WO2023022232A1 - Procédé de fabrication d'un noyau de machine électrique rotative, dispositif de fabrication de noyau et noyau - Google Patents

Procédé de fabrication d'un noyau de machine électrique rotative, dispositif de fabrication de noyau et noyau Download PDF

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Publication number
WO2023022232A1
WO2023022232A1 PCT/JP2022/031419 JP2022031419W WO2023022232A1 WO 2023022232 A1 WO2023022232 A1 WO 2023022232A1 JP 2022031419 W JP2022031419 W JP 2022031419W WO 2023022232 A1 WO2023022232 A1 WO 2023022232A1
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WIPO (PCT)
Prior art keywords
resin
core
core body
manufacturing
layer
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PCT/JP2022/031419
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English (en)
Japanese (ja)
Inventor
愼太郎 馬場
巧 矢野
誠司 宮本
啓太 園田
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株式会社三井ハイテック
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Publication of WO2023022232A1 publication Critical patent/WO2023022232A1/fr

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/64—Electric machine technologies in electromobility

Definitions

  • the present disclosure relates to a manufacturing method and manufacturing apparatus for a core portion in a rotor or stator of a rotating electric machine. Furthermore, the present disclosure also relates to a core portion in a rotor or stator of a rotating electric machine.
  • laminated iron cores are generally used as cores in which coils and permanent magnets are arranged.
  • various ideas have been made in arranging coils and permanent magnets in the core of the laminated core.
  • Patent Document 1 in the case of a rotor core, particularly in the case of a rotor core of an IPM motor, a structure in which magnets are inserted and fixed into magnet insertion holes of a laminated iron core has been adopted.
  • a thermosetting resin or the like in a melted and fluid state is placed in the gap between the inner wall surface of the magnet insertion hole and the permanent magnet. of resin is injected to fill the gap, and then the resin is solidified to fix the permanent magnet.
  • Patent Document 1 Conventional cores for rotating electric machines are manufactured by the method shown in Patent Document 1.
  • resin injection device that injects resin into the magnet storage holes of the rotor core sandwiched and pressed between the upper and lower dies, resin was efficiently injected into the magnet storage holes, and the core and the magnets could be integrated.
  • An object of the present disclosure is to provide a core part manufacturing method, a core part manufacturing apparatus, and a core part with good manufacturing efficiency.
  • a core body formed by laminating a plurality of thin plates made of a magnetic metal material is positioned between a pair of molds, and a plurality of spaces in the core body are filled with resin.
  • the resin held in the resin holding portion located on one mold side of the pair of molds is At least a feeding step of feeding into a space portion of the core body and a solidification step of solidifying the molten resin in the space portion while sandwiching the core body between the pair of molds, In the feeding step, the fed resin is melted in the space, or the melted resin is fed into the space, and the melted resin is positioned in the space.
  • the solidification of the resin consists of a plurality of types and includes at least one resin that solidifies at a predetermined solidification speed faster than the other resins from a molten state, and in the feeding step, the one resin and the other resin The resins are fed in a predetermined order, and in the solidification step, the one resin is interposed between the mold and the other resin to proceed with solidification for the mold through which the space is communicated. , to solidify the at least one resin.
  • one resin having a high solidification rate is fed so as to be interposed between the mold and the other resin positioned in the space. Therefore, even when the other resins are not yet solidified, if one resin is solidified, the core body can be taken out from between the molds without affecting the filled state of the other resins. Compared to the case where only other resins are sent into the space and solidified, the time for restraining the core body between the molds can be shortened by the difference in the solidification time between one resin and the other resin, so the manufacturing efficiency of the core part is improved. improves.
  • FIG. 1 is an explanatory diagram of a resin material holding state of a core portion manufacturing apparatus to which the core portion manufacturing method according to the first embodiment is applied.
  • FIG. 2 is a vertical cross-sectional view of the iron core body used in the core manufacturing method according to the first embodiment in a state of being supported by a jig.
  • FIG. 3 is an explanatory diagram of a state of molten resin feeding in a feeding step in the method for manufacturing the core portion according to the first embodiment.
  • FIG. 4 is an explanatory view of the separated state of the core body and the auxiliary plate from the upper die of the core part manufacturing apparatus in the core part manufacturing method according to the first embodiment.
  • FIG. 5A is a plan view of the core body after being filled with resin by the core manufacturing method according to the first embodiment.
  • FIG. 5B is a cross-sectional view taken along line BB of FIG. 5A.
  • FIG. 6 is an explanatory diagram of a molten resin feeding state without interposition of an auxiliary plate in another core manufacturing apparatus to which the core manufacturing method according to the first embodiment is applied.
  • FIG. 7 is an explanatory diagram of a resin material holding state in another core manufacturing apparatus to which the core manufacturing method according to the first embodiment is applied.
