JP2020120538A - Method of manufacturing rotor for rotary electric machine - Google Patents

Abstract

To provide a method of manufacturing a rotor for a rotary electric machine capable of suppressing scratches on a surface of a hard magnetic material.SOLUTION: A method of manufacturing a rotor 2 for a rotary electric machine, including a plurality of hard magnetic materials 20 formed in a rod shape and a rotor core 21 having a plurality of insertion holes 211 formed along an axial direction, in which the hard magnetic materials 20 are inserted into the insertion holes 211, includes the steps of: arranging an insertion jig 5 with a plurality of holding holes 510 temporarily holding the hard magnetic materials 20 alongside the rotor core 21 in the axial direction; and inserting the hard magnetic materials 20 into a plurality of insertion holes 211 by pressing in the axial direction while pneumatically aspiring the hard magnetic materials into an outer inner surface 510a of the holding holes 510.SELECTED DRAWING: Figure 6

Description

The present invention relates to a method for manufacturing a rotor for a rotary electric machine.

BACKGROUND ART Conventionally, in a rotary electric machine that functions as an electric motor or a generator, a plurality of rod-shaped hard magnetic materials (magnet materials) are inserted into insertion holes (magnet holes) of a rotor core, as shown in Patent Document 1, for example. Some have a rotor. The hard magnetic material is fixed in the insertion hole by the thermoplastic resin injected into the insertion hole, and then magnetized.

In the method of inserting the hard magnetic material described in Patent Document 1, the template having the communication hole communicating with the insertion hole of the rotor core is arranged above the rotor core, and the hard magnetic material inserted into the communication hole is moved downward by the pusher. Press and insert into the insertion hole. A ball plunger is embedded in the template to prevent the hard magnetic material from falling due to its own weight. The ball plunger has a ball and a spring that urges the ball toward the hard magnetic material. The hard magnetic material is pressed by the pusher and descends toward the insertion hole of the rotor core while rotating the ball urged by the spring. An air suction passage is provided in the pusher, and the pusher sucks the upper end surface of the hard magnetic material before the hard magnetic material approaches the descending end and cannot hold the hard magnetic material by the ball plunger.

JP, 2011-182486, A

In the method of inserting the hard magnetic material described in Patent Document 1, the balls of the ball plunger make point contact with the hard magnetic material, so that the surface of the hard magnetic material is easily scratched. Therefore, an object of the present invention is to provide a method for manufacturing a rotor for a rotary electric machine, which is capable of suppressing scratches on the surface of a hard magnetic material.

In order to achieve the above object, the present invention includes a plurality of rod-shaped hard magnetic materials and a rotor core in which a plurality of insertion holes are formed along the axial direction. A method for manufacturing a rotor for a rotary electric machine inserted into a plurality of insertion holes, wherein an insertion jig having a plurality of holding holes for temporarily holding the plurality of hard magnetic materials is arranged side by side in the axial direction with the rotor core. A method for manufacturing a rotor for a rotary electric machine is provided, wherein the plurality of hard magnetic materials are axially pressed into the plurality of insertion holes while being pneumatically attracted to the inner surfaces of the plurality of holding holes, and inserted into the plurality of insertion holes.

According to the present invention, it is possible to insert the hard magnetic material into the insertion hole of the rotor core while suppressing the surface of the rod-shaped hard magnetic material from being scratched.

It is a block diagram which shows the rotary electric machine which has the rotary electric machine rotor manufactured by the manufacturing method which concerns on 1st Embodiment of this invention. (A) is a perspective view showing a rotor. (B) is a cross-sectional view showing the rotor in an axial cross section along the rotation axis. It is a top view which shows a core plate. It is explanatory drawing which shows a lamination process. It is a sectional view showing a pallet and a rotor core with an insertion jig in an insertion process, and shows a state before inserting a hard magnetic material into an insertion hole of a rotor core. It is sectional drawing which shows the pallet and rotor core with an insertion jig in an insertion process, and shows the state which has inserted the hard magnetic material into the insertion hole of a rotor core. It is a perspective view which shows an insertion jig. 5A is a cross-sectional view taken along the line AA of FIG. 5, and FIG. 6B is a plan view showing a shutter as an opening/closing member in the insertion jig. 5A is a sectional view taken along line BB of FIG. 5, and FIG. 6B is a sectional view of the insertion jig taken along line CC of FIG. It is explanatory drawing which shows a fixing process. It is explanatory drawing of the 1st step of the insertion process which concerns on 2nd Embodiment. It is explanatory drawing of the 2nd step of the insertion process which concerns on 2nd Embodiment. It is explanatory drawing of the 3rd step of the insertion process which concerns on 2nd Embodiment. It is explanatory drawing of the 4th step of the insertion process which concerns on 2nd Embodiment.

