JP6069250B2 - Rotor manufacturing apparatus and rotor manufacturing method - Google Patents

Description

  The present invention relates to a rotor manufacturing apparatus and a rotor manufacturing method.

  In recent years, vehicles equipped with electric motors (motors) for driving vehicles such as fuel cell vehicles, hybrid vehicles, and electric vehicles have been developed one after another. An electric motor generally includes a stator in which a coil is disposed, and a rotor that is rotatably supported around an axis on the inner peripheral side of the stator and in which a magnet is disposed. As the rotor, a so-called IPM (Interior Permanent Magnet) rotor is widely known in which a slot is formed in a rotor core, a magnet is inserted into the slot, and the magnet is embedded in the rotor.

Usually, the magnet inserted into the slot of the rotor core is fixed by solidifying after filling a resin material between the inner wall of the slot and the outer surface of the magnet.
Here, the resin material is roughly classified into a thermosetting resin material and a thermoplastic resin material. Generally, the thermosetting resin material has a lower viscosity than the thermoplastic resin material. Therefore, a thermosetting resin material having a low viscosity and easily penetrating between the inner wall of the slot and the outer surface of the magnet is widely used for fixing the magnet of the IPM rotor.
However, in order to solidify the thermosetting resin material, after filling the slot with the resin material, it is necessary to put the rotor into a heater such as a thermostatic bath and to heat it for a predetermined time until it reaches a predetermined temperature. Therefore, there is room for improvement in terms of shortening the manufacturing process time.

  On the other hand, the thermoplastic resin material can be solidified by natural cooling. Therefore, when a thermoplastic resin material is used for fixing the magnet of the IPM rotor, it is not necessary to heat the slot after filling the resin material in the slot, which is advantageous in terms of shortening the solidification time. However, since the thermoplastic resin material has high viscosity and is easily solidified, it needs to be filled at a high injection speed and high injection pressure. Therefore, the rotor core may be deformed by the pressure of the resin material filled in the slot, which may cause manufacturing defects.

  In order to solve such a problem, for example, Patent Document 1 includes a contact member that contacts part or all of the outer periphery of a laminated iron core (rotor core), and the contact member is sandwiched and fixed by an upper mold and a lower mold. In this state, an injection mold apparatus for filling a resin member (thermoplastic resin material) between a hole (slot) and a magnet is described. According to the technique described in Patent Document 1, the magnet is fixed in a well-balanced manner, and even when resin molding pressure is applied to the laminated iron core during filling of the resin member, the laminated iron core is prevented from being damaged and reliable. It can be improved.

  By the way, in recent years, slots having different shapes may be mixed from the viewpoint of improving magnetic characteristics and reducing stress concentration on the rotor core during rotation of the rotor. Therefore, the slots with different shapes have different easiness of inflow when the thermoplastic resin material flows between the inner wall of the slot and the outer surface of the magnet (hereinafter referred to as “inflow resistance”).

JP 2007-318942 A

However, in the prior art, the inflow resistance difference of each slot due to the difference in the shape of the slot is not considered. Therefore, for example, when the injection pressure at the time of filling the thermoplastic resin material is determined on the basis of the slot with a small inflow resistance, there is sufficient thermoplastic resin material between the inner wall of the slot with a large inflow resistance and the outer surface of the magnet. There is a possibility that it cannot penetrate and the magnet cannot be fixed. On the other hand, for example, when the injection pressure at the time of filling the thermoplastic resin material is determined with reference to a slot having a large inflow resistance, an excessive internal pressure is applied to the slot having a small inflow resistance, and the rotor core may be deformed. is there.
Thus, in the prior art, there is room for improvement in that the thermoplastic resin material is filled between the inner wall of the slot having a different shape and the outer surface of the magnet while preventing the deformation of the rotor core.

  In addition, since the rotor core is formed by laminating a large number of electromagnetic steel plates, generally the axial dimension error (hereinafter referred to as “lamination error”) increases. However, in the prior art, the stacking error of the rotor core is not considered. For this reason, when the dimension along the axial direction of the rotor core touches the positive side of the dimensional tolerance with respect to the reference dimension due to a stacking error of the rotor core, an excessive load may be applied to the rotor core during mold clamping. In addition, if the dimension along the axial direction of the rotor core touches the negative side of the dimensional tolerance with respect to the reference dimension due to the stacking error of the rotor core, the magnet will come into contact with the mold during clamping and the gap between the rotor core and the mold There is a risk that a space will be generated in the resin and the thermoplastic resin material will leak. As described above, in the conventional rotor manufacturing apparatus, there is a risk that a rotor manufacturing defect may occur due to a rotor core stacking error.

  Accordingly, the present invention has been made in view of the above circumstances, and a rotor capable of filling a thermoplastic resin material between an inner wall of a slot having a different shape and an outer surface of a magnet while absorbing a stacking error of the rotor core. It is an object to provide a manufacturing apparatus and a rotor manufacturing method.

  In order to solve the above-mentioned problem, a rotor manufacturing apparatus according to the invention described in claim 1 (for example, a rotor manufacturing apparatus 50 in an embodiment described later) includes a first magnet (for example, a first magnet 36A in an embodiment described later). ) Are inserted and fixed by a thermoplastic resin material (for example, a first slot 31 in an embodiment described later) and a second magnet (for example, a second magnet 36B in an embodiment described later) is inserted. And at least a second slot (for example, a second slot 32 in an embodiment described later) fixed by the thermoplastic resin material, and between the inner wall of the first slot and the outer surface of the first magnet. The inflow resistance when the thermoplastic resin material flows in is the inflow resistance when the thermoplastic resin material flows between the inner wall of the second slot and the outer surface of the second magnet. A rotor manufacturing apparatus for manufacturing a rotor (for example, a rotor 3 in an embodiment described later) having a larger rotor core (for example, a rotor core 30 in an embodiment described later) in the axial direction of the rotor core than the rotor core A filling hole arranged on one side and movable along the axial direction and capable of injecting the thermoplastic resin material into the first slot and the second slot (for example, filling in an embodiment described later) A first mold having a hole 53a) (for example, a filling mold 53 in an embodiment described later) and the rotor core are abutted from the other side in the axial direction to support the rotor core and along the axial direction. Movable second mold (for example, a lower mold 56 in an embodiment described later), and the second magnet to the other in the axial direction A support member (for example, a support member 66 in an embodiment described later) that contacts the side and supports the second magnet at a predetermined position in the axial direction and is movable along the axial direction. The second mold and the support member are biased from the other side in the axial direction toward the one side, and the first mold is the second mold when filled with the thermoplastic resin material. The rotor core and the second magnet can be pressed against the urging force of the support member.

