JP2023119467A - Method and device for manufacturing core unit of rotary electric machine - Google Patents

Abstract

To provide a method for manufacturing a core unit capable of executing separation from a jig without adversely affecting a thin plate forming an iron core body of the core unit by appropriately applying force to the core unit when separating the jig from the core unit in a core unit manufacturing process.SOLUTION: When a jig 20 is separated from a core unit 10 obtained through a filling process in a separation process, a push-up unit 41 of a separation mechanism 40 in contact with the core unit 10 through the jig 20 is brought into contact with a position in the vicinity of a non-circumferential section of an inner peripheral section and directly opposing it in an iron core body 11 of the core unit 10, so that force can be efficiently applied from the push-up unit 41. As a result, even if the non-circumferential section of the iron core body 11 receives frictional resistance to a post section 22, it is less likely to produce stress based on deviation of force applied to the iron core body 11 in each section of the iron core body 11, so that adverse effect such as deformation to a thin plate that forms the core main part 11 can be suppressed, and the core unit 10 can be satisfactorily separated from the jig 20.SELECTED DRAWING: Figure 4

Description

The present invention relates to a manufacturing method and manufacturing apparatus for a core portion in a rotor or stator of a rotating electric machine.

2. Description of the Related Art In stators or rotors of rotary electric machines such as electric motors and generators, laminated iron cores are generally used as cores in which coils and permanent magnets are arranged.
Conventionally, various ideas have been made in arranging coils and permanent magnets in the core of such a laminated core.

For example, in the case of rotor cores, particularly in the case of rotor cores of interior permanent magnet (IPM) motors, a structure in which magnets are inserted and fixed in magnet insertion holes of laminated cores has been adopted. In such a structure, when the permanent magnet is fixed, after the permanent magnet is inserted into the magnet insertion hole, the gap in the magnet insertion hole excluding the portion where the permanent magnet exists is filled with a resin such as a thermosetting resin so that the gap is fixed. By filling the , the permanent magnet was fixed.

Conventionally, a jig is placed under the laminated core so that the process of inserting the permanent magnet into the magnet insertion hole of the laminated core and filling the laminated core with resin can be performed without problems. has been adopted.
Japanese Unexamined Patent Application Publication No. 2016-134967 and Japanese Unexamined Patent Application Publication No. 2019-140841 disclose examples of using a jig in manufacturing the core of such a conventional rotary electric machine.

JP 2016-134967 A JP 2019-140841 A

The core of a conventional rotating electric machine is manufactured by the method shown in each of the above-mentioned patent documents. After holding the magnet inserted in the magnet insertion hole, the resin is efficiently filled into the magnet insertion hole, so that the laminated core and the magnet can be reliably integrated.

In the manufacture of such a conventional core, the jig used generally has a post portion that is used for positioning by being inserted through a central hole for mounting the shaft of the laminated core on a base portion on which the laminated core can be placed. It has an upright structure.

After the magnet insertion holes in the laminated core are filled with resin and the magnets are fixed, the jig is separated from the laminated core. must be completely removed from the holes in the laminated core.

The post portion of the jig is formed with dimensional accuracy such that the clearance between the post portion and the center hole of the laminated core is minimized for the purpose of positioning the metal sheets forming the laminated core. In addition, one or a plurality of protrusions for preventing rotation of the shaft are provided on the inner periphery facing the hole of the laminated core because the shaft is attached to the hole in the center of the laminated core. The post portion is provided with a concave portion corresponding to the convex portion so as to be engaged with the convex portion.

Therefore, when the post is pulled out from the hole in the center of the laminated core to separate the jig from the laminated core, the post tends to come into contact with the inner periphery and protrusions of the laminated core, which increases the frictional resistance. , the force applied for separation increases. In addition, if a force is applied directly to the laminated core for movement related to separation from the jig, the laminated core is usually in a state of being in contact with each of the multiple locations and applying force, and uneven force in the laminated core cannot be avoided. do not have. Due to this bias, force applied to the periphery of the holes in the laminated core, especially to the protrusions that tend to come into contact with the surrounding posts due to their shape protruding toward the posts, and friction with the posts. There is a problem that excessive stress associated with resistance is generated, and there is a possibility that each thin plate forming the laminated core may be adversely affected such as deformation.

On the other hand, as shown in Patent Document 2, a spacer is interposed between the jig (supporting member) and the laminated core, and when the jig and the laminated core are separated, the spacer is placed on the post portion. By displacing in the axial direction and moving the laminated core together with the spacer with respect to the jig so that force is applied to the laminated core via the spacer, the force applied to the laminated core is not biased, and each thin plate forming the laminated core A method has also been proposed to suppress the deformation of the However, it is necessary to interpose a spacer between the jig and the laminated core, and additionally provide a mechanism for moving the spacer together with the laminated core. There was a problem of increased cost.

The present invention has been made to solve the above-mentioned problems, and in separating the core from the jig that supports the core after being filled with resin in the manufacturing process of the core, an appropriate force is applied to the core. It is an object of the present invention to provide a core part manufacturing method and a core part manufacturing apparatus capable of separating a core part from a jig without adversely affecting a thin plate forming an iron core body of the core part by moving the core part.

In the method for manufacturing a core according to the present disclosure, a core body formed by laminating a plurality of thin plates made of a magnetic metal material is supported by a jig, and a plurality of spaces in the core body are filled with a resin. and a method for manufacturing a core portion that forms a part of a rotor or a stator of a rotating electric machine, wherein a filling step of filling a space portion of the core body with a resin; a separation step of separating the core portion and the jig by a predetermined separation mechanism, wherein the jig protrudes in a substantially columnar shape from a base portion on which the core body can be placed and the base portion. The base portion is provided with a plurality of through holes, and the core body is provided with a shaft hole penetrating in the lamination direction of the thin plates in a center portion thereof, and faces the shaft hole. The inner peripheral portion has one or a plurality of non-circumferential portions that serve as detents for the shaft inserted into the shaft hole. The separation mechanism has at least a push-up portion that can be protruded and retracted through the through hole with respect to the base portion of the jig, and in the separation step, the push-up portion of the separation mechanism is attached to the jig. It protrudes relatively to the base portion of the tool, and is in contact with a plurality of points including the contacted portion located on an imaginary straight line passing through the center of the shaft hole and the non-circumferential portion of the core body of the core portion. , one or both of the jig and the core are relatively moved to separate the core and the jig.