  • FIG. 8 is an explanatory diagram of a molten resin feeding state in another core manufacturing apparatus to which the core manufacturing method according to the first embodiment is applied.
  • FIG. 6 is an explanatory diagram of a molten resin feeding state without interposition of an auxiliary plate in another core manufacturing apparatus to which the core manufacturing method according to the first embodiment is applied.
  • FIG. 7 is an explanatory diagram of a resin material holding state in another core manufacturing apparatus to which the core manufacturing method according to the first embodiment is applied.
  • FIG. 8 is an explanatory diagram of a molten resin feeding state in another core manufacturing
  • FIG. 9 is an explanatory view of the removal state of the iron core body after resin filling from the jig corresponding to early removal from the jig in the method of manufacturing the core portion according to the first embodiment.
  • FIG. 10 is an explanatory view of a resin material holding state of a core manufacturing apparatus to which the core manufacturing method according to the second embodiment is applied.
  • FIG. 11 is an explanatory diagram of the molten resin injection state in the feeding step in the method for manufacturing the core portion according to the second embodiment.
  • 12A and 12B are diagrams for explaining the separation state of the core body, the auxiliary plate and the jig from the upper and lower molds of the core part manufacturing apparatus in the core part manufacturing method according to the second embodiment.
  • FIG. 13 is an explanatory diagram of a state of resin material holding in another core manufacturing apparatus to which the core manufacturing method according to the second embodiment is applied.
  • FIG. 14 is an explanatory diagram of a molten resin feeding state in another core manufacturing apparatus to which the core manufacturing method according to the second embodiment is applied.
  • FIG. 15 is an explanatory diagram of the separated state of the core body, the auxiliary plate and the jig from the upper and lower dies of another core part manufacturing apparatus to which the core part manufacturing method according to the second embodiment is applied.
  • the method of manufacturing the core part according to the present embodiment is such that the resin held by the resin holding part 24 positioned on the upper die 21 side of the upper die 21 and the lower die 22 forming a pair is placed in the space of the core body 11 . and a solidification step of solidifying the molten resin in the space while holding the core body 11 between the upper mold 21 and the lower mold 22 .
  • the melted resin is fed into the space in the feeding step, and after the melted resin is positioned in the space, solidification of the resin proceeds in the solidification step.
  • first resin will set at a predetermined set rate that is faster than the second resin.
  • the first resin and the second resin are fed in a predetermined order.
  • the solidification step when the first resin is interposed between the mold and the second resin, at least the first resin is solidified.
  • the core part manufacturing apparatus 1 to which the core part manufacturing method according to the present embodiment is applied fills a plurality of spaces to be filled with resin in a core body 11 having a laminated structure with molten resin, solidifies it, and rotates a rotating electric machine.
  • a child core portion 10 is manufactured.
  • the core part manufacturing apparatus 1 includes an upper mold 21 and a lower mold 22 as filling mechanism units that sandwich the core body 11 from both sides in the lamination direction, and a space part of the core body 11 that is positioned on the upper mold 21 side and holds the resin. and a resin holding portion 24 capable of feeding resin into.
  • 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 includes permanent magnets 12 inserted into the magnet insertion holes 11b and resin fillers 13 (see FIGS. 5A and 5B) filled in the magnet insertion holes 11b.
  • 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 application of the rotating electric machine, required performance, and the like.
  • a shaft hole 11c is provided that penetrates the core body 11 in the stacking direction of the thin plates 11a.
  • the rotating shaft is fixed to the core body 11 by inserting the rotating shaft (shaft) of the rotor through the shaft hole 11c.
  • the iron core body 11 is integrated with the jig 30 by being supported by the jig 30 before and after the resin feeding process by the core manufacturing apparatus 1 .
  • a plate-shaped auxiliary plate 40 is attached to the end face of the core body 11 opposite to the side facing the jig 30 to assist the insertion of the resin into the magnet insertion hole 11b as the space.
  • the permanent magnets 12 are inserted into the magnet insertion holes 11b of the iron core body 11 for use in the rotor field system.
  • the permanent magnet 12 is formed slightly smaller than the magnet insertion hole 11 b of the core body 11 . Accordingly, when the permanent magnets 12 are inserted into the respective magnet insertion holes 11b, gaps are created between the permanent magnets 12 and the core body 11. As shown in FIG. That is, the magnet insertion holes 11b into which the permanent magnets 12 are inserted are left partially empty.
  • 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 filler 13 is a resin that is injected 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 solidifies after filling.
  • the resin forming the filler 13 is, for example, a thermosetting resin such as an epoxy resin, a thermoplastic resin, or the like.
  • the filler 13 is obtained by melting a resin material supplied as a resin tablet, powdered resin, or the like, and then solidifying the material. It should be noted that the resin constituting the filler 13 can be made of a plurality of types, and in that case, a plurality of types of base resin materials are also used.