  According to the present invention, the first mold is configured to be able to press the rotor core and the second magnet against the urging force of the second mold and the support member when the thermoplastic resin material is filled. Regardless of the stacking error in the axial direction of the rotor core, the first mold, the rotor core and the second magnet can come into contact with each other. Specifically, if the dimension along the axial direction of the rotor core touches the positive side of the dimensional tolerance with respect to the reference dimension due to the stacking error of the rotor core, the first mold resists the urging force of the second mold. While moving a rotor core toward the other side from the one side of an axial direction, it can contact | abut with a 2nd magnet and can press a rotor core and a 2nd magnet. Also, if the dimension along the axial direction of the rotor core touches the negative side of the dimensional tolerance with respect to the reference dimension due to the stacking error of the rotor core, the first mold will pivot the second magnet against the biasing force of the support member. While moving from one side of the direction toward the other side, the rotor core and the second magnet can be pressed by contacting the rotor core. As a result, regardless of the stacking error of the rotor core, the second magnet of the second slot with a low inflow resistance is brought closer to the first mold side than the first magnet of the first slot with a high inflow resistance. Resin material can be filled. That is, regardless of the stacking error of the rotor core, the flow path cross-sectional area of the thermoplastic resin material formed between the second magnet and the first mold is reduced, and the thermoplastic resin material flows into the second slot side. The resistance and the inflow resistance of the thermoplastic resin material on the first slot side can be adjusted to be balanced. Therefore, the thermoplastic resin material can be filled between the inner wall of the slot having a different shape and the outer surface of the magnet while absorbing the stacking error of the rotor core.

  In the rotor manufacturing apparatus according to the second aspect of the present invention, the support member has an outer shape smaller than the outer shape of the second magnet when viewed from the axial direction.

  According to the present invention, the second magnet can be easily and reliably brought closer to the first mold side than the first magnet only by providing the support member on the second mold. Further, since the support member has an outer shape smaller than the outer shape of the second magnet, the support member can be disposed by being filled with a thermoplastic resin material. Therefore, the second magnet can be firmly held in the second slot.

  A rotor manufacturing method according to a third aspect of the present invention is a rotor manufacturing method using the above-described rotor manufacturing apparatus, wherein the first magnet and the second slot are provided in the first slot and the second slot, respectively. The rotor core against the biasing force of the second mold and the support member by the magnet insertion / arrangement step (for example, magnet insertion / arrangement step S11 in the embodiment described later) for inserting two magnets and the first mold. And a mold clamping step of pressing the second magnet (for example, a mold clamping step S12 in an embodiment described later), and the thermoplastic resin material is injected from the filling hole of the first mold by a predetermined injection pressure, A filling step for filling between the inner wall of the first slot and the outer surface of the first magnet and between the inner wall of the second slot and the outer surface of the second magnet (for example, in an embodiment described later) Filling step S13), and in the filling step, the second magnet is moved closer to the first mold than the first magnet, and the rotor core and the second magnet are moved to the first mold. It is characterized by being performed in a contact state.

According to the present invention, the first mold includes the mold clamping step of pressing the rotor core and the second magnet against the urging force of the second mold and the support member. Regardless, the first mold, the rotor core, and the second magnet can come into contact with each other.
Further, the filling step brings the second magnet of the second slot having a low inflow resistance closer to the first mold side than the first magnet of the first slot having a large inflow resistance, and the rotor core and the second magnet are moved to the first mold. The thermoplastic resin material can be filled in a state where it is in contact with the mold. Thereby, the flow passage cross-sectional area of the thermoplastic resin material formed between the second magnet and the first mold is reduced, and the inflow resistance of the thermoplastic resin material on the second slot side and the first slot side The inflow resistance of the thermoplastic resin material can be adjusted so as to be balanced.
Accordingly, the thermoplastic resin material can be filled between the inner wall of the slot having a different shape and the outer surface of the magnet while absorbing the stacking error of the rotor core.

  The rotor manufacturing method according to the invention described in claim 4 is characterized in that the thermoplastic resin material filled in the filling step is a liquid crystal polymer.

  According to the present invention, a liquid crystal polymer (LCP) can be suitably used as the thermoplastic resin material filled in the slot in the filling step.

  According to the present invention, the first mold is configured to be able to press the rotor core and the second magnet against the urging force of the second mold and the support member when the thermoplastic resin material is filled. Regardless of the stacking error in the axial direction of the rotor core, the first mold, the rotor core and the second magnet can come into contact with each other. Specifically, if the dimension along the axial direction of the rotor core touches the positive side of the dimensional tolerance with respect to the reference dimension due to the stacking error of the rotor core, the first mold resists the urging force of the second mold. While moving a rotor core toward the other side from the one side of an axial direction, it can contact | abut with a 2nd magnet and can press a rotor core and a 2nd magnet. Also, if the dimension along the axial direction of the rotor core touches the negative side of the dimensional tolerance with respect to the reference dimension due to the stacking error of the rotor core, the first mold will pivot the second magnet against the biasing force of the support member. While moving from one side of the direction toward the other side, the rotor core and the second magnet can be pressed by contacting the rotor core. As a result, regardless of the stacking error of the rotor core, the second magnet of the second slot with a low inflow resistance is brought closer to the first mold side than the first magnet of the first slot with a high inflow resistance. Resin material can be filled. That is, regardless of the stacking error of the rotor core, the flow path cross-sectional area of the thermoplastic resin material formed between the second magnet and the first mold is reduced, and the thermoplastic resin material flows into the second slot side. The resistance and the inflow resistance of the thermoplastic resin material on the first slot side can be adjusted to be balanced. Therefore, the thermoplastic resin material can be filled between the inner wall of the slot having a different shape and the outer surface of the magnet while absorbing the stacking error of the rotor core.

It is a schematic sectional drawing of a motor unit. It is a perspective view of a rotor. It is a top view when a rotor is seen from the one side of an axial direction, Comprising: It is an enlarged view of a magnetic pole part. It is a displacement side surface sectional view along the AA line of FIG. It is a top view when a rotor is seen from the other side of an axial direction, Comprising: It is an enlarged view of a magnetic pole part. It is side surface sectional drawing of a rotor manufacturing apparatus. It is a flowchart of the manufacturing process of a rotor. It is explanatory drawing of a magnet insertion arrangement | positioning process. It is explanatory drawing of the state after the magnet insertion arrangement | positioning process by the lamination | stacking error of a rotor core. It is explanatory drawing of the state after the magnet insertion arrangement | positioning process by the lamination | stacking error of a rotor core. It is explanatory drawing of the state after the magnet insertion arrangement | positioning process by the lamination | stacking error of a rotor core. It is explanatory drawing of the difference in the clamping process by the lamination | stacking error of a rotor core. It is explanatory drawing of the difference in the clamping process by the lamination | stacking error of a rotor core. It is explanatory drawing of the difference in the clamping process by the lamination | stacking error of a rotor core.

Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 is a schematic cross-sectional view of the motor unit 1.
As shown in FIG. 1, the motor unit 1 includes a motor 4 and a housing 5 that houses the motor 4. In the following description, a direction along the central axis O of the motor 4 is referred to as an axial direction, a direction orthogonal to the central axis O is referred to as a radial direction, and a direction around the central axis O is referred to as a circumferential direction.

The motor 4 is a so-called inner rotor type motor, and includes a cylindrical stator 2, a rotor 3 disposed inside the stator 2, and a shaft 6 that is press-fitted and fixed coaxially with the rotor 3 and rotatably supported. It is equipped with.
The stator 2 has a stator core 20 formed by laminating a plurality of electromagnetic steel plates along the axial direction. The stator core 20 is provided with teeth 21 that extend inward in the radial direction. A coil 23 is wound around the tooth 21 via an insulator 22.

FIG. 2 is a perspective view of the rotor 3.
As shown in FIG. 2, the rotor 3 has a rotor core 30 formed by laminating a plurality of electromagnetic steel plates along the axial direction.
A through hole 30 a is formed at the center of the rotor core 30. In the central portion of the rotor core 30, the shaft 6 (see FIG. 1) is inserted into the through hole 30a and press-fitted and fixed. Moreover, the rotor core 30 has a plurality of lightening portions 30b around the through hole 30a.

The rotor core 30 has a plurality of slot groups 35 arranged at equal intervals over the circumferential direction. The slot groups 35 are provided at eight locations so as to have a pitch of about 45 ° in the circumferential direction on the outer side in the radial direction from the thinned portion 30b.
The slot group 35 includes a first slot 31, a second slot 32, and a third slot 33. A first magnet 36A, a second magnet 36B, and a third magnet 36C are inserted into the first slot 31, the second slot 32, and the third slot 33, respectively. In the present embodiment, the first magnet 36A, the second magnet 36B, and the third magnet 36C have the same shape.

  In the rotor core 30, the magnetic pole portion 37 is formed by magnetizing the peripheral portion of the slot group 35 by the first magnet 36 </ b> A, the second magnet 36 </ b> B, and the third magnet 36 </ b> C. The rotor 3 of this embodiment is provided with eight slot groups 35 and has eight magnetic pole portions 37 (four pole pairs). The magnetic pole portions 37 adjacent in the circumferential direction are magnetized to different poles by the first magnet 36A, the second magnet 36B, and the third magnet 36C. That is, the magnetic pole portion 37 of the rotor 3 is formed such that the N poles 37A and the S poles 37B are alternately arranged in the circumferential direction.

FIG. 3 is a plan view when the rotor 3 is viewed from one side in the axial direction, and is an enlarged view of the magnetic pole portion 37. One side of the rotor 3 in the axial direction is a side on which a filling mold 53 (see FIG. 6) is arranged and filled with a thermoplastic resin material in a filling step described later.
As shown in FIG. 3, the slot group 35 is formed by a first slot 31 and a second slot 32 and a third slot 33 formed on both sides in the circumferential direction with the first slot 31 interposed therebetween.
The first slot 31 has an isosceles trapezoidal shape in plan view, and is provided so that the longitudinal direction is orthogonal to the radial direction.
An inner wall (hereinafter, referred to as “outer wall 31a”) on the radially outer side of the first slot 31 is recessed in the radially outer side in the middle portion in the longitudinal direction, and a filling groove 31A is formed along the axial direction. Has been. A filling hole 53a (see FIG. 6) of the filling mold 53 is disposed at a position corresponding to the filling groove 31A when the first slot 31 is filled with the thermoplastic resin material in the manufacturing process of the rotor 3 described later. The

A first magnet 36 </ b> A is inserted and arranged in the first slot 31. The first magnet 36A is a permanent magnet such as a neodymium magnet, and is formed in a rectangular plate shape.
The thickness along the radial direction of the first magnet 36 </ b> A is thinner than the width along the radial direction of the first slot 31. 36 A of 1st magnets are distribute | arranged in the state contact | abutted to the inner wall (henceforth "the inner wall 31b") inside the radial direction of the 1st slot 31. FIG. As a result, a gap 31 c is formed between the radially outer surface of the first magnet 36 </ b> A and the outer wall 31 a of the first slot 31.

FIG. 4 is a sectional side view of the displacement along the line AA in FIG.
As shown in FIG. 4, the axial length of the first magnet 36 </ b> A of the present embodiment is slightly shorter than the axial length of the rotor core 30. 36 A of 1st magnets are arrange | positioned so that the end surface of the other side (lower side in FIG. 4) in an axial direction may become substantially flush with the end surface of the other side in the axial direction of the rotor core 30.

  As shown in FIG. 3, cavities 31 d and 31 e are formed in the first slot 31. The hollow portions 31d and 31e are formed from both sides in the circumferential direction of the first magnet 36A to positions corresponding to the outer corners in the radial direction of the first magnet 36A. The cavities 31d and 31e are symmetrical and have substantially the same volume. The hollow portions 31d and 31e function as a so-called flux barrier that prevents the magnetic flux of the first magnet 36A inserted into the first slot 31 from leaking.

  As shown in FIG. 4, a thermoplastic resin material is filled between the inner wall of the first slot 31 and the outer surface of the first magnet 36A and on the end surface on one axial side of the first magnet 36A. One mold part 38A is formed. The first mold portion 38A is formed by filling and solidifying with a thermoplastic resin material in the manufacturing process of the rotor 3 described later. The first mold part 38 </ b> A holds the first magnet 36 </ b> A with respect to the first slot 31. In addition, as a thermoplastic resin which forms 38 A of 1st mold parts, a liquid crystal polymer (Liquid Crystal Polymer: LCP) is suitable.

  As shown in FIG. 3, the second slot 32 and the third slot 33 each have a trapezoidal shape in plan view, and are arranged so as to gradually spread from the inner side to the outer side in the radial direction. The second slot 32 and the third slot 33 are formed symmetrically with respect to the first slot 31.