[First Embodiment]
A first embodiment of the present invention will be described with reference to FIGS. Note that the embodiments described below are shown as preferred specific examples for carrying out the present invention, and some parts specifically exemplify various technically preferable technical matters. The technical scope of the present invention is not limited to this specific embodiment.

(Structure of rotating electric machine)
FIG. 1 is a configuration diagram showing a rotary electric machine having a rotary electric machine rotor (hereinafter, simply referred to as “rotor”) manufactured by a manufacturing method according to a first embodiment of the present invention.

The rotary electric machine 100 includes a stator 1 and a rotor 2. The stator 1 is non-rotatably fixed to a housing (not shown). The rotor 10 has a shaft 10 inserted through the center thereof and rotates integrally with the shaft 10. The rotary electric machine 100 is mounted, for example, in an electric vehicle or a so-called hybrid vehicle as an electric motor that generates a driving force, a generator that converts the rotational force of the shaft 10 into electric energy, or a motor generator that has both functions. It

The stator 1 includes a stator core 11 and a plurality of coils 12. The stator core 11 integrally includes a cylindrical base portion 111, a plurality of teeth 112 that protrude radially inward from the base portion 111, and a plurality of fixed portions 113 that protrude radially outward from the base portion 111. Have In the illustrated example of FIG. 1, the stator core 11 has 15 teeth 112, and the coil 12 is wound around each of the teeth 112. The fixed portion 113 is formed with a bolt insertion hole 113a through which a bolt for fixing the stator core 11 to the housing is inserted.

FIG. 2A is a perspective view showing the rotor 2. FIG. 2B is a cross-sectional view showing the rotor 2 in an axial cross section along the rotation axis O. The rotor 2 has a rotor core 21 and a plurality of magnets 22 held by the rotor core 21. The rotor core 21 is configured by stacking a plurality of core plates 3 in a stacking direction parallel to the rotation axis O. In the present embodiment, the rotor core 21 is composed of 20 core plates 3, but the number of core plates 3 can be appropriately changed according to the required thickness of the rotor core 21.

In the rotor core 21, a central hole 210 through which the shaft 10 is inserted, a plurality of insertion holes 211 that respectively accommodate a plurality of magnets 22, and a plurality of cooling holes 212 for circulating a cooling liquid that cools the magnets 22. Are formed. The center hole 210, the plurality of insertion holes 211, and the plurality of cooling holes 212 penetrate the rotor core 21 in the axial direction (the stacking direction of the plurality of core plates 3). In the present embodiment, the insertion hole 211 and the cooling hole 212 extend in the axial direction parallel to the rotation axis O, but the insertion hole 211 and the cooling hole 212 are inclined with respect to the rotation axis O. It may extend in the stacking direction of the plurality of core plates 3. In the present embodiment, the rotor 2 has 20 magnets 22, and the rotor core 21 also has 20 insertion holes 211 formed therein. A plurality of magnets 22 may be housed in one insertion hole 211.

Further, the rotor core 21 has a pair of protrusions 21 a that are fitted into the pair of key grooves 10 a (shown in FIG. 1) of the shaft 10. The relative rotation of the shaft 10 with respect to the rotor core 21 is restricted by fitting the protrusion 21a into the key groove 10a.

FIG. 3 is a plan view showing one core plate 3. The core plate 3 is formed by pressing an electromagnetic steel plate. The core plate 3 is formed with a center hole 30, a plurality of through holes 31 for inserting a magnet, and a plurality of through holes 32 for circulating a cooling liquid. The core plate 3 has a pair of tongue pieces 3a. The protrusion 21 a of the rotor core 21 is formed by the tongue pieces 3 a of the plurality of core plates 3 that are stacked.

The through hole 31 for inserting the magnet is formed in an elongated hole shape, and the major axis direction thereof is inclined with respect to the radial direction and the circumferential direction of the core plate 3. More specifically, ten through holes 31 for inserting magnets, which are inclined by a predetermined angle to one side at an angle of less than 90° with respect to the radial direction of the core plate 3, and the core plate 3 has a major axis direction. 10 through holes 31 for inserting magnets, which are inclined at a predetermined angle to the other side at an angle of less than 90° with respect to the radial direction, are alternately formed along the circumferential direction of the core plate 3. The through hole 32 for circulating the cooling liquid is formed inside the core plate 3 in the radial direction with respect to the through holes 31 for inserting the plurality of magnets.