  • the filling material 13 fixes the permanent magnets 12 in the magnet insertion holes 11b and also contributes to strengthening the connection between the laminated and adjacent thin plates 11a.
  • the upper die 21 and the lower die 22 sandwich and press the core body 11 placed on the jig 30 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 11 b of the core body 11 can be closed by the plate portion 31 of the jig 30 .
  • the core part manufacturing apparatus 1 injects the resin held by the resin holding part 24 positioned on the upper mold 21 side of the pair of molds into the magnet insertion hole 11b as the space in the core body 11 from above. can be sent.
  • the feeding by the resin holding portion 24 is to inject the molten resin into the magnet insertion hole 11b and position the molten resin in the magnet insertion hole 11b.
  • the resin fed into the resin holding unit 24 includes a plurality of types of resin that solidify from a molten state with different solidification speeds. Specifically, it includes a first resin that has the fastest solidification rate and a second resin that generally has a slower solidification rate than the first resin.
  • the resin holding portion 24 holds the first resin in the upper layer and the second resin in the lower layer in a laminated state.
  • the resin holding unit 24 feeds the first resin and the second resin in the order of the second resin and the first resin in the feeding step. As a result, the resins can be solidified in a layered state in which the melted first resin layer is positioned above the melted second resin layer.
  • the upper die 21 is positioned above the core body 11 placed on the lower die 22 and sandwiches the core body 11 , the auxiliary plate 40 and the jig 30 together with the lower die 22 .
  • the upper die 21 is, for example, a rectangular plate-shaped die, and is provided with a plurality of accommodation holes 21a capable of accommodating and holding resin. Further, the upper die 21 has an accommodating hole 21a into which a resin material such as a tablet-like or powdery first resin and a second resin can be inserted from above, and a resin can be extruded into the magnet insertion hole 11b of the core body 11. and an extrusion portion 23 having the following.
  • the housing hole 21a and the extrusion portion 23 in the upper die 21 form a resin holding portion 24. As shown in FIG. That is, the resin holding portion 24 is integrated with the upper mold 21 .
  • the receiving holes 21a as part of the resin holding portion 24 are positioned at locations corresponding to the magnet insertion holes 11b of the core body 11 when the core body 11 is sandwiched between the upper die 21 and the lower die 22. , are arranged side by side at predetermined intervals.
  • Each accommodation hole 21a can accommodate a resin material supplied in the form of a resin tablet, powder, or the like.
  • the resin material two types of resin material 81, which is the first resin, and resin material 82, which is the second resin, are used.
  • Each accommodation hole 21a holds a laminated state in which the resin material 81 is the upper layer and the resin material 82 is the lower layer.
  • the upper die 21 also has a mechanism for heating and melting the resin materials 81 and 82 to obtain molten resins 84 and 85 as a function of the resin holding portion 24 .
  • the upper die 21 is provided with heaters (not shown) capable of heating the resin materials 81 and 82 contained in the respective containing holes 21a. When the resin materials 81 and 82 are heated, they are melted in the accommodation holes 21 a to become molten resins 84 and 85 .
  • the extruding portion 23 can extrude the molten resins 84 and 85 into the magnet insertion holes 11b of the core body 11.
  • the pushing part 23 is, for example, a plurality of plungers that can be vertically moved by being driven by a predetermined driving source.
  • Each extruding part 23 may be driven by a corresponding drive source for each extruding part and can move up and down, and a plurality of extruding parts can be driven together by one drive source and can move up and down as a unit. may be
  • the molten resins 84 and 85 held in the accommodation hole 21 a are extruded from the accommodation hole 21 a of the upper die 21 by the extruding portion 23 in the feeding process, and arranged between the upper die 21 and the upper end surface of the core body 11 .
  • the resin passes through the resin passage 41 of the auxiliary plate 40 and flows into each magnet insertion hole 11 b of the core body 11 .
  • the lower molten resin is fed first, that is, the lower molten resin 85 that is the second resin and the upper molten resin 84 that is the first resin are fed in this order.
  • the lower mold 22 holds the core body 11 and the jig 30 together with the upper mold 21 while supporting the core body 11 and the jig 30 thereon.
  • the lower mold 22 is, for example, a mold formed in the shape of a rectangular plate, and is fitted with projections or recesses provided on the lower surface of the jig 30 as necessary to prevent unnecessary movement of the jig. of recesses or protrusions.
  • the jig 30 includes a plate portion 31 on which the core body 11 can be placed, and a post portion 32 projecting upward from a substantially central portion of the plate portion 31 (see FIG. 2).
  • the plate portion 31 is, for example, a rectangular plate-like pedestal 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 post part 32 is formed in a columnar shape and is arranged so as to protrude upward from substantially the center of the upper surface of the plate part 31 .