  The outer wall 32a of the second slot 32 is recessed on the outer side in the radial direction on the first slot 31 side with respect to the intermediate portion in the longitudinal direction, and a filling groove 32A is formed along the axial direction. A filling hole 53a (see FIG. 6) of the filling mold 53 is disposed at a position corresponding to the filling groove 32A when the second slot 32 is filled with a thermoplastic resin material in the manufacturing process of the rotor 3 described later. The

A second magnet 36 </ b> B is inserted and disposed in the second slot 32. The second magnet 36 </ b> B is disposed in contact with the inner wall 32 b of the second slot 32. As a result, a gap 32 c is formed between the radially outer surface of the second magnet 36 </ b> B and the outer wall 32 a of the second slot 32.
As shown in FIG. 4, the second magnet 36 </ b> B is arranged so that the end surface on one side in the axial direction (upper side in FIG. 4) is substantially flush with the end surface on the one side in the axial direction of the rotor core 30. .

  As shown in FIG. 3, cavities 32 d and 32 e are formed in the second slot 32. Of the hollow portions 32d and 32e, the hollow portion 32d on the first slot 31 side is formed on the side in the circumferential direction of the second magnet 36B. Further, the cavity 32e opposite to the first slot 31 across the second magnet 36B is formed on the second magnet 36B on the outer side in the radial direction from the second magnet 36B from the side in the circumferential direction of the second magnet 36B. It is formed over the vicinity of the middle part in the longitudinal direction. The cavities 32d and 32e have an asymmetric shape. The hollow portions 32d and 32e function as so-called flux barriers that prevent the magnetic flux of the second magnet 36B inserted into the second slot 32 from leaking.

  As shown in FIG. 4, a thermoplastic resin material is filled between the inner wall of the second slot 32 and the outer surface of the second magnet 36B and on the other end surface in the axial direction of the second magnet 36B. Two mold parts 38B are formed. The second mold portion 38B is formed by filling and solidifying a thermoplastic resin material in the rotor 3 manufacturing process described later. The second mold part 38 </ b> B holds the second magnet 36 </ b> B with respect to the second slot 32. As the thermoplastic resin forming the second mold portion 38B, a liquid crystal polymer (LCP) is suitable as in the first mold portion 38A.

FIG. 5 is a plan view when the rotor 3 is viewed from the other side in the axial direction, and is an enlarged view of the magnetic pole portion 37.
As shown in FIG. 5, in the second mold portion 38B formed by filling the second slot 32 with a thermoplastic resin material, a recess 39 is formed on the other end surface in the axial direction. The recess 39 has a circular shape in plan view. The second magnet 36 </ b> B is exposed from the recess 39. The process of forming the recess 39 will be described in a method for manufacturing the rotor 3 described later.

  Here, as shown in FIG. 3, when viewed from the axial direction, the area of the cavities 31 d and 31 e in the first slot 31 is smaller than the area of the cavities 32 d and 32 e in the second slot 32. It has become. For this reason, when viewed from the axial direction, the narrow gap 31c is formed between the outer wall 31a of the first slot 31 and the outer surface of the first magnet 36A. It becomes larger than the formation range of the narrow gap 32c between the outer surface of 36B. Therefore, when the first slot 31 and the second slot are filled with the thermoplastic resin material at the same injection pressure, the thermoplastic resin is inserted into the gap 31c between the outer wall 31a of the first slot 31 and the outer surface of the first magnet 36A. An inflow resistance (hereinafter simply referred to as “inflow resistance R1 of the first slot 31”) when the material flows in is a thermoplastic resin in a gap 32c between the outer wall 32a of the second slot 32 and the outer surface of the second magnet 36B. It becomes larger than the inflow resistance when the material flows in (hereinafter simply referred to as “inflow resistance R2 of the second slot 32”).

  The third slot 33 is formed symmetrically with the second slot 32. Therefore, the configuration of the filling groove 33A of the third slot 33, the outer wall 33a, the inner wall 33b, the gap 33c, the cavity portions 33d and 33e, and the third mold portion 38C is the same as the filling groove 32A of the second slot 32 described above, Since it is the same as the outer side wall 32a, the inner side wall 32b, the gap 32c, the cavities 32d and 32e, and the second mold part 38B, detailed description is omitted.

As shown in FIG. 1, the housing 5 includes a motor housing 5A that is formed in a substantially cylindrical shape and covers the motor 4, and a sensor housing (not shown) provided on one end side in the axial direction of the motor housing 5A. Yes.
A stator core 20 of the stator 2 is fixed to the motor housing 5A with, for example, a bolt (not shown).
A rotation sensor (not shown) such as a resolver capable of detecting the rotation angle of the rotor 3 is attached to the sensor housing so as to be coaxial with the rotor 3. The sensor housing is provided with a bearing (not shown) that rotatably supports one end of the shaft 6 of the rotor 3. Note that the other end of the shaft 6 of the rotor 3 is rotatably supported by a bearing provided in a transmission housing (not shown) or the like. Thereby, the rotor 3 can be rotated inside the stator 2.

  Subsequently, a rotor manufacturing apparatus 50 for manufacturing the rotor 3 described above and a manufacturing process of the rotor 3 performed using the rotor manufacturing apparatus 50 (corresponding to a “rotor manufacturing method” in the claims) will be described.

(Rotor manufacturing equipment)
FIG. 6 is a side cross-sectional view of the rotor manufacturing apparatus 50 and illustrates a state where the rotor core 30, the first magnet 36A, and the second magnet 36B are set. 6 is a side sectional view including the central axis O of the rotor core 30, the first slot 31, and the second slot 32. FIG. Further, the vertical direction in FIG. 6 coincides with the vertical direction of gravity. In the present embodiment, the upper side corresponds to one side in the axial direction, and the lower side corresponds to the other side in the axial direction.
As shown in FIG. 6, the rotor manufacturing apparatus 50 of the present embodiment mainly includes a filling mold 53 (corresponding to “first mold” in the claims), a base 60, and a lower mold 56 (invoice). And the support member 66.). Details of each component will be described below.

The filling mold 53 is disposed on one axial side (the upper side in FIG. 6) of the rotor core 30 and is movable along the axial direction of the rotor core 30 by, for example, a hydraulic actuator (not shown). The filling mold 53 is pressed by a predetermined pressing force toward the axial end surface of the rotor core 30 so as to be in contact with the axial end surface of the rotor core 30 and not to be separated from the rotor core 30 during filling of the thermoplastic resin material. (So-called mold clamping)
The filling mold 53 has a filling hole 53a through which a thermoplastic resin material can be injected from the first slot 31 to the third slot 33 (see FIG. 3). A plurality of filling holes 53a of the filling mold 53 are formed, and positions corresponding to the filling grooves 31A, 31B, 31C (see FIG. 3) from the first slot 31 to the third slot 33 (see FIG. 3), respectively. Is formed.