As described above, according to the disclosure of the present invention, after the core portion is obtained through the filling step of filling the resin into the space portion of the core body supported by the jig, the jig is separated from the core portion in the separation step. In doing so, the push-up portion of the separation mechanism, which is in contact with the core portion through the base portion of the jig, is positioned on a virtual straight line passing through the center of the shaft hole and the non-circumferential portion of the inner circumference of the iron core body of the core portion. At least contact with the contact portion, and when the core portion moves relative to the jig, the core body of the core portion is efficiently applied from the push-up portion in contact with the non-circumferential portion in the vicinity of the non-circumferential portion. Even if the non-circumferential part of the core body receives frictional resistance between the post part and the non-circumferential part of the core body, stress is generated in each part of the core body due to the uneven force applied to the core body. The core can be stably manufactured, for example, by suppressing adverse effects such as deformation of the thin plate forming the main body of the core, and by separating the core from the jig and sending it to the next process without any problems.

FIG. 3 is an explanatory diagram of a resin material injection state of the core portion manufacturing apparatus to which the core portion manufacturing method according to the first embodiment of the present invention is applied; FIG. 2(a) is a plan view of a jig used in the core portion manufacturing method according to the first embodiment of the present invention, and FIG. 2(b) is a core portion manufacturing method according to the first embodiment of the present invention. FIG. 2C is a bottom view of a core body used in the first embodiment of the present invention, and FIG. 2C is a vertical cross-sectional view of the core body used in the core manufacturing method according to the first embodiment of the present invention in a state of being supported by a jig. FIG. 4 is an explanatory diagram of a state in which the core body is released from clamping by the upper and lower dies of the core portion manufacturing apparatus in the core portion manufacturing method according to the first embodiment of the present invention; FIG. 4(a) is an explanatory view of the state of contact with the iron core body of the push-up portion in the separation step in the core portion manufacturing method according to the first embodiment of the present invention, and FIG. 4(b) is the first embodiment of the present invention. FIG. 10 is an explanatory diagram of the separation progress state of the core portion from the jig in the separation step in the core portion manufacturing method according to the embodiment; FIG. 10 is an explanatory view showing a completion state of separation of the core portion from the jig in the separation step in the method for manufacturing the core portion according to the first embodiment of the present invention; FIG. 6(a) is a plan view of the core portion obtained by the core portion manufacturing method according to the first embodiment of the present invention, and FIG. 6(b) is a cross-sectional view taken along line AA of FIG. 6(a). be. FIG. 7(a) is an explanatory diagram of the state before movement of a jig and a lower mold in a separation step in a core portion manufacturing method according to a second embodiment of the present invention, and FIG. 7(b) is a second embodiment of the present invention. Fig. 10 is an explanatory view of a contact state of the push-up portion with the core body in the separation step in the core portion manufacturing method according to the embodiment; FIG. 8(a) is an explanatory view of the separation progress state of the core portion from the jig in the separation step in the core portion manufacturing method according to the second embodiment of the present invention, and FIG. FIG. 10 is an explanatory diagram of a completion state of separation of the core portion from the jig in the separation step in the core portion manufacturing method according to Embodiment 2; FIG. 10 is an explanatory diagram of a molten resin injection state in a filling step in the method for manufacturing the core portion according to the third embodiment of the present invention; FIG. 10 is an explanatory diagram of a state in which the core body is released from clamping by the upper and lower dies of the core portion manufacturing apparatus in the core portion manufacturing method according to the third embodiment of the present invention; FIG. 11(a) is an explanatory view of the state before movement of the push-up portion in the separation step in the core portion manufacturing method according to the third embodiment of the present invention, and FIG. 11(b) is the third embodiment of the present invention. Fig. 10 is an explanatory view of the state of contact with the iron core body of the push-up portion in the separation step in the core portion manufacturing method according to the present invention; FIG. 12(a) is an explanatory diagram of the separation progress state of the core portion from the jig in the separation step in the core portion manufacturing method according to the third embodiment of the present invention, and FIG. FIG. 11 is an explanatory view of a completion state of separation of the core portion from the jig in the separation step in the core portion manufacturing method according to Embodiment 3; FIG. 13(a) is a bottom view of a core body used in the core manufacturing method according to another embodiment of the present invention, and FIG. 13(b) is used in the core manufacturing method according to another embodiment of the present invention. It is a top view of a jig.

(First embodiment of the present invention)
An apparatus for manufacturing a core portion of a rotating electric machine according to a first embodiment of the present invention will be described below with reference to FIGS. 1 to 6. FIG.
In each figure, the method for manufacturing the core portion according to the present embodiment includes a filling step of filling a plurality of spaces in the core body 11 with a resin while the core body 11 is supported by a jig 20, and a resin obtained through this filling step. and a separation step of separating the jig from the core portion 10 thus formed by a predetermined separation mechanism. The core portion 10 is moved relative to the jig 20 while being brought into contact with a plurality of points on the end surface of the core body 11 of the core portion 10 supported by the jig 20, thereby separating the core portion 10 and the jig 20. be.

The core part manufacturing apparatus 1 to which the core part manufacturing method according to the present embodiment is applied fills resin into a plurality of spaces in the core body 11 in a state where the core body 11 having a laminated structure is supported by a jig 20, and rotates. A core part 10 forming a rotor of an electric machine is manufactured. Specifically, the core part manufacturing apparatus 1 is obtained through an upper mold 31 and a lower mold 32 as a filling mechanism for filling resin into the core body 11 supported by the jig 20, and filling the core body 11 with resin. It is configured to include a separating mechanism 40 for separating the jig 20 from the core portion 10 which is formed.

The core portion 10 manufactured by the core portion manufacturing method according to the present embodiment includes a core body 11 formed by laminating a plurality of thin plates 11a made of a magnetic metal material, and a plurality of space portions provided in the core body 11. It is composed of a permanent magnet 12 inserted into each magnet insertion hole 11b and a resin filler 13 filled in each magnet insertion hole 11b (see FIG. 6). The core portion 10 has a known structure as a rotor of a rotary electric machine (motor or generator), and detailed description thereof will be omitted.

