a core member such as a stator around which a coil of a rotating electrical machine such as a motor or a generator is wound (see Patent Document 1).

  In Patent Document 1, a stator around which a coil is wound is housed in a cavity formed by an upper mold and a lower mold, and a void is not generated from the upper mold so as not to generate voids from the viewpoint of heat dissipation during resin molding. A method of injecting resin from below the cavity while discharging the air is being carried out.

JP 2008-260190 A

  By the way, when the stator around which the coil is wound is accommodated in the cavity formed by the upper mold and the lower mold and the resin is injected and filled in the cavity as in the above-described conventional example, the filled resin is There is a case of turning around to the inner diameter side of the workpiece. As described above, when the filled resin goes around to the inner diameter side of the stator, there is a possibility that a problem that an air gap cannot be secured with respect to the rotor that is rotatably arranged on the inner periphery may occur. In addition, after the molding, when the core holding the workpiece from the inner diameter side is pulled out of the workpiece and removed, there is a possibility that a defect may occur that causes the resin to crack and deform.

  Therefore, the present invention has been made in view of the above problems, and an object of the present invention is to provide a core member of a rotating electrical machine, a manufacturing method thereof, and a manufacturing apparatus that are suitable for preventing the resin from flowing into the inner diameter side.

  The present invention provides a cylindrical core member in which a plurality of teeth are disposed on a circumferential inner peripheral surface or an outer peripheral surface, a radial slot space is provided between the teeth, and a coil wire is disposed in the slot space. Is a molding target. And it is a manufacturing apparatus of the core member of the rotary electric machine which inject | pours resin into a pair of metal mold | die in which the cavity which accommodates the said cylindrical core member was formed, and molds a core member with resin. The coil wire disposed in the slot space is biased to the inner diameter side of the core member in the slot space, and the coil wire is biased to the inner diameter side by the biasing means or on the inner diameter side. And a resin filling means for filling the cavity with resin while energizing.

  Therefore, in the present invention, after the coil wire material is urged toward the inner diameter side by the urging means or while being urged toward the inner diameter side, the cavity is filled with resin, so that the coil wire materials are brought into close contact with each other and moved toward the inner diameter side. Can be made. For this reason, the insulating sheet as a wedge that wraps the coil wire can be pressed against the surface of the core, and the resin can be prevented from leaking from the inner peripheral side of the slot space to the outside, and the clearance portion between the core and the stator core Can not flow into.

Sectional drawing (A) and AA sectional drawing (B) which explain a core member molded by a manufacturing method and a manufacturing apparatus of a core member of a rotating electrical machine of an embodiment of the present invention, taking a stator as an example. is there. It is sectional drawing which shows the state of the previous process for molding resin with respect to a core member similarly. It is sectional drawing which shows the main structures of the molding apparatus containing the workpiece | work in the state by which the mold was opened. It is sectional drawing which shows the main structures of the molding apparatus in the state where the mold was closed. It is sectional drawing which shows the state from which resin began to be inject | poured into a cavity. It is sectional drawing (A) explaining the state of the coil wire inserted in the slot space of a core member, and the figure (B) explaining the distribution state of a coil wire. It is sectional drawing (A) explaining the state of the coil wire inserted in the slot space after the molding of a core member, and the figure (B) explaining the distribution state of a coil wire. It is sectional drawing which shows the core extraction process implemented after mold forming. FIG. 7 is a cross-sectional view showing a core removal step subsequent to FIG. 6. FIG. 5 is a cross-sectional view of a principal part in which resin core molding is performed on a rotor (rotor, armature) of a rotating electrical machine as a core member. It is sectional drawing of the molding apparatus of 1st Example which is a manufacturing apparatus for mold-molding with respect to the workpiece | work in 2nd Embodiment of this invention. It is sectional drawing which shows the operation state in the mold forming of the molding apparatus shown in FIG. It is sectional drawing of the molding apparatus of 2nd Example which is a manufacturing apparatus for mold-molding with respect to the workpiece | work in 2nd Embodiment of this invention.

  Hereinafter, a core member of a rotating electrical machine of the present invention, a manufacturing method thereof, and a manufacturing apparatus will be described based on each embodiment.

(First embodiment)
First, a core member to be molded by a core member manufacturing method and manufacturing apparatus according to the present invention will be described with reference to FIG. 1, taking a stator as an example. FIG. 1 is a cross-sectional view (A) and a cross-sectional view A-A (B) of the stator 10A. As shown in FIG. 1, a stator 10 </ b> A as a core member 10 is mounted in a stator core 11 made of a laminated steel plate having a plurality (24 places) of teeth 12 on the inner periphery and a slot space 13 between the teeth 12. And a plurality of coils 14.