Further, a connection hole 53b to which an injection nozzle (not shown) is connected is provided at the center of the outer surface of the filling mold 53. The connection hole 53b and the filling hole 53a communicate with each other through a flow path 53c through which the thermoplastic resin material flows.
The injection nozzle is for injecting a thermoplastic resin material to fill each slot from the first slot 31 to the third slot 33 (see FIG. 3) of the rotor core 30. In the injection nozzle, the injection port at the tip is inserted and arranged in the connection hole 53 b of the filling mold 53 when the thermoplastic resin material is filled. The thermoplastic resin material injected from the injection nozzle is injected from the first slot 31 of the rotor core 30 into each slot of the third slot 33 (see FIG. 3) through the flow passage 53c and the filling hole 53a.

  The base 60 is, for example, a disk-shaped member whose outer shape is formed substantially the same as the rotor core 30 in plan view, and is installed on the installation table S. From the center of the base 60, a cylindrical shaft portion 61 is erected along the central axis O upward. The diameter of the shaft portion 61 is slightly smaller than the diameter of the through hole 30a so that a gap can be fitted into the through hole 30a of the rotor core 30, for example. The length of the shaft portion 61 is such that when the rotor core 30 is set in the rotor manufacturing apparatus 50, the tip portion is substantially flush with the end surface on one side (the upper side in FIG. 6) of the rotor core 30, or the end surface on one side of the rotor core 30. It is set not to protrude from.

A plurality of first recesses 62 are formed around the central axis O on the upper surface 60 a of the base 60. In the first recess 62, a lower end portion of a first elastic member 71 that urges a lower mold 56 described later is disposed. The first elastic member 71 is preferably a coil spring, for example.
Further, a second recess 63 is formed on the upper surface 60 a of the base 60 at a position corresponding to the second slot 32 of the rotor core 30 installed in the rotor manufacturing apparatus 50 on the outer side in the radial direction from the first recess 62. Is formed. The second recess 63 is provided with a lower end portion of a second elastic member 72 that urges a support member 66 described later. The second elastic member 72 is preferably a coil spring, for example.

The lower die 56 is, for example, a disk-shaped member whose outer shape is formed substantially the same as the rotor core 30 in plan view. A third recess 57 is formed on the lower surface 56 b of the lower mold 56 at a position facing the first recess 62 of the base 60. The upper end portion of the first elastic member 71 is disposed in the third recess 57.
In addition, a through hole 58 is formed in the lower die 56 at a position corresponding to the second slot 32 of the rotor core 30 installed in the rotor manufacturing apparatus 50 and outside in the radial direction from the third recess 57. Yes. A support member 66 described later is inserted through the through hole 58.

Further, a circular insertion hole 59 is formed in the center of the lower die 56 so as to penetrate the lower die 56 in plan view. The diameter of the insertion hole 59 is slightly larger than the outer shape of the shaft portion 61 of the base 60. The lower die 56 is movable in the vertical direction along the axial direction when the shaft portion 61 of the base 60 is loosely inserted into the insertion hole 59.
The lower die 56 is disposed above the base 60 while being spaced apart from the base 60 via the first elastic member 71 and being biased upward.

The support member 66 is a rod-shaped member, and is inserted into the through hole 58 of the lower mold 56 and arranged with the upper end portion protruding from the upper surface 56a of the lower mold 56 by a predetermined distance. The diameter of the support member 66 is smaller than the diameter of the through hole 58 of the lower mold 56. The support member 66 is movable in the vertical direction by being loosely inserted into the through hole 58 of the lower mold 56.
The lower end portion of the support member 66 is a receiving portion 66a formed with a large diameter. The upper end portion of the second elastic member 72 is in contact with the receiving portion 66a. As a result, the support member 66 protrudes upward from the base 60 while being spaced apart from the bottom of the second recess 63 of the base 60 by the second elastic member 72 and being biased upward. Established.
The length of the support member 66 is such that the end surface on one side (the upper side in FIG. 6) of the second magnet 36B is filled when the filling mold 53 is clamped in the mold clamping step S12 (see FIG. 7) described later. It is set so that it can come into contact with the metal mold 53.

(Rotor manufacturing process)
FIG. 7 is a flowchart of the rotor 3 manufacturing process S10.
Then, the manufacturing process of the rotor 3 performed using the above-mentioned rotor manufacturing apparatus 50 is demonstrated.
As shown in FIG. 7, the manufacturing process S10 of the rotor 3 according to the present embodiment mainly includes a magnet insertion and placement process S11, a mold clamping process S12, a filling process S13, and a solidifying process S15. Below, the detail of each process is demonstrated using drawing. It should be noted that the steps described below are performed at the same timing for each of the first slot 31 to the third slot 33 of the rotor core 30. Further, the step of inserting and fixing the second magnet 36 </ b> B to the second slot 32 is the same as the step of inserting and fixing the third magnet 36 </ b> C to the third slot 33. Therefore, in the following, the process of inserting and fixing the first magnet 36A and the second magnet 36B to the first slot 31 and the second slot 32 of the rotor core 30, respectively, will be described, and the third slot 33 will be described. Description of the process of inserting and fixing the three magnets 36C is omitted. In the following description, refer to FIGS. 1 to 6 as necessary for the reference numerals of the respective components.

The manufacturing process S10 of the rotor 3 of the present embodiment is performed by the rotor manufacturing apparatus 50 configured as described above.
FIG. 8 is an explanatory diagram of the magnet insertion and placement step S <b> 11 and is a schematic side sectional view of the rotor core 30. In FIG. 8, the first magnet 36A after being inserted into the first slot 31 is indicated by a two-dot chain line.
As shown in FIG. 8, in the manufacturing process S <b> 10 of the rotor 3, a magnet insertion and placement process S <b> 11 is first performed.

In the magnet insertion and placement step S11, first, the through hole 30a of the rotor core 30 is inserted into the shaft portion 61 of the base 60, and the end surface on the other side (lower side in FIG. 6) of the rotor core 30 is brought into contact with the lower mold 56. Then, the rotor core 30 is set in a positioned state. Subsequently, the first magnet 36 </ b> A and the second magnet 36 </ b> B are inserted and arranged along the axial direction in the first slot 31 and the second slot 32 of the rotor core 30, respectively.
Thus, the first magnet 36A is disposed at a position where the end surface on one side (upper side in FIG. 8) is lowered by one step from the end surface on one side of the rotor core 30, and the end surface on the other side (lower side in FIG. 8). Comes into contact with the lower die 56 (see the two-dot chain line in FIG. 8).