The core body 11 is a laminated core formed by laminating a plurality of thin plates 11a made of a magnetic metal material. The thin plate 11a forming the core body 11 is formed by punching a thin plate material made of electromagnetic steel, amorphous alloy, or the like.

The core body 11 is provided with a plurality of magnet insertion holes 11b as spaces into which the permanent magnets 12 can be inserted. The magnet insertion holes 11b are holes that penetrate the core body 11 in the stacking direction of the thin plates 11a, and are provided in a predetermined arrangement along the circular outer periphery of the core body 11 . The position, shape, and number of the magnet insertion holes 11b can be appropriately set according to the use of the rotating electric machine, the required performance, and the like.
In addition, a shaft hole 11c passing through the core body 11 in the direction in which the thin plates 11a are stacked is provided at the center of the core body 11, and the rotating shaft (shaft) of the rotor can be inserted and fixed through the shaft hole 11c. be.

The inner peripheral portion of the core body 11 facing the shaft hole 11c is designed so that the rotating shaft of the rotor inserted through the shaft hole 11c can maintain a fixed state without causing unnecessary rotation with respect to the core body 11. A non-circumferential portion is formed as a stop. Specifically, the noncircumferential portion is a convex portion 11d having two corners and protruding into the shaft hole 11c. In this case, the shaft hole 11c has a hole shape having a circumferential portion with a predetermined diameter and a plurality of non-circumferential portions that are concave with respect to the circle of the circumferential portion.
The core body 11 is supported by the jig 20 during, before, and after the resin filling process by the core manufacturing apparatus 1, and is handled integrally with the jig 20 until it is separated in the separation process.

The permanent magnets 12 are inserted into the respective magnet insertion holes 11b of the iron core body 11 for use in the magnetic field of the rotor. When the permanent magnets 12 are inserted into the magnet insertion holes 11b, gaps are created between the permanent magnets 12 and the core body 11. As shown in FIG. The filler 13 is filled in the remaining portion of the magnet insertion hole 11b except for the permanent magnet 12. As shown in FIG.

The filling material 13 is resin that is injected and filled in a molten state into the magnet insertion hole 11b, more specifically, into the remaining portion of the magnet insertion hole 11b after the permanent magnet 12 is inserted, and then solidifies after filling. The resin constituting the filler 13 is, for example, a thermosetting resin such as an epoxy resin or a thermoplastic resin. A resin material supplied as a resin tablet or powdered resin is melted and then solidified. It is obtained by
The filling material 13 fixes the permanent magnet 12 in the magnet insertion hole 11b and contributes to strengthening the connection between the laminated and adjacent thin plates 11a.

The jig 20 includes a base portion 21 on which the core body 11 can be placed, and a post portion 22 projecting in a substantially columnar shape from the base portion 21 (see FIG. 2(a)).
The base portion 21 is, for example, a rectangular plate-like platform member, and supports the core body 11 from below in a state where the core body 11 is placed and abuts against the lower end surface of the core body 11 . The base portion 21 is provided with a plurality of holes 21a penetrating through the base portion 21 and having an oval hole shape having an arc portion and a parallel straight portion at a predetermined arrangement.

The post portion 22 is formed in a substantially columnar shape and is arranged so as to protrude upward from the substantially central portion of the upper surface of the base portion 21 . The post portion 22 has a substantially columnar shape corresponding to the shape and orientation of the shaft hole 11c of the core body 11, and can be inserted through the shaft hole 11c of the core body 11. As shown in FIG. The post portion 22 is provided with a concave portion 22a corresponding to the convex portion 11d of the inner peripheral portion of the core body 11, and the concave portion 22a can be engaged with the convex portion 11d when the post portion 22 is inserted into the shaft hole 11c. be.

The post portion 22 is inserted through the shaft hole 11c of the core body 11 while the core body 11 is supported by the jig 20. The center c of the post portion 22 is aligned with the center C of the shaft hole 11c, and the position of the recess 22a is adjusted. The positions of the protrusions 11 d of the core body 11 are aligned with each other.

The through-holes 21a of the base portion 21 are arranged so as to be symmetrical about the center c of the post portion 22 which coincides with the center C of the shaft hole 11c. Further, the holes 21a of the base portion 21 are arranged so that at least one of them is positioned on an imaginary straight line L passing through the center c of the post portion 22 and the recess 22a, and are symmetrical about the imaginary straight line L. (see FIG. 2(b)).

An upper mold 31 and a lower mold 32 forming a filling mechanism of the core part manufacturing apparatus 1 sandwich the core body 11 and position it between these upper and lower molds while filling the magnet insertion hole 11b as a space with resin. The resin in the molten state is pressurized in the magnet insertion hole 11b, and the solidification of the resin is advanced.

The upper die 31 and the lower die 32 sandwich and press the core body 11 supported by the jig 20 from both sides in the stacking direction. As a result, a predetermined load is applied to the core body 11 from the height direction, and the magnet insertion hole 11b in the core body 11 can be closed.

The upper mold 31 and the lower mold 32 forming these filling mechanisms can fill the magnet insertion hole 11b as a space in the core body 11 from above with the resin held on the upper mold 31 side as a filling process.

The upper die 31 is positioned above the core body 11 placed on the lower die 32 and sandwiches the core body 11 and the jig 20 together with the lower die 32 . The upper die 31 is, for example, a rectangular plate-shaped die, and is provided with a plurality of accommodation holes 31a capable of accommodating and holding resin. The upper die 31 is arranged to be inserted from above into the housing hole 31 a and has a push-out portion 33 capable of pushing the resin into the magnet insertion hole 11 b of the core body 11 .

The accommodation holes 31 a are provided at positions corresponding to the magnet insertion holes 11 b of the core body 11 when the core body 11 is sandwiched between the upper die 31 and the lower die 32 . A resin material in the form of a resin tablet, powder, or the like is supplied to each accommodation hole 31a.

Further, the upper die 31 has a heater (not shown) capable of heating the resin material contained in each containing hole 31 a as a mechanism for heating and melting the resin material to obtain the molten resin 81 .