  The coil 14 wound around each tooth 12 includes a region (referred to as a coil wire 14 </ b> A) that is wrapped in an insulating sheet 16 and accommodated in the slot space 13. The coil 14 includes a region (referred to as a coil end 14 </ b> B) that protrudes from the axial end portion of the slot space 13 and winds the axial end portion of the tooth 12. Each coil 14 is connected to the end of the wire 14 (not shown) by a bus bar so as to form three phases of U, V, and W, and each end of the U, V, and W phases of the bus bar has three terminals. 14C (U, V, W).

  As shown in FIG. 2, the stator 10 </ b> A in which the coil 14 is attached to the stator core 11 is attached to the housing 15 in a press-fit state. The housing 15 includes a cooling member, for example, a water jacket 15 </ b> A that is formed in a hollow inside and circulates the cooling liquid. Thereby, the heat generated in the coil 14 is transmitted to the housing 15 via the stator core 11 and is cooled by the coolant circulating through the water jacket 15A. Hereinafter, the stator 10A in which the coil 14 is attached to the stator core 11 and press-fitted to the housing 15 is simply referred to as “work W”.

  Next, as a pre-process for molding the resin 52 on the workpiece W, the core 20 is inserted into the inner periphery of the stator 10A. The core 20 forms the inner peripheral surface of the cavity C filled with the mold resin 52 by engaging the outer peripheral surface of the core 20 with the inner periphery of the stator core 11. One axial end of the core 20 on which the bus bar is disposed protrudes from the axial end of the stator core 11 and is set to be slightly longer than the coil end 14B that is similarly disposed to protrude. One end portion in the axial direction is in contact with an upper mold 30 described later, and forms an inner peripheral surface of the upper region of the cavity C. The other axial end portion of the core 20 protrudes from the other axial end portion of the stator core 11, and its end surface comes into contact with a lower mold 40 described later, so that the inner peripheral surface of the lower region of the cavity C Form.

  In the workpiece W to which the core 20 is attached, the opening on the inner peripheral side is closed by the core 20 in the slot space 13 in which the coil wire 14A is disposed. Therefore, each slot space 13 becomes an independent axial space that opens at both ends of the stator core 11 and continues in the axial direction.

  Next, as a pre-process for molding the resin 52 on the workpiece W, a terminal mold 23 for forming the molding resin 52 for the terminal 14C on each of the U, V, and W phase terminals 14C (U, V, W). Is mounted, and the pre-process for molding the workpiece W is completed.

  Next, a first embodiment of a molding apparatus that is a manufacturing apparatus for molding a workpiece W will be described with reference to FIG. FIG. 3 is a cross-sectional view showing the main configuration of a molding apparatus that molds the workpiece W on which the core 20 and the terminal mold 23 shown in FIG. 2 are mounted. The molding apparatus M engages with the upper part of the cavity 15 by engaging with the upper part of the housing 15 of the workpiece W, and also with the lower part of the cavity 15 by engaging with the lower part of the housing 15 of the stator 10A. And a lower mold 40 for forming The upper mold 30 is supported by the die plate 31 (fixed side) of the molding apparatus M, the lower mold 40 is supported by the die plate 41 (movable side) of the molding apparatus M, and the lower mold 40 moves up and down. Thus, the mold is closed and opened. A resin injection part 50 for injecting the resin 52 into the mold is provided on the back surface (upper part in the drawing) of the upper mold 30.

  The upper mold 30 is provided with an annular nozzle 32 that is arranged in an annular shape and is continuous with the resin injection portion 50 and penetrates in the vertical direction. On the front surface (lower part in the figure) of the upper mold 30 facing the workpiece W, a recess 33 is provided so as to abut one end of the core 20 when the mold is closed and accommodate the coil end 14B. And the front-end | tip of the cylindrical part 34 which protrudes below surrounding the dent 33 contact | abuts to the end surface of the housing 15 of the workpiece | work W at the time of mold closing. Thus, the recess 33, the core 20, and the housing 15 surround the coil end 14B to form an upper region of the cavity C. The annular nozzle 32 has an inner wall surface and an outer wall surface formed in a tapered shape so that a cross-sectional area becomes smaller as it moves away from the resin injection portion 50 and approaches the recess 33, and has a minimum cross section in an area opened to the recess 33. The gate 35 is constituted by the portion. Further, a cutout 34A is provided in a part of the cylindrical portion 34 so that the terminal mold 23 is received and accommodated in the cutout 34A when the mold is closed.