9 to 11 are explanatory diagrams of the state after the magnet insertion and placement step S11 due to the stacking error of the rotor core 30, and FIG. 9 illustrates the case where the dimension along the axial direction of the rotor core 30 is as the reference dimension. FIG. 10 illustrates the case where the dimensional tolerance of the rotor core 30 swings to the plus side, and FIG. 11 illustrates the case where the dimensional tolerance of the rotor core 30 swings to the minus side. 10 and 11, for the sake of easy understanding, the dimensional tolerance is exaggerated and the case where the dimensional error is the maximum value is shown.
Here, as shown in FIGS. 9 to 11, the positional relationship between the rotor core 30 and the second magnet 36 </ b> B after the magnet insertion and placement step S <b> 11 corresponds to the stacking error of the rotor core 30 in the following three states. It will be in either state.

As shown in FIG. 9, when the dimension along the axial direction of the rotor core 30 is the same as the reference dimension, the second magnet 36 </ b> B has an end face on one side (upper side in FIG. 9) and an end face on one side of the rotor core 30. While being arranged so as to be substantially flush with each other, an end surface on the other side (lower side in FIG. 9) abuts on the support member 66.
Further, as shown in FIG. 10, when the dimensional tolerance of the rotor core 30 swings to the plus side, the second magnet 36 </ b> B has an end surface on one side (upper side in FIG. 10) more than an end surface on one side of the rotor core 30. While being disposed at a position lowered by one step, the end surface on the other side (the lower side in FIG. 10) contacts the support member 66.
As shown in FIG. 11, when the dimensional tolerance of the rotor core 30 swings to the minus side, the second magnet 36 </ b> B has an end surface on one side (upper side in FIG. 11) protruding from the end surface on one side of the rotor core 30. The other end surface (the lower side in FIG. 11) abuts on the support member 66.
When the first magnet 36A and the second magnet 36B are arranged in the first slot 31 and the second slot 32, respectively, the magnet insertion arrangement step S11 is completed.

  FIGS. 12 to 14 are explanatory diagrams of the difference in the clamping process S12 due to the stacking error of the rotor core 30, and FIG. 12 illustrates the clamping process S12 when the dimension along the axial direction of the rotor core 30 is the same as the reference dimension. FIG. 13 illustrates the mold clamping step S12 when the dimensional tolerance of the rotor core 30 swings to the plus side, and FIG. 14 illustrates the case where the dimensional tolerance of the rotor core 30 swings to the minus side. The mold clamping process S12 is illustrated. In FIGS. 13 and 14, the dimensional tolerance is exaggerated and the case where the dimensional error is the maximum value is illustrated for easy understanding as in FIGS. 10 and 11.

  In the mold clamping step S <b> 12, the filling mold 53 is moved downward and pressed (clamped) with a predetermined pressing force toward the axial end surface of the rotor core 30. Here, as shown in FIGS. 12 to 14, the mold clamping step S <b> 12 is in one of the following three states corresponding to the stacking error of the rotor core 30.

  As shown in FIG. 9, when the dimension along the axial direction of the rotor core 30 is the same as the reference dimension, when the filling mold 53 moves downward, one side of the rotor core 30 on the one side of the rotor core 30 is moved. The end face and the end face on one side of the second magnet 36B are in contact with each other substantially simultaneously. Subsequently, the filling mold 53 moves further downward and presses the rotor core 30 and the second magnet 36B with a predetermined pressing force against the urging force of the first elastic member 71 and the second elastic member 72. Tighten the mold. As a result, as shown in FIG. 12, in the rotor manufacturing apparatus 50, the first elastic member 71 and the second elastic member 72 are compressed, and the separation distance between the upper surface 60a of the base 60 and the lower mold 56 is L1. Retained.

  As shown in FIG. 10, when the dimensional tolerance of the rotor core 30 swings to the plus side, when the filling mold 53 moves downward, the end surface on one side of the rotor core 30 contacts the filling mold 53. Touch. Subsequently, when the filling mold 53 moves further downward, the rotor core 30 and the lower mold 56 move downward against the urging force of the first elastic member 71 that elastically supports the lower mold 56, and the filling mold 53 53, the one end surface of the second magnet 36B abuts. Subsequently, the filling mold 53 moves further downward and presses the rotor core 30 and the second magnet 36B with a predetermined pressing force against the urging force of the first elastic member 71 and the second elastic member 72. Tighten the mold. Thereby, as shown in FIG. 13, in the rotor manufacturing apparatus 50, the first elastic member 71 and the second elastic member 72 are compressed, and the separation distance between the upper surface 60a of the base 60 and the lower mold 56 is L2. Retained.

  As shown in FIG. 11, when the dimensional tolerance of the rotor core 30 swings to the negative side, when the filling mold 53 moves downward, the end surface on one side of the second magnet 36 </ b> B with respect to the filling mold 53. Abut. Subsequently, when the filling mold 53 moves further downward, the second magnet 36B and the support member 66 move downward against the urging force of the second elastic member 72 that elastically supports the support member 66, and the filling die 53 is filled. One end face of the rotor core 30 abuts against the mold 53. Subsequently, the filling mold 53 moves further downward and presses the rotor core 30 and the second magnet 36B with a predetermined pressing force against the urging force of the first elastic member 71 and the second elastic member 72. Clamp the mold. Thereby, as shown in FIG. 14, in the rotor manufacturing apparatus 50, the first elastic member 71 and the second elastic member 72 are compressed, and the separation distance between the upper surface 60a of the base 60 and the lower mold 56 is L3. Retained.

Here, the separation distances L1 to L3 between the upper surface 60a of the base 60 and the lower mold 56 are:
L2 <L1 <L3
Satisfied with the relationship. That is, since the pushing amount of the rotor core 30 by the filling mold 53 increases as the dimensional tolerance of the rotor core 30 swings to the plus side, the separation distance between the upper surface 60a of the base 60 and the lower mold 56 is reduced (FIG. 10 and FIG. 13). Further, since the pushing amount of the rotor core 30 by the filling mold 53 becomes smaller as the dimensional tolerance of the rotor core 30 moves to the minus side, the separation distance between the upper surface 60a of the base 60 and the lower mold 56 becomes larger (FIGS. 11 and FIG. 14).