By stacking the plurality of core plates 3, the central holes 30 of the respective core plates 3 communicate with each other to form the central holes 210, and the through holes 31 for inserting the plurality of magnets of the respective core plates 3 are stacked in the stacking direction. To form a plurality of insertion holes 211, and a plurality of through holes 32 for circulating the cooling liquid of each core plate 3 communicate in the stacking direction to form a plurality of cooling holes 212. In addition, when it is not necessary to cool the magnet 22 with the cooling liquid, the through hole 32 for circulating the cooling liquid may not be provided in the core plate 3.

The magnet 22 is a quadrangular prism having a rectangular cross section orthogonal to the longitudinal direction. The magnet 22 is fixed to the rotor core 21 by the resin 23 with which the insertion hole 211 is filled. The end face in the longitudinal direction of the magnet 22 is covered with the resin 23. The magnet 22 is obtained by magnetizing a rod-shaped hard magnetic material obtained by sintering powder such as ferrite or neodymium, and is not magnetized before being housed in the insertion hole 211 and is fixed to the rotor core 21. After being magnetized.

(Method of manufacturing rotor)
Next, a manufacturing method of the rotor 2 and a manufacturing apparatus for manufacturing the rotor 2 by this manufacturing method will be described. The manufacturing method of the rotor 2 includes a molding step of molding a plurality of core plates 3 each having a plurality of through holes 31 formed therein, a stacking step of stacking a plurality of core plates 3 to form a rotor core 21, and a rotor core. 21, a step of inserting a rod-shaped hard magnetic material to be the magnet 22 into each of the plurality of insertion holes 211, a fixing step of fixing the hard magnetic material in the insertion hole 211, and magnetizing the hard magnetic material to magnetize the magnet. And a magnetizing step of 22.

In the forming step, a thin electromagnetic steel plate is pressed to form the core plate 3. In the stacking step, a plurality of core plates 3 are stacked in the thickness direction and stacked.

FIG. 4 is an explanatory view showing the stacking process. The stacking of the core plates 3 is performed by sequentially stacking a plurality of core plates 3 on the pallet 4 in the vertical direction. 4, the lower side of the drawing corresponds to the lower side in the vertical direction, and the upper side of the drawing corresponds to the upper side in the vertical direction. Hereinafter, "upper" and "lower" mean the upper and lower sides in the vertical direction.

The pallet 4 includes a base plate 41, a lower plate 42 arranged on the upper side of the base plate 41, an upper plate 43 arranged on the upper side of the lower plate 42, and a plurality of hard magnetic materials abutted against each other in an inserting step described later. Abutting pins 44, a bottomed cylindrical tubular body 45 arranged on the base plate 41, a plurality of fixing pins 46 for fixing the tubular body 45 to the base plate 41, and a locking pin in the fixing step. It has a plurality of positioning pins 47 for positioning a plate (described later). The tubular body 45 has a cylindrical tubular portion 451 and a disc-shaped bottom portion 452, and the lower end portion of the tubular portion 451 is inserted into the central portions of the lower plate 42 and the upper plate 43 to contact the base plate 41. Touching. The bottom portion 452 closes the upper end portion of the tubular portion 451. The plurality of positioning pins 47 project upward from the upper surface 452a of the bottom portion 452.

The abutting pin 44 has a large-diameter portion 441 inserted into an insertion hole 430 formed in the upper plate 43 and a small-diameter portion 442 protruding above the upper surface 43a of the upper plate 43. It is prevented from coming off from the insertion hole 430. The plurality of butting pins 44 are provided corresponding to each of the plurality of insertion holes 211, and the small diameter portions 442 are arranged so as to project into the insertion holes 211.

The plurality of core plates 3 are stacked on the upper plate 43 so that the tubular body 45 is inserted into the center hole 30 to form the rotor core 21. In addition, the core plate 3 is a plurality of sheets (five sheets in the illustrated example of FIG. 4) as one block, and the core plates 3 are collectively stacked for each block. The core plates 3 of each block are connected to each other by caulking (for example, dowel caulking). However, the core plates 3 may be laminated one by one. The pallet 4 on which the rotor core 21 formed by stacking the core plates 3 is placed is conveyed to an assembling machine that performs an inserting step. Next, this insertion step will be described with reference to FIGS.