  The resin injection unit 50 compresses the pot 51 (cylinder) fixed to the back surface of the upper mold 30 and the thermosetting resin 52 charged in the pot 51, and the annular nozzle 32 and the gate 35 of the upper mold 30. And a pressurizer (not shown) that pressurizes the plunger 53 downward. In addition, as a pressurizer, a hydraulic cylinder, an air cylinder, etc. are used, for example.

  The thermosetting resin 52 is a resin such as an unsaturated polyester resin molding material or an epoxy resin molding material that is cured to form an insoluble and infusible cured product. Further, the thermosetting resin 52 may be mixed with an inorganic filler or a reinforcing agent. Inorganic fillers include calcium carbonate, aluminum hydroxide, silica, clay, talc and the like. Further, examples of the reinforcing agent include glass fiber and vinylon fiber. A fluidized thermosetting resin 52 is inserted into the pot 51 at the start of molding. Hereinafter, the thermosetting resin 52 is simply referred to as “resin 52”.

  The lower mold 40 includes an annular groove 42 that accommodates the coil end 14B of the stator 10A on the upper surface. The central region surrounded by the annular groove 42 protrudes upward and contacts the lower surface of the core 20 to form the inner peripheral surface of the cavity C. The outer peripheral region of the annular groove 42 contacts the end surface of the housing 15. Then, a lower region of the cavity C is formed by surrounding the coil end 14 </ b> B by the inner surface of the housing 15, the lower mold 40 (annular groove 42, central region / outer peripheral region), and the core 20. An eject pin 43 is disposed at the bottom of the annular groove 42 so as to be able to appear and retract.

  A molding method using the molding apparatus M having the above configuration will be described below with reference to FIGS. First, as shown in FIG. 3, the lower mold 40 is moved downward by the actuator (not shown) of the molding apparatus M to be separated from the upper mold 30, and the upper mold 30 and the lower mold 40 are opened. Is done. In this state, the handling device or the operator sets and positions the workpiece W on which the core 20 and the terminal mold 23 are mounted on the lower mold 40.

  Next, as shown in FIG. 4, the lower mold 40 is raised by an actuator (not shown). As a result, the upper end of the housing 15 of the workpiece W set in the lower die 40 comes into contact with the upper die 30, and the terminal mold 23 on the workpiece W side is cut out 34 A in the cylindrical portion 34 of the upper die 30. And the mold is closed. At this time, the coil end 14 </ b> B of the workpiece W enters into the recess 33 of the upper mold 30, and the upper end surface of the core 20 comes into contact with the bottom of the recess 33 of the upper mold 30. Then, the lower mold 40 is further urged in the upward direction so that a pressing force of several tens of tons is applied. That is, the mold is clamped. Thus, by applying a load of several tens of tons, the upper and lower end surfaces of the housing 15 of the workpiece W can be brought into close contact with the lower mold 40 and the upper mold 30.

  In this state, the upper mold 30 and the lower mold 40 are closed with the workpiece W interposed therebetween, so that the cavity C is formed by the recess 33 of the upper mold 30, the outer peripheral surface of the core 20, and the inner surface of the housing 15. An upper region is formed. The lower region of the cavity C is formed by the annular groove 42 of the lower mold 40 and its outer peripheral region, the outer periphery of the core 20 and the inner surface of the housing 15. At the same time, the upper and lower regions of the cavity C are in communication with each other via the slot space 13 of the stator core 11 in which the coil wire 14 </ b> A is disposed and the inner peripheral side is closed by the core 20.

  In molding, the resin 52 put into the pot 51 is preheated to 30 ° C. to 80 ° C. so as to easily flow stably, and the upper mold 30, the lower mold 40, and the workpiece W are preliminarily heated. The temperature is adjusted to 120 to 160 ° C. Thus, it is preferable to set the temperature of the upper and lower molds 30 and 40 and the workpiece W to be equal. In such a state, the resin 52 is inserted into the pot 51.

  In this state, the plunger 53 is lowered by the pressurizer of the resin injection unit 50 to pressurize the resin 52 put in the pot 51 and start injection through the annular nozzle 32 of the upper mold 30. The resin 52 enters from the outer peripheral side of the upper region of the cavity C through the annular nozzle 32 and through the gate 35 from all positions of 360 degrees. Here, the width of the portion of the gate 35 that enters the cavity C from the annular nozzle 32 becomes narrow, and the workpiece W and the annular nozzle 32 can be easily separated after the molding is completed.