  Further, the maximum values of the urging forces of the first elastic member 71 and the second elastic member 72 are the electromagnetic steel sheets that constitute the rotor core 30 when the filling mold 53 is pressed and clamped in the mold clamping step S12. The size is set such that each of the first magnet 36A to the third magnet 36C is not plastically deformed.

Further, the minimum value of the urging force of the first elastic member 71 and the second elastic member 72 is obtained when the thermoplastic resin material is filled with a predetermined injection pressure while the filling mold 53 is clamped in the filling step S13 described later. The rotor core 30 (electromagnetic steel plate) and the magnets 36A to 36C are urged against the injection pressure.
Specifically, the urging force of the first elastic member 71 is K1, the injection pressures applied to the slots 31 to 33 are P1 to P3, and the cross-sectional areas perpendicular to the axial direction of the slots 31 to 33 are respectively When D1 to D3 and the numbers of the slots 31 to 33 are n1 to n3, respectively,
K1> P1 × D1 × n1 + P2 × D2 × n2 + P3 × D3 × n3
Satisfied with the relationship.
Further, when the urging force of the second elastic member 72 is K2, and the cross-sectional area perpendicular to the axial direction of the second magnet 36B is M2,
K2> P2 × M2
Satisfied with the relationship.
Corresponding to the stacking error of the rotor core 30, the mold clamping step S <b> 12 ends when the rotor core 30 is clamped and held by a predetermined pressing force in any state of FIGS. 12 to 14.

Subsequently, a filling step S13 is performed.
In the filling step S13, an injection port at the tip of an injection nozzle (not shown) is inserted into the connection hole 53b of the filling mold 53, and a thermoplastic resin material is injected to fill the first slot 31 and the second slot 32. .
Here, at the positions corresponding to the filling groove 31 </ b> A formed in the first slot 31 of the rotor core 30 and the filling groove 32 </ b> A formed in the second slot 32, the filling hole 53 a of the filling mold 53 is arranged. Accordingly, the first magnet 36A disposed in the first slot 31 and the second magnet 36B disposed in the second slot 32 are pressed radially inward by the internal pressure of the filled thermoplastic resin material. , Abut against the inner wall 31b of the first slot 31 and the inner wall 32b of the second slot 32, respectively.

By the way, as described above, as shown in FIG. 3, the narrow gap 31c between the outer wall 31a of the first slot 31 and the outer surface of the first magnet 36A is formed with the outer wall 32a of the second slot 32. The inflow resistance R1 of the first slot 31 is larger than the inflow resistance R2 of the second slot 32 because it is larger than the formation range of the narrow gap 32c between the outer surface of the second magnet 36B.
On the other hand, as shown in FIGS. 12 to 14, in the filling step S <b> 13, the support member 66 and the end surface on the other side (lower side in each drawing) of the second magnet 36 </ b> B are in contact with each other, and the second elasticity A bias is applied from the other side to one side (from the lower side to the upper side in each figure) via the member 72. For this reason, the second magnet 36 </ b> B is closer to the filling mold 53 than the first magnet 36 </ b> A, and the second magnet 36 </ b> B is disposed in a state where one end face of the second magnet 36 </ b> B is in contact with the filling mold 53.

For this reason, the space formed between the second magnet 36 </ b> B and the filling mold 53 is narrower than the space formed between the first magnet 36 </ b> A and the filling mold 53. As a result, the inflow resistance from the filling hole 53a to the second slot 32 becomes larger than the inflow resistance from the filling hole 53a to the first slot 31, so the inflow resistance R1 of the first slot 31 and the inflow resistance of the second slot 32 The difference from the resistor R2 can be canceled out. Therefore, according to the present embodiment, the first slot 31 is located between the inner wall of the first slot 31 and the outer surface of the first magnet 36A, and between the inner wall of the second slot 32 and the outer surface of the second magnet 36B. Regardless of the difference in the shapes of 31 and the second slot 32, the thermoplastic resin material can be filled uniformly.
When the first slot 31 and the second slot 32 are filled with the thermoplastic resin material, the filling step S13 ends.

Then, solidification process S15 is performed. In the solidification step S15, the thermoplastic resin material filled in the first slot 31 and the second slot 32 is solidified by natural cooling. Here, in the prior art, when the first slot 31 and the second slot 32 are filled with the thermosetting resin material, the rotor 3 is put into a heater such as a thermostatic bath to reach a predetermined temperature. It was necessary to heat for a predetermined time. In contrast, in the present embodiment, since the thermoplastic resin material is filled in the first slot 31 and the second slot 32, it can be quickly solidified by natural cooling without heating for a predetermined time. Therefore, the manufacturing process for manufacturing the rotor 3 can be simplified and the manufacturing time can be shortened.
At this time, as shown in FIG. 5, the second mold part 38B and the third mold part 38C formed by solidifying the thermoplastic resin material filled in the second slot 32 and the third slot 33 have shafts. A concave portion 39 is formed at a position corresponding to the support member 66 (see FIG. 6) on the other end face in the direction.
When the thermoplastic resin material is solidified, the solidification step S15 is completed and the rotor 3 manufacturing step S10 is completed.

  According to the present embodiment, the filling mold 53 is configured to be able to press the rotor core 30 and the second magnet 36B against the urging force of the lower mold 56 and the support member 66 when the thermoplastic resin material is filled. Therefore, regardless of the stacking error in the axial direction of the rotor core 30, the filling mold 53, the rotor core 30, and the second magnet 36B can contact each other. Specifically, when the dimension along the axial direction of the rotor core 30 touches the positive side of the dimensional tolerance with respect to the reference dimension due to a stacking error of the rotor core 30, the filling mold 53 resists the urging force of the lower mold 56. Then, the rotor core 30 can be moved from one side in the axial direction toward the other side, and in contact with the second magnet 36B, the rotor core 30 and the second magnet 36B can be pressed. Further, when the dimension along the axial direction of the rotor core 30 touches the negative side of the dimensional tolerance with respect to the reference dimension due to the stacking error of the rotor core 30, the filling mold 53 is resistant to the urging force of the support member 66. The two magnets 36B can be moved from one side in the axial direction toward the other side, and in contact with the rotor core 30, the rotor core 30 and the second magnet 36B can be pressed. As a result, regardless of the stacking error of the rotor core 30, the second magnet 36B of the second slot 32 having a small inflow resistance is moved closer to the filling mold 53 side than the first magnet 36A of the first slot 31 having a large inflow resistance. In this state, the thermoplastic resin material can be filled. That is, regardless of the stacking error of the rotor core 30, the flow path cross-sectional area of the thermoplastic resin material formed between the second magnet 36 </ b> B and the filling mold 53 is reduced, and the thermoplasticity on the second slot 32 side is reduced. The inflow resistance of the resin material and the inflow resistance of the thermoplastic resin material on the first slot 31 side can be adjusted to be balanced. Therefore, while absorbing the stacking error of the rotor core 30, the thermoplasticity between the inner wall of each slot of the first slot 31 to the third slot 33 having a different shape and the outer surface of each magnet of the first magnet 36A to the third magnet 36C. Resin material can be filled.