5 and 6 are sectional views showing the pallet 4 and the rotor core 21 in the inserting step together with the inserting jig 5 which is a part of the assembling machine. 5 shows a state before the hard magnetic material 20 is inserted into the insertion hole 211 of the rotor core 21, and FIG. 6 shows a state where the hard magnetic material 20 is inserted into the insertion hole 211 of the rotor core 21. FIG. 7 is a perspective view showing the insertion jig 5. 8A is a cross-sectional view taken along the line AA of FIG. 5, and FIG. 8B is a plan view showing the shutter 54 as the opening/closing member in the insertion jig 5. 9A is a sectional view taken along line BB of FIG. 5, and FIG. 9B is a sectional view of the insertion jig 5 taken along line CC of FIG. 9A. 5 and 6, the upper side of the drawings corresponds to the upper side in the vertical direction, and the lower side of the drawings corresponds to the lower side in the vertical direction.

The pallet 4 is conveyed by a roller conveyor 40 having a plurality of rollers 400 to an assembling machine that performs an inserting step. The roller conveyor 40 moves in the horizontal direction due to the rolling of the rollers 400, and the horizontal end surface 41a of the base plate 41 abuts against a stopper 401 that can move back and forth between adjacent rollers 400 in a predetermined position. Stop at. After being stopped at this predetermined position, the pallet 4 is lifted upward toward the insertion jig 5 by the plurality of lifters 402.

The insertion jig 5 has a disc-shaped holding member 51 having holding holes 510 for holding the plurality of hard magnetic materials 20, and an outer shell member 52 arranged so as to surround the outer peripheral side of the holding member 51. Main components are a rectangular base 53 arranged below the outer shell member 52, a shutter 54 arranged below the base 53 and the holding member 51, and a support shaft 55 fixed to the shutter 54. Have as. The outer shell member 52 and the base 53 are fastened with a plurality of bolts 561, and the holding member 51 is fitted in the outer shell member 52.

An annular gap 50 is formed between the holding member 51 and the outer shell member 52. The holding member 51 is formed with the same number of holding holes 510 as the insertion holes 211 of the rotor core 21, and a plurality of communication holes 511 for communicating the respective holding holes 510 with the voids 50. In the present embodiment, two communication holes 511 are formed for one holding hole 510. These communication holes 511 are opened on the outer inner surface 510a of the inner surface of the holding hole 510, which is on the outer side in the radial direction of the holding member 51. The outer inner surface 510a is a mirror-finished flat surface and faces the inner inner surface 510b, which is the radially inner side of the holding member 51, in parallel. The distance between the outer inner surface 510a and the inner inner surface 510b is formed to be slightly larger than the thickness of the hard magnetic material 20.

The communication hole 511 extends in a direction perpendicular to the outer inner surface 510a. In the present embodiment, like the through holes 31 in the core plate 3 described above, ten holding holes whose major axis direction is inclined to one side by a predetermined angle at an angle of less than 90° with respect to the radial direction of the holding member 51. 510 and ten holding holes 510 whose major axis direction is inclined at a predetermined angle to the other side at an angle of less than 90° with respect to the radial direction of the holding member 51 are alternately formed along the circumferential direction. Therefore, the two communication holes 511 extending from the outer inner surface 510a of the pair of holding holes 510 adjacent to each other in the circumferential direction of the holding member 51 communicate with each other.

The holding hole 510 is formed such that the width thereof widens in a part of the upper side opening to the upper surface 51 a of the holding member 51. This facilitates insertion of the hard magnetic material 20 into the holding hole 510 from the upper surface 51a side. Although the hard magnetic material 20 is inserted into each of the plurality of holding holes 510 in the holding member 51, in FIGS. 5 and 6, the two holding holes 510 and the two holding holes 510 are inserted. Only the two hard magnetic materials 20 thus formed are shown. The hard magnetic material 20 is rod-shaped and has a rectangular cross section perpendicular to the longitudinal direction.

An air joint 57, to which one end of a pneumatic pipe 571 is connected, is attached to the outer shell member 52. In the present embodiment, four air joints 57 are attached to the outer circumference of the outer shell member 52 at equal intervals in the circumferential direction. The outer shell member 52 is formed with a plurality of (four) through holes 520 communicating with the annular space 50 and extending in the radial direction, and four air joints 57 are provided on the outer peripheral side of each of the through holes 520. It is fixed to the end of. The other end of the pneumatic pipe 571 is connected to a vacuum pump (not shown), and air is sucked out from the gap 50 by the operation of this vacuum pump. O-rings 581 to 583 prevent the air from flowing into the gap 50 between the holding member 51 and the outer shell member 52 and the base 53, and the gap between the outer shell member 52 and the base 53.