  As shown in FIG. 5, the resin 52 that has passed through the gate 35 is filled in the outer peripheral side region of the coil end 14 </ b> B in the upper region of the cavity C. Next, the inner end side region of the coil end 14B is also filled through the gap between the coil end 14B and the upper mold 30. That is, the resin 52 is filled on the outer peripheral side of the coil end 14B, and then is filled on the inner peripheral side of the coil end 14B. For this reason, the resin 52 is filled from the outer diameter side without being filled from the inner diameter side with respect to the coil wire 14 </ b> A arranged inside the slot space 13. In the upper area of the cavity C, the gap between the axial end of the coil end 14B and the bottom of the recess 33 of the upper mold 30 is formed to be relatively small, thereby further facilitating the filling of the slot space 13 from the outer diameter side. Can be made.

  The filling of the resin 52 on the outer diameter side of the slot space 13, that is, on the outer diameter side of the coil wire 14 </ b> A, is performed from above the slot space 13 downward while pressing the coil wire 14 </ b> A toward the inner diameter side of the workpiece W. Progress gradually.

  As shown in FIG. 6, the coil wire 14 </ b> A is arranged in the slot space 13 in a state of being wrapped by the insulating sheet 16. For this reason, when the outer diameter side of the coil wire 14A in the slot space 13 is filled with resin, the coil wire 14A wrapped in the insulating sheet 16 is moved to the inner diameter side of the slot space 13 as the resin 52 is filled. It is done. As a result, as shown in FIG. 7, the coil wire 14 </ b> A is pressed against the inner diameter side of the slot space 13 while being wrapped by the insulating sheet 16, and the coil wires 14 </ b> A are in close contact with each other. Since the inner diameter side insulating sheet 16 (also referred to as a wedge) is pressed against the surface of the core 20 closing the inner diameter side opening of the slot space 13, the resin 52 is on the inner peripheral side of the stator core 11 and the slot space 13. And entering the gap between the core 20 can be prevented.

  Thereafter, the resin 52 reaches the lower region of the cavity C, fills the outer peripheral side region of the coil end 14B in the lower region, and passes through the gap between the axial end of the coil end 14B and the annular groove 42 of the lower mold 40. Thus, the inner peripheral region of the coil end 14B is filled. When the entire region of the cavity C is completely filled with the resin 52, the pressurization of the pressurizer and the plunger is stopped, and the injection of the resin 52 from the annular nozzle 32 is completed.

  After the resin 52 is filled into the cavity C, the plunger 53 is moved upward by the pressurizer of the resin injection unit 50. Next, when the resin 52 filled in the cavity C is cured, the lower mold 40 is moved downward by an actuator (not shown) and opened.

  Next, the workpiece W is moved upward from the lower mold 40 by the handling device or the operator. Next, as shown in FIG. 8, the core is removed between the housing 15 of the workpiece W and the die plates 31 and 41 that support the lower mold 40 and between the core 20 and the upper mold 30. A jig 24 is interposed. Next, as shown in FIG. 9, mold closing is performed in which the lower mold 40 is raised by an actuator (not shown) to bring the upper and lower molds 30 and 40 closer to each other. Thereby, although the workpiece | work W raises with the raise of the lower metal mold | die 40, since the core 20 has stopped with the upper metal mold | die 30 via the core removal jig | tool 24, the core 20 and the workpiece | work W The core 20 can be extracted downward from the workpiece W.

  As described above, since the insulating sheet 16 as a wedge is pressed against the surface of the core 20 in a state where the coil wire 14A is dense, the resin 52 leaks from the inner peripheral side of the slot space 13 to the outside. Can be prevented. That is, it does not flow into the clearance portion between the core 20 and the stator core 11, and an air gap with the rotor 10B can be secured. Thus, since the clearance is ensured between the core 20 and the stator core 11, the galling that occurs due to the resin 52 being interposed between the two at the time of core removal does not occur. For this reason, it is not necessary to wait for cooling of the core 20 as the timing of pulling out the core 20, and the cycle time can be secured.

  In this way, the workpiece W from which the core 20 has been removed is carried out of the molding apparatus M, and the upper and lower molds 30, 40 in which the new workpiece W on which the core 20 and the terminal mold 23 are mounted are opened. Then, the molding for the next workpiece W is started. In addition, as a method of extracting the core 20 from the workpiece W after molding, it is not limited to the above-described method, and may be executed in another method or in the next step.

  In the above embodiment, the core member 10 has been described for the stator 10A of the rotating electrical machine. However, the molding is performed for the rotor (rotor, armature) of the rotating electrical machine. Also good. That is, also in the rotor 10B (rotor, armature) of the rotating electrical machine, as shown in FIG. 10, a plurality of teeth 12 are arranged in the circumferential direction on the outer periphery of the rotor core 17, and an insulating sheet is provided between these teeth 12. A slot space 13 that accommodates a coil wire 14 </ b> A wrapped in 16 is provided. Also in such a rotor 10B (rotor, armature), the resin 52 is injected into a pair of molds in which cavities C for housing the rotor 10B as the core member 10 are formed, and the rotor 10B (core member 10). Is molded with resin 52, and can be carried out in the same manner as the stator 10A.