The extruding part 33 can extrude the molten resin 81 into the magnet insertion hole 11b of the core body 11. For example, the extruding part 33 is configured as a plurality of plungers that can be vertically moved by being driven by a predetermined driving source. .
Each extruding portion 33 is driven by a corresponding driving source for each extruding portion so as to be vertically movable. can be
The molten resin 81 held in the accommodation hole 31 a is pushed out from the accommodation hole 31 a of the upper mold 31 by the extrusion part 33 in the filling process and reaches each magnet insertion hole 11 b of the core body 11 .

The lower die 32 holds the core body 11 and the jig 20 thereon and supports them while holding the core body 11 and the jig 20 together with the upper die 31 . The lower mold 32 is, for example, a mold formed in a rectangular plate shape, and is fitted with a convex portion or a concave portion provided on the lower surface of the jig 20 as necessary to prevent unnecessary movement of the jig. Alternatively, a convex portion is provided.

The separating mechanism 40 includes a push-up portion 41 that can be retracted through a hole 21a of the base portion 21 with respect to the base portion 21 of the jig 20 placed and supported by the lower mold 32, and a jig. 20, and a jig holding portion 43 that holds the jig 20 and prevents the jig 20 from moving together with the core portion 10. be.

The push-up portion 41 protrudes with respect to the base portion 21 of the jig 20, and the center C of the shaft hole 11c and the convex portion 11d of the inner peripheral portion of the end face of the core body 11 of the core portion 10 supported by the jig 20 are located. The core portion 10 is moved with respect to the jig 20 to separate the core portion 10 and the jig 20 while being in contact with a plurality of locations including the contacted portion 15 located on the imaginary straight line L passing through. Specifically, the push-up portion 41 pushes the end surface of the core body 11 of the core portion 10 to enable the core portion 10 to move relative to the jig 20 in the direction in which the core body 11 is laminated. It is configured as a plurality of plungers that can be moved up and down by being driven by a source.

This push-up portion 41 is placed on and supported by the lower mold 32, and the iron core body 11 of the core portion 10 supported by the jig 20 is positioned in the same manner as the holes 21a in the base portion 21 of the jig 20 are arranged. It is arranged so as to contact a plurality of locations on the end face, which are symmetrical about the center C of the shaft hole 11c on the end face. By symmetrical arrangement about the center of the shaft hole 11c in this way, the force applied to the core body 11 is balanced over the entire end face, and the inclination and displacement of the core body 11 with respect to the jig 20 are less likely to occur. Frictional resistance generated when the core portion 10 is moved with respect to the jig 20 and stress associated therewith can be suppressed.

Each contact surface 41a of the push-up portion 41 to the end surface of the core body 11 of the core portion 10 is a contact surface in contact with the contacted portion 15 located on the imaginary straight line L passing through the center C of the shaft hole 11c and the convex portion 11d. are symmetrical with respect to the imaginary straight line L. Specifically, the shape of each contact surface 41a of the push-up portion 41 is an oval shape having a circular arc portion and a parallel straight portion, like the shape of each hole 21a in the base portion 21 of the jig 20 .

By making the shape of the contact surface 41a of the push-up portion 41 symmetrical, the contacted portion 15 of the core body 11, which the push-up portion 41 contacts, directly faces the convex portion 11d as a non-circumferential portion, and is balanced in the vicinity of the convex portion. By properly arranging and applying the force from the push-up portion 41 to this position, the force acts appropriately and the generation of stress in the core body 11 can be suppressed.

Except for the symmetrical arrangement of the push-up portions 41 and the symmetrical shape of the contact surface 41a, the number and shape of the push-up portions 41 are not particularly limited. As long as it is possible and the core part 10 can be stably supported and moved, it may be set appropriately. For example, the shape of the contact surface of the push-up part is not limited to an elliptical shape with a circular arc part and a parallel straight part. A shape combining a straight line is also possible. The contact surface 41a of the push-up portion 41 of the separation mechanism 40 and the holes 21a in the base portion 21 of the jig 20 through which the push-up portion 41 is passed are the magnet insertion holes 11b in the end surface of the core body 11 of the core portion 10. is placed at a position that does not overlap with the area corresponding to . As a result, the base portion 21 closes the magnet insertion hole 11b in the resin filling process, and resin leakage from the magnet insertion hole 11b to the base portion 21 side can be prevented.

The core part support part 42 supports and moves the core part 10 after being moved by the push-up part 41 and separated from the jig 20, and removes the core part 10 from between the upper and lower molds for transfer to the next step. It is possible.

The jig holding portion 43 holds the jig 20 so as not to move at least until the core portion 10 is separated from the jig 20 when the core portion 10 is moved with respect to the jig 20 by the push-up portion 41 . is prevented from moving upward together with the core portion 10, and after the core portion 10 is separated, the jig 20 is moved while being supported so that it can be taken out from between the upper and lower molds.

Next, the manufacturing process of the core portion based on the core portion manufacturing method according to the present embodiment will be described.
As a premise, it is assumed that the core body 11 in which a plurality of thin plates 11a punched from a thin plate material are laminated in advance by a known manufacturing method has been obtained. The iron core body 11 is placed on the base portion 21 of the jig 20, and the post portion 22 of the jig 20 is inserted into the shaft hole 11c to support the jig 20. After the permanent magnet 12 is inserted into the insertion hole 11b and preheated to an appropriate temperature, it is carried in between the upper and lower dies of the core manufacturing apparatus 1 together with the jig 20 by a predetermined transfer mechanism.

In the upper mold 31 of the core part manufacturing apparatus 1, a resin material as a material of the molten resin 81 is automatically supplied to the accommodation hole 31a of the upper mold 31, and the resin material is heated by the upper mold 31 before injection. It shall be melted by

The core body carried into the core part manufacturing apparatus 1 by the transfer mechanism is arranged between the upper and lower dies by placing the jig 20 supporting the core body 11 on the lower die 32 . there is
On the other hand, in the upper die 31 of the core part manufacturing apparatus 1, the resin material is accommodated and held in each accommodation hole 31a, and the resin material held in each accommodation hole 31a is heated at an appropriate timing and melted in each accommodation hole 31a. and melted resin 81 is obtained.

The upper die 31 is lowered or the lower die 32 is raised with respect to the core body 11 and the jig 20 positioned between the upper die 31 and the lower die 32, and the upper die 31 and the lower die 32 move the core body 11 and the jig 20 together. The state shifts to a state in which the jig 20 is clamped and pressed.
After the magnet insertion holes 11b of the iron core body 11 are isolated from the outside by being closed by being clamped by the upper mold 31 and the lower mold 32, the resin filling process is performed.