The shutter 54 has a disk shape that is rotatable with respect to the holding member 51, and an operation member 59 is attached to one location of the outer edge portion. The operation member 59 has a fixing portion 591 arranged in the notch 500 formed in the holding member 51 and the base 53 and fixed to the shutter 54, and a rotor 592 attached to the upper side of the fixing portion 591. There is. The shutter 54 rotates within a predetermined angle range with respect to the holding member 51 when the rotor 592 of the operation member 59 is operated by an actuator (not shown) such as an air cylinder.

The shutter 54 has a plurality of openings 540 having a common shape, size, and arrangement with the plurality of holding holes 510 of the holding member 51 when viewed in the axial direction along the vertical direction, and a bolt hole 541 provided at the center. A pair of arc holes 542 into which the pair of positioning pins 47 are fitted are formed so as to penetrate in the thickness direction.

Further, the support shaft 55 is fixed to the shutter 54 by a bolt 563 which is inserted through the bolt hole 541. The support shaft 55 is inserted into a cylindrical boss portion 512 provided at the center of the holding member 51, and is prevented from coming off by a snap ring 564. A bush 565 for smoothing the rotation of the shutter 54 is arranged between the outer peripheral surface of the support shaft 55 and the inner peripheral surface of the boss portion 512. The shutter 54 rotates integrally with the support shaft 55 around the central axis of the support shaft 55.

In FIG. 8A, a part of the shutter 54 is shown by a broken line, and the holding hole 510 is closed by the shutter 54. In this state, the inclination direction of the holding holes 510 and the inclination direction of the openings 540 of the shutters 54 corresponding to the respective holding holes 510 are opposite to each other, and the hard magnetic material 20 housed in the holding holes 510 does not fall off. Is temporarily held. When the shutter 54 is rotated by a predetermined angle from this state, the holding hole 510 and the opening 540 are brought into an open state in which the tilt direction of the holding hole 510 and the tilt direction of the opening 540 coincide with each other, and the hard magnetic material 20 can pass through the holding hole 510 and the opening 540. In the present embodiment, this predetermined angle is 18° (=360°/20 (the number of holding holes 510)).

In the insertion step, as shown in FIG. 5, the shutter 54 is closed and the hard magnetic material 20 is temporarily held in all the holding holes 510 of the holding member 51, and the insertion jig 5 and the rotor core 21 are axially (up and down). ) Side by side. Then, the hard magnetic material 20 is attracted toward the radially outer side of the rotor core 21. Specifically, as shown in FIG. 6, while the hard magnetic material 20 is pneumatically suctioned to the outer inner surface 510a of the holding hole 510, the hard magnetic material 20 is axially pressed by the pressing member 6 to be inserted into the insertion hole 211. insert. Pneumatic suction of the hard magnetic material 20 is performed by setting a negative pressure (atmospheric pressure lower than atmospheric pressure) in the gap 50 and the plurality of communication holes 511 by the operation of the vacuum pump. The shutter 54 is opened after the negative pressure is applied to the void 50 and the plurality of communication holes 511.

When the hard magnetic material 20 is pressed by the pressing member 6, the side surface 20a of the hard magnetic material 20 facing the outer inner surface 510a is pressed against the outer inner surface 510a to make surface contact, and a friction force is generated between the side surface 20a and the outer inner surface 510a. Occurs. Due to this frictional force, even when the shutter 54 is in the open state, the hard magnetic material 20 does not drop and moves down together with the pressing member 6. The pressing member 6 has a disk-shaped base portion 61 and a plurality of leg portions 62 extending downward from the base portion 61, and moves forward and backward in the vertical direction by a linear actuator (not shown). As a result, the impact when the hard magnetic material 20 contacts the small diameter portion 442 of the butting pin 44 is mitigated, and it is possible to prevent the hard magnetic material 20 from cracking or chipping.

The lower end of the leg portion 62 of the pressing member 6 contacts the upper end surface 20b of the hard magnetic material 20 to press the hard magnetic material 20 downward. Further, the pressing member 6 is retracted above the insertion jig 5 after the entire longitudinal direction of the hard magnetic material 20 is inserted into the insertion hole 211. The pressing member 6 has the same number of legs 62 as the hard magnetic material 20, but in FIG. 6, two legs 62 are shown. The rotor core 21 in which the hard magnetic material 20 is inserted into the insertion hole 211 is transferred together with the pallet 4 and sent to the next fixed step.