  That is, when the resin 52 is injected into the cavity C from the outer diameter side of the cavity C that accommodates the rotor 10B and the resin 52 flows from the outer diameter side of the rotor core 17 toward the inner diameter side, the coil wire 14A is moved into the slot space. 13 can be moved toward the inner diameter side of the rotor core 17. As a result, the coil wire 14 </ b> A in the slot space 13 can be shifted to the inner diameter side of the rotor core 17 and resin-molded. Since the coil wire 14 </ b> A is arranged to be biased toward the inner diameter side in the slot space 13 of the rotor core 17, the coil wire 14 </ b> A can be arranged closer to the shaft 18 that supports the rotor core 17. For this reason, the generated heat of the coil wire 14A generated at the time of rotational driving can be efficiently discharged to the outside by the shaft 18, the cooling performance of the coil 14 can be improved, and the efficiency of the rotating electrical machine can be improved.

  In the present embodiment, the following effects can be achieved.

  (A) A cylinder in which a plurality of teeth 12 are disposed on a circumferential inner peripheral surface or outer peripheral surface, a radial slot space 13 is provided between the teeth 12, and a coil wire 14A is disposed in the slot space 13. The shaped core member 10 is a molding target. Then, the core member 10 of the rotating electrical machine is manufactured in which the resin 52 is injected into the pair of molds 30 and 40 in which the cavity C that accommodates the cylindrical core member 10 is formed, and the core member 10 is molded with the resin 52. Device. Then, an urging means (an annular nozzle 32 for injecting the coil wire rod 14 </ b> A arranged in the slot space 13 toward the inner diameter side of the core member 10 in the slot space 13 toward the outer diameter side of the cavity C of the resin 52. Gate 35) and resin filling means (resin injection part 50) for filling the cavity 52 with the resin 52 after the coil wire 14A is urged toward the inner diameter side by the urging means or while being urged toward the inner diameter side. Prepare.

  That is, the coil wire 14A in the slot space 13 is brought into close contact with each other in order to fill the resin 52 into the cavity C after the coil wire 14A is urged toward the inner diameter side by the urging means or while being urged toward the inner diameter side. Can be arranged on the inner diameter side. When the core member 10 is the stator 10A, the insulating sheet 16 as a wedge is pressed against the surface of the core 20 in a state where the coil wire 14A is dense. It is possible to prevent leakage from the circumferential side to the outside. That is, it does not flow into the clearance portion between the core 20 and the stator core 11, and an air gap with the rotor 10B can be secured. As described above, since the clearance is secured between the core 20 and the stator core 11, the galling caused by the resin 52 being interposed between the cores does not occur when the core is removed. For this reason, it is not necessary to wait for cooling of the core 20 as the timing of pulling out the core 20, and the cycle time can be secured. Further, when the core member 10 is the rotor 10B, the coil wire 14A is arranged closer to the inner diameter side in the slot space 13 of the rotor core 17, so that the coil wire 14A is brought closer to the shaft 18 that supports the rotor core 17. Can be arranged. For this reason, the generated heat of the coil wire 14A generated at the time of rotational driving can be efficiently transmitted by the shaft 18, the cooling performance of the coil 14 can be improved, and the efficiency of the rotating electrical machine can be improved.

  (A) The urging means injects resin into the cavity C from the outer diameter side of the cavity C that houses the core member 10 and causes the resin to flow from the outer diameter side of the core member 10 toward the inner diameter side. . Thus, the coil wire 14 </ b> A can be urged toward the inner diameter side of the core member 10 in the slot space 13. For this reason, the coil wire 14A is pressed against the inner diameter side of the slot space 13 by the flow of the resin 52 from the outer diameter side to the inner diameter side in the state of being wrapped in the insulating sheet 16, and the coil wire materials 14A are closely packed with each other. Can be in contact. Further, since the coil wire 14A is biased toward the inner diameter side of the slot space 13 by the flow of the resin 52, the coil wire 14A can be reliably biased toward the inner diameter side.

  (C) The core member 10 obtained by using the manufacturing apparatus described above, and the resin in which the coil wire 14A in the slot space 13 is arranged to be biased toward the inner diameter side of the core member 10 and is filled in the slot space 13 It is molded by. That is, the coil wire 14 </ b> A in the slot space 13 is molded by the resin 52 that is arranged to be biased toward the inner diameter side of the core member 10 and is filled in the slot space 13. For this reason, when the core member 10 is the stator 10A, the resin 52 does not flow into the clearance portion between the core 20 and the stator core 11, and an air gap with the rotor 10B can be secured. Further, when the core member 10 is the rotor 10B, the generated heat of the coil wire 14A generated at the time of rotational driving can be efficiently transmitted by the shaft 18, the cooling performance of the coil 14 can be improved, and the rotating electric machine Efficiency can be improved.