In the filling step, the extruding portion 33 inserted into each accommodation hole 31a moves downward to press the molten resin 81 in each accommodation hole 31a of the upper mold 31, thereby pushing the molten resin 81 into the accommodation hole 31a. (see Figure 1). The extruded molten resin 81 is injected and filled into the magnet insertion hole 11 b of the core body 11 .

When the molten resin 81 filled in each magnet insertion hole 11b is solidified and the permanent magnet 12 is fixed to the core body 11 to obtain the core portion 10, the extruded portion 33 is pulled up to return to its original state, and The die 31 is lifted or the lower die 32 is lowered to end the clamping and pressing of the core body 11 by the upper die 31 and the lower die 32 (see FIG. 3), and the separation step is started.

In the separating step, the pushing-up portion 41 of the separating mechanism 40 is moved with respect to the core portion 10 supported by the jig 20 so that the pushing-up portion 41 passes through the hole 21 a of the base portion 21 and is placed on the base portion 21 . The end face of the iron core body 11 of the core portion 10 placed thereon is brought into contact (see FIG. 4(a)). At this time, the push-up portion 41 is in contact with a plurality of locations including the contacted portion 15 positioned on an imaginary straight line L passing through the center C of the shaft hole 11c and the convex portion 11d of the inner peripheral portion of the end face of the core body 11. Become.
Moreover, the jig 20 on the lower die is held by the jig holding portion 43, and the movement of the jig 20 in each direction including the upward direction is restricted.

In this state, the push-up portion 41 is moved upward, and the core portion 10 is pushed from below by the push-up portion 41 to move upward with respect to the jig 20 . As a result, the end face of the core body 11 in the core portion 10 is separated from the base portion 21 of the jig 20, and the post portion 22 of the jig 20 is removed from the shaft hole 11c of the core body 11 (FIG. 4B )reference).

In addition to the movement of the jig 20 being restricted by the jig holding portion 43, the push-up portion 41 moves only upward, contacting and pushing a plurality of symmetrical locations on the end face of the core body 11, When the core portion 10 is moved with respect to the jig 20 , no unnecessary movement other than upward movement occurs in the core portion 10 , and the inner peripheral portion including the convex portion 11 d of the core body 11 is aligned with the post of the jig 20 . The frictional resistance generated in contact with the portion 22 can be minimized, and the core portion 10 can be moved without problems.

In addition, the position (contacted portion 15) on the end surface of the core body 11 where the push-up portion 41 is brought into contact and the pressing force is applied is on the imaginary straight line L passing through the center C of the shaft hole 11c and the convex portion 11d. By being positioned near the portion 11d, excessive stress does not occur in the inner peripheral portion of the core body 11 including the protrusion 11d, and deformation of the thin plate 11a forming the core body 11 can be prevented.

By moving the core portion 10 upward with the push-up portion 41 until the upper end of the post portion 22 of the jig 20 is below the lower end of the core portion 10, the core portion 10 is separated from the jig 20, and the core portion 10 is separated from the jig 20. The part 10 can be moved in any direction with respect to the jig 20 .

When the core portion 10 separated from the jig 20 is newly held by the core portion support portion 42 (see FIG. 5), the push-up portion 41 is moved downward to separate from the core portion 10, and the upper end of the push-up portion 41 It is returned to the original position below the jig 20 . The core portion 10 is moved by the core portion support portion 42 while being held by the core portion support portion 42, and is taken out from between the upper and lower molds. In addition, after returning the push-up portion 41 to the original position, the jig 20 is kept in the holding state of the jig 20 by the jig holding portion 43, and the jig 20 is made movable with respect to the lower mold, The jig 20 is moved by the jig holder 43 and taken out from between the upper and lower dies.
The core part 10 and the jig 20 taken out from between the upper and lower molds are respectively transferred to the next process by a predetermined transfer mechanism.

As described above, in the method for manufacturing the core portion according to the present embodiment, after the core portion 10 is obtained through the filling step of filling the resin into the space portion of the core body 11 supported by the jig 20, the separation step is performed. In separating the jig 20 from the core portion 10, the push-up portion 41 of the separation mechanism 40, which contacts the core portion 10 through the base portion 21 of the jig 20, is placed at the center of the shaft hole 11c in the core body 11 of the core portion 10. When the core portion 10 moves relative to the jig 20, the iron core body 11 of the core portion 10 is brought into contact with the contact portion 15 positioned on the imaginary straight line L passing through C and the convex portion 11d of the inner peripheral portion. A force is efficiently applied from the push-up portion 41 in contact with the portion (contacted portion 15) facing the portion 11d in the vicinity of the portion 11d, and the state is appropriately supported by the push-up portion 41. Therefore, the convex portion of the core body 11 Even if 11d receives the frictional resistance between the post portion 22 and the core body 11, the stress due to the bias of the force applied to the core body 11 is less likely to occur in each part of the core body 11. , and the core portion 10 can be stably manufactured by separating the core portion 10 from the jig 20 without any problem and sending it to the next step.

In the method of manufacturing the core portion according to the present embodiment, although the relationship between the stacked thin plates 11a forming the core body 11 is not particularly shown, the respective thin plates 11a forming the core body 11 are separated from each other by the shaft hole 11c of the core body 11. The core body 11 is connected by caulking at one or a plurality of points in at least one of the inner peripheral portion facing the inner peripheral portion and the peripheral portion of the inner peripheral portion, and the obtained core body 11 is supported by the jig 20 and supplied to the filling process. You can also
In this case, even if a force based on frictional resistance is applied to the protrusions 11d as the non-circumferential portions in the separation process, the thin plates 11a are strongly connected and integrated with each other, so that the strength against the force is increased. A state in which no deformation occurs can be ensured.

When the thin plates 11a forming the core body 11 are connected to each other by crimping in this way, the crimping position and the contact position of the push-up portion 41 may be overlapped, and the force from the push-up portion 41 may be applied to the portion where the strength is increased by the crimping. As a result, deformation such as indentation can be prevented from occurring on the core body 11 side even if the force from the push-up portion 41 is somewhat large.
Alternatively, the thin plates 11a forming the core body 11 may be connected to each other by welding, adhesion, or the like.