FIG. 10 is an explanatory view showing the fixing step. In the fixing step, the cull plate 81 is arranged on the rotor core 21, and the upper die 82 is arranged above the cull plate 81 to fix the hard magnetic material 20 in the insertion hole 211 with a resin 23 ( 2(b)) is injected into the insertion hole 211. When the resin 23 is injected into the insertion hole 211, the base plate 41 mounted on the mounting table 84 is fixed by the clamper 85.

The upper mold 82 is formed with an insertion hole 820 into which a cylindrical resin base material 80 made of a thermosetting resin is inserted. A filling pot 810 for introducing the resin base material 80 into the insertion hole 211 of the rotor core 21 is formed in the cull plate 81. The cull plate 81 has a fitting hole 811 into which the positioning pin 47 is fitted, and the positioning pin 47 is fitted into the fitting hole 811 to be positioned.

The resin base material 80 is pressed by the plunger 83 and is introduced into the gap between the inner surface of the insertion hole 211 and the hard magnetic material 20 through the filling pot 810 while being melted by heat. Then, when the temperature decreases, the resin solidifies to become a solid resin 23, and the hard magnetic material 20 is fixed in the insertion hole 211. Cull, which is a cured product of unnecessary resin, remains in the filling pot 810. This cull is removed from the rotor core 21 together with the cull plate 81.

After that, in the magnetizing step, a strong magnetic field is applied to the hard magnetic material 20, and the hard magnetic material 20 is magnetized to become the magnet 22, whereby the rotor 2 is completed. The rotor 2 is combined with the stator 1 to form the rotary electric machine 100.

(Operation and effect of the first embodiment)
According to the first embodiment described above, in the insertion step, the side surface 20a of the hard magnetic material 20 is attracted to the outer inner surface 510a of the holding hole 510 to make surface contact, and the hard magnetic material 20 drops due to this frictional force. Without moving down with the pressing member 6. As a result, the hard magnetic material 20 can be inserted into the insertion hole 211 of the rotor core 21 while suppressing the surface of the hard magnetic material 20 from being scratched. Further, since the plurality of hard magnetic materials 20 are attracted toward the outer side of the rotor core 21 in the radial direction, the respective hard magnetic materials 20 are arranged on the outer side in the insertion hole 211 of the rotor core 21 in the radial direction, and are located at the radial positions. The variation is suppressed, and the distance between the magnet 22 magnetized by the hard magnetic material 20 and the tooth 112 of the stator core 11 is shortened. As a result, the torque generated when the rotary electric machine 100 functions as an electric motor becomes larger than that when the hard magnetic material 20 (magnet 22) is arranged radially inward in the insertion hole 211, for example. When the rotating electric machine 100 functions as a generator, the generated electric power becomes large.

[Second Embodiment]
Next, a second embodiment of the present invention will be described with reference to FIGS. 11 to 14. In the present embodiment, a plurality of insertion jigs 5A to 5C are used in order to shorten the process work time (tact time) in the insertion process. Hereinafter, these insertion jigs 5A to 5C will be referred to as a first insertion jig 5A, a second insertion jig 5B, and a third insertion jig 5C. The first and second insertion jigs 5A and 5B have the same structure as the insertion jig 5 described with reference to FIGS. 5 to 9. The third insertion jig 5C has the same structure and function as the insertion jig 5 except that it does not have the shutter 54. 11 to 14, members and the like common to those described in the first embodiment are denoted by the same reference numerals as those used in the first embodiment, and duplicate description will be omitted.

The first and second insertion jigs 5B and 5C are provided between a forward moving position that is vertically above the rotor core 21 and a backward moving position that is horizontally separated from the forward moving position by a linear motion mechanism such as a ball screw. It is possible to move forward and backward. 11 and 12 show a state in which the first insertion jig 5A is in the forward movement position and the second insertion jig 5B is in the backward movement position. Further, in FIGS. 11 and 12, the first insertion jig 5A when moved to the retracted position is shown by a broken line. 13 and 14 show a state in which both the first and second insertion jigs 5B and 5C are in their respective retracted positions.

The third insertion jig 5C is arranged between the forward positions of the first and second insertion jigs 5B and 5C and the rotor core 21 conveyed by the roller conveyor 40, and is fixed at this position. When the first insertion jig 5A moves to the forward position, the plurality of holding holes 510 of the first insertion jig 5A and the plurality of holding holes 510 of the third insertion jig 5C are aligned in the vertical direction, When the second insertion jig 5B moves to the forward position, the plurality of holding holes 510 of the second insertion jig 5B and the plurality of holding holes 510 of the third insertion jig 5C are aligned in the vertical direction.