(Second Embodiment)
11 to 12 show a second embodiment of a core member of a rotating electrical machine to which the present invention is applied, a method for manufacturing the same, and a manufacturing apparatus, and FIG. 11 is a molding apparatus that is a manufacturing apparatus for molding a workpiece. FIG. 12 is a sectional view of the molding apparatus showing an operating state during molding. In the molding apparatus of this embodiment, the structure which provides the coil wire arrange | positioned in the slot space of a core member to an inner diameter side with an airflow is added to 1st Embodiment. The same devices as those in the first embodiment are denoted by the same reference numerals, and description thereof is omitted or simplified.

  In the present embodiment, the coil wire 14A disposed in the slot space 13 of the stator core 11 that is the core member 10 is applied to the inner diameter side by airflow. That is, the core 20 includes an axial passage 24A and a radial passage 24B for discharging air in the cavity C formed by the upper and lower molds 30 and 40 and the housing 15. That is, the radial passage 24B is arranged in the radial direction of the core 20 at a plurality of locations (four locations in the figure) separated in the axial direction of the core 20 so as to face the opening on the inner diameter side of the slot space 13. Are arranged in the radial direction. The axial passage 24A is disposed at the center of the core 20 and communicates with the radial passage 24B so as to suck out air from the radial passage 24B and discharge it to the outside. An air exhaust device 25 is connected to the axial passage 24A. Other configurations are the same as those in the first embodiment.

  In the present embodiment, as in the first embodiment, the upper mold 30 and the lower mold 40 sandwich the workpiece W and close the mold to obtain the state shown in FIG. Next, the air discharge device 25 is operated. The air in the cavity C passes through the slot space 13 and is discharged by the air discharge device 25 through the radial passage 24B and the axial passage 24A.

  For this reason, in the slot space 13 of the stator core 11 that is the core member 10, an urging force is generated by an air flow from the radially outer side to the radially inner side. With this urging force, the coil wire 14A disposed in the slot space 13 of the workpiece W is pressed from the state shown in FIG. 6 to the inner diameter side of the slot space 13 as shown in FIG. Thereby, in the slot space 13 in which the coil wire 14A of the stator core 11 is arranged, a large space portion is formed on the outer peripheral side far from the core 20, and the upper and lower regions of the cavity C can communicate with each other through the space.

  In this state, the air discharge device 25 is stopped, the plunger 53 is lowered by the pressurizer of the resin injection unit 50, pressurizing the resin 52 put in the pot 51, and the annular nozzle 32 of the upper mold 30 is moved. Start injection via. The resin 52 enters from the upper region of the cavity C through the annular nozzle 32 through the gate 35 from all positions of 360 degrees.

  The resin 52 that has passed through the gate 35 is filled in the outer peripheral side region of the coil end 14B in the upper region of the cavity C as shown in FIG. Next, the inner end side region of the coil end 14B is also filled through the gap between the coil end 14B and the upper mold 30. At the same time, the resin 52 flows into the vacant outer diameter side when the coil wire 14A in the slot space 13 moves toward the inner diameter side, and fills the slot space 13 while pressing the coil wire 14A further toward the inner diameter side.

  The filling of the resin 52 on the outer diameter side of the slot space 13, that is, on the outer diameter side of the coil wire 14 </ b> A, is performed from above the slot space 13 downward while pressing the coil wire 14 </ b> A toward the inner diameter side of the workpiece W. Progress gradually.

  That is, when the resin 52 is filled on the outer diameter side of the coil wire 14 </ b> A in the slot space 13, the coil wire 14 </ b> A wrapped in the insulating sheet 16 is pressed against the inner diameter side of the slot space 13 as the resin 52 is filled. . As a result, the coil wire 14 </ b> A is pressed against the inner diameter side of the slot space 13 while being wrapped by the insulating sheet 16, and the coil wires 14 </ b> A are in close contact with each other.

  Thereafter, the resin 52 reaches the lower region of the cavity C, fills the outer peripheral side region of the coil end 14B in the lower region, and passes through the gap between the axial end of the coil end 14B and the annular groove 42 of the lower mold 40. Thus, the inner peripheral region of the coil end 14B is filled. When the entire region of the cavity C is completely filled with the resin 52, the lowering of the pressurizer and the plunger 53 stops and the injection of the resin 52 from the annular nozzle 32 is completed.