Further, in the core part manufacturing method according to the present embodiment, the core part 10 and the jig 20 are separated from the core part 10 by the separation mechanism 40 as a separation process in a state where the core part 10 and the jig 20 exist between the upper and lower molds of the core part manufacturing apparatus 1 . 20, but this is not the only option. After carrying out the core part 10 and the jig 20 from between the upper and lower molds, the jig 20 is held by a predetermined holding means, and the core part manufacturing apparatus The core part 10 and the jig 20 can be separated from each other by moving the core part 10 upward with a push-up part of a separating mechanism that is separate from the jig 20 .

In addition, in the core part manufacturing method according to the present embodiment, in the filling step, the molten resin 81 is melted from the upper mold 31 while the core body 11 and the upper mold 31 having the accommodation hole 31a containing the molten resin 81 are in direct contact with each other. Although the resin 81 is extruded and the molten resin 81 is injected and filled into the magnet insertion hole 11 b of the core body 11 , it is not limited to this, and communicates with the magnet insertion hole 11 b of the core body 11 on the upper side of the core body 11 . A plate-shaped cull plate provided with recesses and through holes that serve as possible resin flow paths is attached, and the molten resin 81 pushed out from the accommodation hole 31a is injected into the magnet insertion hole 11b of the core body 11 through this cull plate. , can also be configured to be filled.
In this case, after the molten resin 81 is solidified, the solidified resin remaining on the core body can be removed by removing the cull plate, and unnecessary resin can be removed more easily.

Further, in the core part manufacturing method according to the present embodiment, in the filling step, the permanent magnet 12 has already inserted the molten resin 81 obtained by heating and melting the resin material accommodated and held in the accommodation holes 31a of the upper mold 31. However, it is not limited to this, and before the permanent magnet 12 is inserted into the magnet insertion hole 11b as a space of the iron core body 11, An unmelted tablet-like, granular, or powdery resin material is fed in, and then the permanent magnet 12 is inserted and the resin material is melted. , may be used as a procedure for solidifying the resin.

(Second embodiment of the present invention)
In the core portion manufacturing method according to the first embodiment, in the separating step, the push-up portion 41 is moved upward with respect to the jig 20 to protrude from the hole of the base portion 21 of the jig 20, and the core portion 10 is moved upward. Although the core portion 10 and the jig 20 are separated by moving the core portion 10 and the jig 20, this is not a limitation, and as a second embodiment, as shown in FIGS. It is also possible to move the lower mold 32 and the jig 20 downward without moving the part 10 to separate the core part 10 and the jig 20 .

In this case, the push-up portion 41 of the separation mechanism 40 is protruded relative to the base portion 21 of the jig 20 so that the axial hole 11c of the end surface of the core body 11 of the core portion 10 supported by the jig 20 is projected. By moving the jig 20 downward while bringing the jig 20 into contact with a plurality of locations including the contacted portion 15 located on the imaginary straight line L passing through the center and the convex portion 11d of the inner peripheral portion, the core portion 10 move relative to each other to separate the core portion 10 and the jig 20 . Specifically, the push-up portion 41 allows the jig 20 to move downward together with the lower die 32 on which it is placed, while supporting the core portion 10 in contact with the end surface of the core body 11 of the core portion 10 and moving it. By holding the position of the core portion 10 without moving with respect to the jig 20 , the core portion 10 projects relative to the base portion 21 and moves upward relative to the jig 20 . .

Further, the core part support part 42 is held in a state not to move by the push-up part 41 and supports and moves the core part 10 after being separated from the jig 20, thereby moving the core part 10 from between the upper and lower dies to the next step. be transportable.

Further, when the jig holding portion 43 moves the jig 20 with respect to the core portion 10 supported by the push-up portion 41 , the jig 20 and the lower die 32 are kept at least until the jig 20 is separated from the core portion 10 . The jig 20 is held in conjunction with the movement of the lower mold 32 so as to move integrally, and after the core portion 10 is separated, the jig 20 is supported and moved so that it can be removed from between the upper and lower molds.

In the separation process of the present embodiment, first, the jig 20 is held by the jig holder 43, and the relative movement of the jig 20 with respect to the lower die 32 in each direction is restricted (see FIG. 7A). Then, while maintaining the position of the push-up portion 41 of the separation mechanism 40, the lower die 32 and the jig holding portion 43 are moved downward with respect to the push-up portion 41, so that the push-up portion 41 moves into the hole of the base portion 21. Through 21a, the core portion 10 is brought into contact with the end face of the core body 11 supported by the jig 20 (see FIG. 7B).

In this state, the lower mold 32 and the jig holder 43 are moved downward with respect to the thrust-up portion 41 while the position of the thrust-up portion 41 is still held. At this time, the core portion 10 is supported by the push-up portion 41 which is in contact with and does not move, and the downward movement of the core portion 10 is restricted. Moving away from the core portion 10, the post portion 22 of the jig 20 is pulled out of the shaft hole 11c of the core body 11 in the core portion 10 (see FIG. 8A).

In addition to the movement of the jig 20 being restricted by the jig holding portion 43, the push-up portion 41 contacts and supports an appropriate portion of the end face of the core body 11, thereby preventing the jig 20 from moving downward. In addition, no unnecessary movement occurs between the jig 20 and the core portion 10 other than relative movement in the vertical direction. Frictional resistance generated by the contact between the two can be minimized, and the jig 20 can be moved with respect to the core portion 10 without any problem.

By moving the jig 20 downward until the upper end of the post portion 22 of the jig 20 is below the lower end of the core portion 10, the core portion 10 is separated from the jig 20, and the core portion 10 is separated from the jig 20. 20 can be moved in any direction.

After the core portion 10 separated from the jig 20 is newly held by the core portion support portion 42 (see FIG. 8B), the core portion 10 is moved with respect to the push-up portion 41 by the core portion support portion 42, and the core is The part 10 is taken out from between the upper and lower molds. After removing the core part 10, the lower mold 32 is raised together with the jig 20 and returned to its original position. In addition, while the jig 20 is held by the jig holding portion 43 as it is, the jig 20 is made movable with respect to the lower mold 32, and the jig 20 is moved by the jig holding portion 43, thereby take out from
The core part 10 and the jig 20 taken out from between the upper and lower molds are transferred to the next process by the respective predetermined transfer mechanisms, as in the first embodiment.