  Further, the second magnet 36B can be easily and reliably brought closer to the filling mold 53 side than the first magnet 36A simply by providing the support member 66 on the lower die 56. Further, since the support member 66 has an outer shape smaller than the outer shape of the second magnet 36 </ b> B, the support member 66 can be disposed by being filled with a thermoplastic resin material. Therefore, the second magnet 36 </ b> B can be firmly held in the second slot 32.

In addition, since the filling mold 53 includes a mold clamping step S12 that presses the rotor core 30 and the second magnet 36B against the urging force of the lower mold 56 and the support member 66, the rotor core 30 is laminated in the axial direction. Regardless of the error, the filling mold 53 can contact the rotor core 30 and the second magnet 36B.
Further, in the filling step S13, the second magnet 36B of the second slot 32 having a small inflow resistance is brought closer to the filling mold 53 side than the first magnet 36A of the first slot 31 having a large inflow resistance, and the rotor core 30 and The thermoplastic resin material can be filled with the second magnet 36 </ b> B in contact with the filling mold 53. Thereby, the flow path cross-sectional area of the thermoplastic resin material formed between the second magnet 36B and the filling mold 53 is reduced, and the inflow resistance of the thermoplastic resin material on the second slot 32 side, It can be adjusted so that the inflow resistance of the thermoplastic resin material on the one slot 31 side is balanced.
Therefore, while absorbing the stacking error of the rotor core 30, the thermoplasticity between the inner wall of each slot of the first slot 31 to the third slot 33 having a different shape and the outer surface of each magnet of the first magnet 36A to the third magnet 36C. Can be filled with resin material

  In addition, a liquid crystal polymer can be suitably used as the thermoplastic resin material filled in each slot from the first slot 31 to the third slot 33 in the filling step.

  The present invention is not limited to the above-described embodiment, and includes various modifications made to the above-described embodiment without departing from the spirit of the present invention.

  For example, in the embodiment, the method for manufacturing the rotor 3 having the slot group 35 including the first slot 31, the second slot 32, and the third slot 33 has been described. However, the number and shape of the slots are described in the embodiment. It is not limited. Further, the shape and number of the lower mold 56 and the support member 66 constituting the rotor manufacturing apparatus 50 are not limited to the embodiment.

  For example, in the embodiment, the first magnet 36A, the second magnet 36B, and the third magnet 36C that are inserted into the first slot 31, the second slot 32, and the third slot 33 are so-called mainly composed of neodymium. Although the neodymium magnet was employ | adopted, the kind of 1st magnet 36A, the 2nd magnet 36B, and the 3rd magnet 36C is not limited to embodiment. Therefore, the first magnet 36A, the second magnet 36B, and the third magnet 36C are, for example, so-called samarium cobalt magnets mainly made of samarium (Sm), cobalt (Co), etc., aluminum (Al), nickel (Ni). In addition, a so-called alnico magnet made mainly of cobalt (Co) or the like may be used.

  In the embodiment, the case where the liquid crystal polymer is used as the thermoplastic resin material filled in each slot from the first slot 31 to the third slot 33 has been described. However, each slot is filled. The thermoplastic resin material is not limited to a liquid crystal polymer. Therefore, for example, a thermoplastic resin material other than a liquid crystal polymer such as polybutylene terephthalate (PBT), polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or the like.

  In addition, it is possible to appropriately replace the components in the above-described embodiments with known components without departing from the spirit of the present invention.

3 Rotor 30 Rotor core 31 First slot 32 Second slot 36A First magnet 36B Second magnet 50 Rotor manufacturing apparatus 53 Filling mold (first mold)
53a Filling hole 56 Lower mold (second mold)
66 Support member S11 Magnet insertion arrangement process S12 Clamping process S13 Filling process

Claims (4)

A first slot in which the first magnet is inserted and fixed by the thermoplastic resin material; and a second slot in which the second magnet is inserted and fixed by the thermoplastic resin material. The inflow resistance when the thermoplastic resin material flows between the inner wall and the outer surface of the first magnet is such that the thermoplastic resin material flows between the inner wall of the second slot and the outer surface of the second magnet. A rotor manufacturing apparatus for manufacturing a rotor having a rotor core larger than an inflow resistance when
The filling is arranged on one side of the rotor core in the axial direction of the rotor core and is movable along the axial direction so that the thermoplastic resin material can be injected into the first slot and the second slot. A first mold having a hole;
A second mold that contacts the rotor core from the other side in the axial direction to support the rotor core and is movable along the axial direction;
A support member that contacts the second magnet from the other side in the axial direction to support the second magnet at a predetermined position in the axial direction, and is movable along the axial direction;
With
The second mold and the support member are biased from the other side in the axial direction toward the one side,
The first mold is configured to be able to press the rotor core and the second magnet against the urging force of the second mold and the support member when filling the thermoplastic resin material. A rotor manufacturing apparatus. The rotor manufacturing apparatus according to claim 1,
The rotor manufacturing apparatus according to claim 1, wherein the support member has an outer shape smaller than an outer shape of the second magnet when viewed from the axial direction. A rotor manufacturing method using the rotor manufacturing apparatus according to claim 1,
A magnet insertion and placement step of inserting the first magnet and the second magnet into the first slot and the second slot, respectively;
A mold clamping step of pressing the rotor core and the second magnet against the urging force of the second mold and the support member by the first mold;
The thermoplastic resin material is injected from the filling hole of the first mold by a predetermined injection pressure, between the inner wall of the first slot and the outer surface of the first magnet, and the inner wall of the second slot and the A filling step for filling the outer surface of the second magnet;
Including
In the filling step, the second magnet is moved closer to the first mold than the first magnet, and the rotor core and the second magnet are in contact with the first mold. A rotor manufacturing method. The rotor manufacturing method according to claim 3,
The rotor manufacturing method, wherein the thermoplastic resin material filled in the filling step is a liquid crystal polymer.

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