  After the resin is filled into the cavity C, the plunger 53 is moved upward by the pressurizer of the resin injection unit 50. Next, when the resin 52 filled in the cavity C is cured, the lower mold 40 is moved downward by an actuator (not shown) and opened. Next, as in the first embodiment, the core removal step and the subsequent steps are performed.

  As described above, since the insulating sheet 16 as a wedge is pressed against the surface of the core 20 in a state where the coil wire 14A is dense, the resin 52 leaks from the inner peripheral side of the slot space 13 to the outside. Therefore, the air does not flow into the clearance between the core 20 and the stator core 11, and an air gap with the rotor 10B can be secured. As described above, since the clearance is secured between the core 20 and the stator core 11, the galling caused by the resin 52 being interposed between the cores does not occur when the core is removed. For this reason, it is not necessary to wait for cooling of the core 20 as the timing of pulling out the core 20, and the cycle time can be secured.

  In the above embodiment, as means for generating an air flow for urging the coil wire 14A toward the inner diameter side of the slot space 13, the inside of the cavity C is provided via the axial passage 24A and the radial passage 24B provided in the core 20. Described what extracts air. However, in the present embodiment, an air flow from the radially outer side to the radially inner side may be generated in the slot space 13. For this reason, air is supplied to the upper and lower regions of the cavity C, and the air flows into the outside of the slot space 13 in the radial direction (outside of the coil wire 14A in the radial direction). You may make it approach inside. In addition to this method, the air extraction method according to the above embodiment may be used in combination.

  Moreover, in the said embodiment, what filled the resin 52 to the outer peripheral side area | region of the coil end 14B of the upper area | region of the cavity C via the annular nozzle 32 as the upper metal mold | die 30 was demonstrated. However, in the present embodiment, the coil wire 14A disposed in the slot space 13 of the core member 10 is applied to the inner diameter side by air pressure before filling with the resin. Therefore, as shown in FIG. May be filled in the inner peripheral side region of the coil end 14B in the upper region of the cavity C. In the upper mold 30 shown in FIG. 13, a sprue 36 that is continuous with the resin injection part 50 and penetrates in the vertical direction is provided at the center. Further, the end surface of one axial end portion of the core 20 has a central region formed in a flat shape 21 and an outer peripheral region formed in an annular ridge portion 22 protruding in the axial direction. The planar portion 21 and the annular ridge portion 22 form a runner 37 and a gate 38 of the mold resin 52 that flows into the cavity C by a gap with the bottom surface of the recess 33 of the upper mold 30.

  Further, the core member 10 according to the present embodiment has been described for the stator 10A of the rotating electrical machine, but the mold for the rotor 10B (rotor, armature) of the rotating electrical machine described in the first embodiment. You may implement shaping | molding. Even in this case, it can be implemented by forming an appropriate passage on the inner diameter side of the slot space 13 of the rotor 10B so as to generate an air flow flowing from the outer diameter side to the inner diameter side of the rotor 10B. The coil wire 14 </ b> A can be biased toward the inner diameter side in the slot space 13 of the rotor core 17 by the air flow acting from the outer diameter side to the inner diameter side of the rotor 10 </ b> B. As a result, the coil wire 14 </ b> A in the slot space 13 can be shifted to the inner diameter side of the rotor core 17 and resin-molded. Since the coil wire 14 </ b> A is arranged to be biased toward the inner diameter side in the slot space 13 of the rotor core 17, the coil wire 14 </ b> A can be arranged closer to the shaft 18 that supports the rotor core 17. For this reason, the generated heat of the coil wire 14A generated at the time of operation can be efficiently transmitted by the shaft 18, the cooling performance of the coil 14 can be improved, and the efficiency of the rotating electrical machine can be improved.

  In the core member 10 obtained by the present embodiment described above, the coil wire 14A in the slot space 13 is brought into close contact with each other, and the insulating sheet 16 as a wedge is pressed against the surface of the core 20, so that the resin 52 Can be prevented from leaking from the inner peripheral side of the slot space 13 to the outer side. For this reason, the resin 52 does not flow into the clearance portion between the core 20 and the stator core 11, and an air gap with the rotor 10 </ b> B can be secured, and the galling caused by the resin 52 being interposed between them when the core is removed. Does not occur. For this reason, it is not necessary to wait for cooling of the core 20 as the timing of pulling out the core 20, and the cycle time can be secured. When the core member 10 is the rotor 10 </ b> B, the coil wire 14 </ b> A can be arranged to be biased toward the inner diameter side in the slot space 13 of the rotor core 17, and the coil wire 14 </ b> A can be moved to the shaft 18 that supports the rotor core 17. Can be placed close together. For this reason, the generated heat of the coil wire 14A generated at the time of rotational driving can be efficiently transmitted by the shaft 18, the cooling performance of the coil 14 can be improved, and the efficiency of the rotating electrical machine can be improved.