The hard magnetic material 20 is inserted into the plurality of holding holes 510 of the first and second insertion jigs 5B and 5C at the retracted position, and is temporarily held. The plurality of hard magnetic materials 20 are inserted one by one into the corresponding holding holes 510 by an automatic machine such as a robot. 11 to 14, a part of the robot hand 9 holding the hard magnetic material 20 is shown as an example. When the first and second insertion jigs 5B and 5C are in the retracted position, the shutter 54 is closed and the hard magnetic material 20 is not sucked.

In the present embodiment, the first operation mode of inserting the plurality of hard magnetic materials 20 temporarily held by the first insertion jig 5A into the plurality of insertion holes 211 of the rotor core 21, and the second insertion jig 5B. The second operation mode of inserting the plurality of hard magnetic materials 20 temporarily held in the plurality of insertion holes 211 of the rotor core 21 is alternately repeated.

In the first operation mode, the step of inserting the plurality of hard magnetic materials 20 temporarily held by the first insertion jig 5A that has moved to the forward position into the plurality of insertion holes 211 of the rotor core 21 and the step of moving to the retracted position. The steps of arranging the plurality of hard magnetic materials 20 in the plurality of holding holes 510 of the second insertion jig 5B are performed in parallel. In the first operation mode, the plurality of hard magnetic materials 20 temporarily held by the first insertion jig 5A are inserted into the plurality of insertion holes 211 of the rotor core 21 via the third insertion jig 5C, and After the plurality of hard magnetic materials 20 are moved from the first insertion jig 5A to the third insertion jig 5C, the whole hard magnetic materials 20 in the longitudinal direction are inserted into the plurality of insertion holes 211 of the rotor core 21. The first insertion jig 5A moves to the retracted position before moving.

Similarly, in the second operation mode, the step of inserting the plurality of hard magnetic materials 20 temporarily held by the second insertion jig 5B moved to the forward position into the plurality of insertion holes 211 of the rotor core 21, and the retracted position. The steps of arranging the plurality of hard magnetic materials 20 in the plurality of holding holes 510 of the first insertion jig 5A moved to are performed in parallel. Further, in the second operation mode, the plurality of hard magnetic materials 20 temporarily held by the second insertion jig 5B are inserted into the plurality of insertion holes 211 of the rotor core 21 via the third insertion jig 5C, and After the plurality of hard magnetic materials 20 are moved from the second insertion jig 5B to the third insertion jig 5C, the entire longitudinal direction of the plurality of hard magnetic materials 20 is inserted into the plurality of insertion holes 211 of the rotor core 21. The second insertion jig 5B moves to the retracted position before moving.

11 to 14 show the first to fourth steps of the first operation mode, respectively. In the first step shown in FIG. 11, the first insertion jig 5A in which the hard magnetic materials 20 are arranged in all the holding holes 510 is moved to the forward position, and the hard magnetic materials 20 are moved outside the holding holes 510. After the air pressure is suctioned to the inner surface 510a, the shutter 54 is opened. In the second step shown in FIG. 12, a plurality of hard magnetic materials 20 are pressed by the pressing member 6 and the entire hard magnetic materials 20 in the longitudinal direction are pushed downward from the first insertion jig 5A. At this time, the third insertion jig 5C pneumatically sucks each hard magnetic material 20 to the outer inner surface 510a of the holding hole 510.

In the third step shown in FIG. 13, the pressing member 6 once rises and the first insertion jig 5A moves to the retracted position. The hard magnetic material 20 is inserted into each of the insertion holes 211 of the first insertion jig 5A after being moved to the retracted position. In the fourth step shown in FIG. 14, the pressing member 6 descends again, and the plurality of hard magnetic materials 20 temporarily held by the third insertion jig 5C are inserted into the plurality of insertion holes 211 of the rotor core 21. During this time, the hard magnetic material 20 is sequentially inserted into the holding holes 510 of the first insertion jig 5A. When the insertion of the plurality of hard magnetic materials 20 into the plurality of insertion holes 211 of the rotor core 21 is completed, the pressing member 6 moves up to the initial position shown in FIG. 11, the lifter 402 moves down, and the pallet 4 is moved by the roller conveyor 40 to the rotor core 40. 21 is sent to the next process (fixing process).