In the core part manufacturing method according to the present embodiment, the core part 10 and the jig 20 are separated from the core part 10 by the separation mechanism 40 as a separation process in a state where the core part 10 and the jig 20 exist between the upper and lower molds of the core part manufacturing apparatus 1 . 20, but this is not the only option. In a state in which the push-up portion of the separation mechanism, which is separate from the above, is brought into contact with the core portion 10 to support the core portion 10, the holding means is moved downward together with the jig 20 with respect to the stationary push-up portion. A configuration in which the core part 10 and the jig 20 are separated can also be used.

Further, in the method for manufacturing the core portion according to the first embodiment, the push-up portion 41 is moved upward in the separation step, and the core portion 10 is pushed by the push-up portion 41 against the jig 20 that does not move and is moved upward. The core part 10 and the jig 20 are separated from each other, and in the core part manufacturing method according to the second embodiment, the pushing-up part 41 and the core part 10 are not moved in the separation step, and the lower mold 32 and the jig 20 are moved downward. In separating the core portion 10 and the jig 20 in each separation step, such as moving the core portion 10 and the jig 20 apart, only one of the jig 20 and the core portion 10 is actually moved. The jig 20 and the core portion 10 are moved relative to each other such that one of them separates from the other. However, it is not limited to these, and in the separation step, the push-up portion is moved upward, and the core portion is pushed by the push-up portion and moved upward, and at the same time, the jig is moved downward, that is, the jig and the core. A method of separating the core section and the jig by moving both of the sections may be adopted. In this case, both the jig and the core portion actually move away from each other, so that the separation of the core portion and the jig progresses quickly, and the separation process can be completed in a shorter time.

Further, in the separation step, both the jig and the core are moved in opposite directions to each other, and both the jig and the core are moved upward, and the moving speed of the core is made higher than the moving speed of the jig. By separating the core from the jig, or by moving both the jig and the core downward while making the moving speed of the jig higher than the moving speed of the core, You may make it isolate|separate from a jig|tool.

(Third embodiment of the present invention)
In the core part manufacturing method according to the first embodiment, in the filling step, the resin is supplied to the accommodation hole 31a provided in the upper mold 31 of the core part manufacturing apparatus 1, and the heated and melted resin is accommodated in the extruding part 33. The resin is pushed downward from the hole 31a to fill the magnet insertion hole 11b, which is the space of the core body 11, from above. As shown in FIGS. 9 to 12, in the filling process, resin can be injected and filled into the core body 11 from the lower die 37 side of the core part manufacturing apparatus 2 .

In this case, the upper mold 36 in the core part manufacturing apparatus 2 is not provided with the receiving hole 31a and the extruding part 33 in the first embodiment. On the other hand, the lower die 37 has a plurality of accommodation holes 37a capable of accommodating and holding resin, and an extrusion portion 38 which is inserted into the accommodation holes 37a from below and capable of extruding the resin.

The jig 25 for supporting the core body 11 includes a base portion 26 and a post portion 27 as in the first embodiment. It is a configuration in which a plurality of resin passages 26b are provided. The plurality of resin passages 26b of the base portion 26 are arranged corresponding to the accommodation holes 37a of the lower die 37, and are through holes communicating with the accommodation holes 37a of the lower die 37 and the magnet insertion holes 11b of the core body 11. is.

In the filling step, the resin is supplied to the accommodation hole 37a provided in the lower die 37, and the molten resin 81 heated and melted is pushed upward from the accommodation hole 37a by the extruding part 38, and the magnet insertion hole 11b of the core body 11 is pushed out. On the other hand, the molten resin 81 is injected and filled from below through the resin passage 26b of the jig 25 (see FIG. 9).

In the filling process, when the molten resin 81 filled in each magnet insertion hole 11b is solidified and the permanent magnet 12 is fixed to obtain the core portion 10, the filling process is completed, and the extruded portion 38 is pulled down to return to the original state. At the same time, the upper die 36 is lifted or the lower die 37 is lowered to end the clamping and pressing of the core body 11 by the upper die 36 and the lower die 37 (see FIG. 10).

Then, the process shifts to the separation step, where the jig 25 on the lower die 37 is held by the jig holding portion 43, and the movement of the jig 25 in each direction including the upward direction is restricted (see FIG. 11(a)). Then, the push-up portion 41 of the separation mechanism 40 is moved upward with respect to the core portion 10 supported by the jig 25, and the push-up portion 41 passes through the hole 26a of the base portion 26, and the base portion 26, the core portion 10 is in contact with the end face of the core body 11 (see FIG. 11(b)).

From this state, the push-up portion 41 is further moved upward to push up the core portion 10 and move the core portion 10 upward with respect to the jig 25 . As a result, the end surface of the core body 11 in the core portion 10 is separated from the base portion 26 of the jig 25, and the post portion 27 of the jig 25 is removed from the shaft hole 11c of the core body 11 (Fig. 12(a)). )reference).

When the core portion 10 is moved with respect to the jig 25 by the push-up portion 41 coming into contact with and pushing an appropriate portion of the end surface of the core body 11, as in the first embodiment, the convex portion of the core body 11 is pushed. Frictional resistance generated when the inner peripheral portion including 11d comes into contact with the post portion 27 of the jig 25 can be minimized, and the stress in each portion of the core body 11 is not excessively increased, thereby forming the core body 11. Deformation or the like of the thin plate 11a can be prevented.

The core portion 10 is separated from the jig 25 by moving the core portion 10 upward until the upper end of the post portion 27 of the jig 25 is below the lower end of the core portion 10 . The core portion 10 thus separated from the jig 25 is newly held by the core portion support portion 42 (see FIG. 12(b)) as in the first embodiment, and then the core portion support portion 42 is held again. and removed from between the upper and lower molds. Also, the jig 25 is also moved by the jig holding portion 43 while being held by the jig holding portion 43 after being returned to its original position by moving the push-up portion 41 downward, and is moved from between the upper and lower dies. It will be taken out.