  In the present embodiment, in addition to the effects (a) to (c) in the first embodiment, the following effects can be achieved.

  (D) The urging means is an air flow that is extracted from the outer peripheral side of the cavity C toward the inner periphery through the core 20 that is fitted to the inner periphery of the core member 10 and forms the inner peripheral surface of the cavity C. Accordingly, the coil wire 14 </ b> A can be urged and moved toward the inner diameter side of the core member 10 in the slot space 13. Therefore, before the resin 52 is injected into the cavity C, the coil wire 14A can be moved to the inner diameter side of the core member 10, and the coil wire 14A can be positioned reliably. Moreover, the subsequent injection of the resin 52 into the cavity C, combined with the biasing action in the inner diameter direction by the resin 52 in the first embodiment, makes the coil wire 14 </ b> A more reliably positioned toward the inner diameter side of the core member 10. Can be molded.

C Cavity M Molding device W Workpiece 10 Core member 10A Stator 10B Rotor 11 Stator core 12 Teeth 13 Slot space 14 Coil 14A Coil wire 14B Coil end 15 Housing 15A Water jacket 16 Insulating sheet 17 Rotor core 18 Shaft 20 Core 23 Terminal mold material 24A Axial passage 24B as urging means Radial passage 25 as urging means 25 Air exhaust device 30 Upper mold 32 Annular nozzle as improper means 35 Gate as urging means 40 Lower mold 50 Resin filling Resin injection part as means 52 Resin

Claims (7)

A cylindrical core member in which a plurality of teeth are arranged on a circumferential inner peripheral surface or outer peripheral surface, a radial slot space is provided between the teeth, and a coil wire is arranged in the slot space is a molding target. In an apparatus for manufacturing a core member of a rotating electrical machine, a resin is injected into a pair of molds formed with cavities for accommodating the cylindrical core member, and the core member is molded with the resin.
Biasing means for biasing the coil wire disposed in the slot space toward the inner diameter side of the core member in the slot space;
A core member for a rotating electrical machine, comprising: a resin filling unit that fills the cavity with resin while the coil wire is urged toward the inner diameter side by the urging means or while being urged toward the inner diameter side. apparatus.   The urging means injects resin into the cavity from the outer diameter side of the cavity housing the core member, and causes the resin to flow from the outer diameter side of the core member toward the inner diameter side, thereby causing the coil wire to move into the slot space. 2. The apparatus for manufacturing a core member of a rotating electrical machine according to claim 1, wherein the device is biased toward an inner diameter side of the core member.   The biasing means is adapted to draw the coil wire in the slot space by an air flow that is fitted to the inner periphery of the core member and forms an inner peripheral surface of the cavity through the core, and is extracted from the outer peripheral side of the cavity toward the inner periphery. The apparatus for manufacturing a core member of a rotating electrical machine according to claim 1 or 2, wherein the device is biased toward the inner diameter side of the core member. A cylindrical core member in which a plurality of teeth are arranged on a circumferential inner peripheral surface or outer peripheral surface, a radial slot space is provided between the teeth, and a coil wire is arranged in the slot space is a molding target. In the method of manufacturing a core member of a rotating electrical machine, a resin is injected into a pair of molds in which cavities for housing the cylindrical core member are formed, and the core member is molded with the resin.
The coil wire disposed in the slot space is biased by the biasing means toward the inner diameter side of the core member in the slot space,
A method of manufacturing a core member of a rotating electrical machine, wherein the cavity is filled with a resin by a resin filling means after the coil wire is biased toward the inner diameter side or while being biased toward the inner diameter side.   The urging means injects resin into the cavity from the outer diameter side of the cavity housing the core member, and causes the resin to flow from the outer diameter side of the core member toward the inner diameter side, thereby causing the coil wire to move into the slot space. 5. The method of manufacturing a core member for a rotating electrical machine according to claim 4, wherein the core member is biased toward the inner diameter side of the core member.   The biasing means is adapted to draw the coil wire in the slot space by an air flow that is fitted to the inner periphery of the core member and forms an inner peripheral surface of the cavity through the core, and is extracted from the outer peripheral side of the cavity toward the inner periphery. 6. The method of manufacturing a core member for a rotating electrical machine according to claim 4, wherein the core member is biased toward the inner diameter side of the core member. A core member obtained by using the production method according to any one of claims 4 to 6,
A core member of a rotating electrical machine, wherein the coil wire in the slot space is arranged to be biased toward the inner diameter side of the core member and is molded with a resin filled in the slot space.

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