The hard magnetic material 20 is sequentially inserted into the holding holes 510 of the second insertion jig 5B during the first to fourth steps. The step of inserting the plurality of hard magnetic materials 20 into the plurality of holding holes 510 of the second insertion jig 5B is completed during the execution of the first to fourth steps in the first operation mode. In the second operation mode, the rotor core 21 different from the rotor core 21 in which the plurality of hard magnetic materials 20 are inserted in the first operation mode is inserted into the second insertion jig by the same procedure as in the first operation mode. The plurality of hard magnetic materials 20 temporarily held by 5B are inserted into the plurality of insertion holes 211, and the hard magnetic material 20 is inserted into each of the plurality of holding holes 510 of the first insertion jig 5A therebetween.

According to the present embodiment described above, the work of inserting the hard magnetic material 20 into each of the plurality of holding holes 510, which takes a relatively long time, can be performed in parallel with the other work. Work time is reduced.

(Appendix)
The present invention has been described above based on the first and second embodiments, but these embodiments do not limit the invention according to the claims. Further, it should be noted that not all combinations of the features described in the embodiments are essential to the means for solving the problems of the invention.

Further, the present invention can be appropriately modified and implemented without departing from the spirit of the present invention. For example, in the second embodiment described above, the case of using three insertion jigs including the third insertion jig 5C has been described, but the present invention is not limited to this, and the first and second insertion jigs 5B and 5C are used. You may perform an insertion process using only. In this case, the plurality of hard magnetic materials 20 are directly inserted into the rotor core 21 from the first insertion jig 5A, and the hard magnetic materials 20 are inserted into the plurality of holding holes 510 of the second insertion jig 5B therebetween. It Further, the plurality of hard magnetic materials 20 are directly inserted into the rotor core 21 from the second insertion jig 5B, and the hard magnetic materials 20 are inserted into the plurality of holding holes 510 of the first insertion jig 5A therebetween. ..

Further, in the above-described embodiment, the case where the leg 62 of the pressing member 6 is not provided with the suction passage for sucking air has been described. However, as in the case of the above-mentioned Patent Document 1, the leg 62 is described. A suction passage may be provided at the upper end to adsorb the upper end surface 20b of the hard magnetic material 20.

100... Rotating electric machine 2... Rotor (rotor for rotating electric machine)
20... Hard magnetic material 21... Rotor core 211... Insertion holes 5, 5A, 5B, 5C... Insertion jig 510... Holding hole

Claims (4)

For a rotating electric machine including a plurality of hard magnetic materials formed in a rod shape and a rotor core having a plurality of insertion holes formed along the axial direction, and the plurality of hard magnetic materials being inserted into the plurality of insertion holes, respectively. A method of manufacturing a rotor,
An insertion jig having a plurality of holding holes for temporarily holding the plurality of hard magnetic materials is arranged side by side in the axial direction with the rotor core, and the plurality of hard magnetic materials are vacant on the inner surfaces of the plurality of holding holes. While pressurizing and pressing, press in the axial direction to insert into the plurality of insertion holes,
Manufacturing method of rotor for rotating electric machine. Attracting the plurality of hard magnetic materials outward in the radial direction of the rotor core,
A method of manufacturing a rotor for a rotary electric machine according to claim 1. Using a plurality of the insertion jigs including the first and second insertion jigs,
The first and second insertion jigs are capable of moving back and forth between a forward position that is above the rotor core and a backward position that is horizontally separated from the forward position.
Inserting the plurality of hard magnetic materials temporarily held by the first insertion jig moved to the advance position into the plurality of insertion holes of the rotor core, and the second insertion moved to the retracted position. A first operation mode in which the steps of arranging the plurality of hard magnetic materials in the plurality of holding holes of the jig are performed in parallel;
Inserting the plurality of hard magnetic materials temporarily held by the second insertion jig moved to the advance position into the plurality of insertion holes of the rotor core, and the first insertion moved to the retracted position. A second operation mode in which the steps of arranging the plurality of hard magnetic materials in the plurality of holding holes of the jig are performed in parallel;
Alternately and repeatedly,
A method for manufacturing a rotor for a rotary electric machine according to claim 1. The plurality of insertion jigs include a third insertion jig arranged between the forward position of the first and second insertion jigs and the rotor core,
In the first operation mode, the plurality of hard magnetic materials temporarily held by the first insertion jig are inserted into the plurality of insertion holes via the third insertion jig, and After the plurality of hard magnetic materials move from the insertion jig to the third insertion jig, the first insertion jig moves to the retracted position,
In the second operation mode, the plurality of hard magnetic materials temporarily held by the second insertion jig are inserted into the plurality of insertion holes via the third insertion jig, and After the plurality of hard magnetic materials move from the insertion jig to the third insertion jig, the second insertion jig moves to the retracted position.
The method for manufacturing the rotor for a rotating electric machine according to claim 3.

Images