(Other embodiments of the present invention)
In the core portion manufacturing method according to the first embodiment, the arrangement and shape of the contacted portion 15 on the imaginary straight line L passing through the center C of the convex portion 11d as the non-circumferential portion of the core body 11 and the shaft hole 11c, that is, , the arrangement and shape of the contact surface 41a of the push-up portion 41 in contact with the core body 11 are symmetrical about the imaginary straight line L, but are not limited to this. is on the imaginary straight line L, at least one of the arrangement and shape of the contact surface (contacted portion 15) may be asymmetrical (see FIG. 13(a)). In this case, the shape of each part of the jig 20 is set according to each shape and arrangement of the core body 11 and the push-up part that supports it in contact therewith (see FIG. 13(b)). In particular, when a portion of the contact surface of the push-up portion is on the imaginary straight line L and the arrangement of the contact surface (contacted portion 15) is asymmetrical about the imaginary straight line L, one arrangement with respect to the convex portion 11d may be used. One core body 11 (for example, FIG. 2(b)) provided with a certain magnet insertion hole 11b and another core body 11 (for example, FIG. 13(a) )) and , a common jig (base part) can be used.

Furthermore, in the first embodiment, the push-up portions 41 in the separation mechanism 40 of the core manufacturing apparatus 1 are arranged symmetrically about the center C of the shaft hole 11c of the core body 11 supported by them. As long as the end face of the core body 11 can be supported by the push-up portion 41 in a well-balanced manner, an asymmetric arrangement may be used.

In addition, in the method of manufacturing the core portion according to the first embodiment, two convex portions 11d as non-circumferential portions of the core body 11 are provided so as to face each other across the center C of the shaft hole 11c. However, it is also possible to provide only one non-circumferential portion, or to provide three or more non-circumferential portions. The noncircumferential portion is not limited to a convex portion, and may be, for example, a concave portion. One or more recesses corresponding to the serrated shaft may be provided.

Furthermore, even if the non-circumferential portion is a convex portion, as long as it is convex toward the inside of the circumference, it has a convex shape without corners, for example, a substantially D shape with a part of the shaft being flat. In order to obtain a substantially D-shaped shaft hole for fixing a rotating shaft having a cross-sectional shape of It may have a shape that protrudes to the position. In addition, a plurality of protrusions are formed on each side of the polygon from the circumference so as to obtain a polygonal hole-shaped shaft hole for fixing the rotating shaft having a polygonal cross-sectional shape. It may be of a shape that protrudes to the respective position.

Reference Signs List 1, 2 core portion manufacturing apparatus 10 core portion 11 core body 11a thin plate 11b magnet insertion hole 11c shaft hole 11d convex portion 12 permanent magnet 13 filler 15 contacted portion 20, 25 jig 21, 26 base portion 21a, 26a hole 22, 27 Post part 22a Recess 26b Resin passage 31, 36 Upper die 31a Accommodating hole 32, 37 Lower die 33, 38 Extruding part 37a Accommodating hole 40 Separation mechanism 41 Push-up part 41a Contact surface 42 Core part supporting part 43 Jig holding part 81 molten resin

Claims (5)

A core body formed by laminating a plurality of thin plates made of a magnetic metal material is supported by a jig, and a plurality of spaces in the core body are filled with resin to form a part of the rotor or stator of a rotating electric machine. In the core portion manufacturing method for manufacturing the core portion forming
A filling step of filling resin into the space of the core body;
At least a separation step of separating the core part and the jig obtained through the filling step by a predetermined separation mechanism,
The jig has a base portion on which the core body can be placed, and a post portion projecting in a substantially columnar shape from the base portion, and the base portion is provided with a plurality of through holes penetrating therethrough. become,
The core body is provided with a shaft hole penetrating in the lamination direction of the thin plates at the center, and a non-circumferential portion that prevents rotation of the shaft inserted into the shaft hole is provided on the inner peripheral portion facing the shaft hole. having one or more, and in the filling step, the post portion of the jig is inserted through the shaft hole and supported;
The separation mechanism has at least a push-up portion that can be retracted through the through hole with respect to the base portion of the jig,
In the separation step, the push-up portion of the separation mechanism protrudes relative to the base portion of the jig and passes through the center of the shaft hole and the non-circumferential portion of the core body of the core portion. Contacting a plurality of locations including the contacted portion positioned on the imaginary straight line, and relatively moving one or both of the jig and the core portion to separate the core portion and the jig. A method for manufacturing the core part. In the core part manufacturing method according to claim 1,
In the separation step, the plurality of locations of the core portion on the core body that are brought into contact with the push-up portion of the separation mechanism are a plurality of locations that are symmetrical about the center of the shaft hole on the end face of the core body. core manufacturing method. In the core part manufacturing method according to claim 1 or 2,
Of the contact surfaces of the push-up portion of the separation mechanism with the core body end surface of the core portion, the contact surface that contacts the contacted portion has a shape that is symmetrical about the imaginary straight line. core manufacturing method. In the core part manufacturing method according to any one of claims 1 to 3,
In a state in which the thin plates forming the core body are connected to each other by caulking at one or a plurality of locations in at least one of the inner peripheral portion facing the shaft hole and the peripheral portion of the inner peripheral portion of the core body, A method for manufacturing a core portion, wherein the core portion is supported by the jig and supplied to the filling step. A core body formed by laminating a plurality of thin plates made of a magnetic metal material is supported by a jig, and a plurality of spaces in the core body are filled with resin to form a part of the rotor or stator of a rotating electric machine. In a core part manufacturing device that manufactures a core part that forms
A separation mechanism for separating the jig from the core portion obtained by filling the core body supported by the jig with resin,
The jig has a base portion on which the core body can be placed, and a post portion projecting in a substantially columnar shape from the base portion, and the base portion is provided with a plurality of through holes penetrating therethrough. become,
The core body is provided with a shaft hole penetrating in the lamination direction of the thin plates at the center, and a non-circumferential portion that prevents rotation of the shaft inserted into the shaft hole is provided on the inner peripheral portion facing the shaft hole. The post portion is inserted through the shaft hole in a state of being supported by the jig, and
The separation mechanism has at least a push-up portion that can be retracted through the through hole with respect to the base portion of the jig,
The push-up portion protrudes relatively to the base portion of the jig and is positioned on a virtual straight line passing through the center of the shaft hole and the non-circumferential portion of the core body of the core portion. A core portion manufacturing apparatus, wherein the core portion and the jig are separated from each other by moving one or both of the jig and the core portion relative to each other.

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