  • the post portion 32 has a columnar shape with a size corresponding to the shaft hole 11 c of the core body 11 and can be inserted through the shaft hole 11 c of the core body 11 .
  • the auxiliary plate 40 is a plate-like member formed with resin passages 41 (for example, runners, gate holes) that guide resin to the magnet insertion holes 11b.
  • the auxiliary plate 40 is attached as a so-called cull plate to the end face of the core body 11 on the side not in contact with the jig 30, and the core body 11 is sandwiched between the upper mold 21 and the lower mold 22 of the feeding mechanism section 20. , between the upper die 21 and the core body 11 .
  • the auxiliary plate 40 By attaching the auxiliary plate 40 to the core body 11 , after the molten resin 84 injected and filled into the core body 11 is solidified, the solidified resin remaining above the core body 11 (cull) is removed from the auxiliary plate 40 . It can be removed by detachment, and unnecessary resin can be removed more easily.
  • the bottom surface of the auxiliary plate 40 directly below the accommodation hole 21a may be sloped.
  • the slope may be linear or gently curved.
  • the core body 11 is obtained in advance by stacking a plurality of thin plates 11a punched from a thin plate material by a known manufacturing method.
  • the permanent magnet 12 is inserted into the magnet insertion hole 11b, and the iron core body 11 is preheated to an appropriate temperature. transported to
  • the auxiliary plate 40 may be attached to the core body 11 before preheating, and the auxiliary plate 40 may be preheated together with the core body 11 .
  • a separate preheated auxiliary plate 40 may be attached to the preheated core body 11 .
  • the iron core body 11 is transferred toward the core manufacturing apparatus 1 together with the attached auxiliary plate 40 .
  • Two types of resin materials 81 and 82 as materials for molten resins 84 and 85 are automatically supplied to the upper mold 21 of the core part manufacturing apparatus 1 into the accommodation holes 21 a of the upper mold 21 .
  • the resin materials 81 and 82 are heated and melted by the upper mold 21 before the resin materials 81 and 82 are injected into the magnet insertion holes 11b.
  • the core body 11 to which the auxiliary plate 40 is attached and the jig 30 on which the core body 11 is placed are transferred toward the core part manufacturing apparatus 1 by the operation of the transfer mechanism.
  • the core body 11 reaches the core manufacturing apparatus 1 the core body 11 , the auxiliary plate 40 and the jig 30 pass through the core body carrying-in/out opening of the core manufacturing apparatus 1 . It is carried in between 21 and lower mold 22 .
  • the jig 30 with the core body 11 placed thereon is placed on the lower die 22 by the transfer mechanism, the carrying-in of the core body 11, the auxiliary plate 40 and the jig 30 into the core manufacturing apparatus 1 is completed.
  • two types of resin materials 81 and 82 are supplied to the upper mold 21 of the core part manufacturing apparatus 1, and are accommodated in a laminated state in which the resin material 81 is the upper layer and the resin material 82 is the lower layer in each accommodation hole 21a. retained (see FIG. 1).
  • the resin materials 81 and 82 held in the accommodation holes 21a are heated at appropriate timings and melted in the lamination state in the accommodation holes 21a to form molten resins 84 and 85, respectively.
  • the auxiliary plate 40 and the jig 30 between the upper die 21 and the lower die 22 After carrying the core body 11, the auxiliary plate 40 and the jig 30 between the upper die 21 and the lower die 22, the upper die 21 is lowered or the lower die 22 on which the core body 11 is mounted is lifted. The core body 11 is sandwiched and pressed between the upper die 21 and the lower die 22 via the plate 40 and the jig 30 .
  • the auxiliary plate 40 and the jig 30 are brought into contact with both end surfaces of the core body 11 in the stacking direction and pressed, so that the magnet insertion holes 11b are formed at the ends of the core body 11 in the stacking direction. blocked.
  • each extrusion part 23 is driven and inserted into the accommodation hole 21a of the upper mold 21, respectively.
  • the molten resins 84, 85 are extruded downward from the accommodation hole 21a in the order of the lower layer molten resin 85 and the upper layer molten resin 84 (see FIG. 3).
  • the extruded resin is injected and filled into the magnet insertion holes 11 b of the core body 11 through the resin passages 41 of the auxiliary plate 40 in order from the lower layer molten resin 85 .
  • the molten resins 84 and 85 existing in the resin passage 41 and the magnet insertion hole 11b of the auxiliary plate 40 are placed above the layer of the molten resin 85, which is the second resin. It is in a laminated state in which a layer of molten resin 84 is positioned.
  • the boundary between the layer of the molten resin 85 and the layer of the molten resin 84 located on the side of the upper die 21, that is, on the upper side of the molten resin 85 is the core body on the side of the upper die 21 in the magnet insertion hole 11b as a space. 11, and both the molten resin 84 and the molten resin 85 are filled in the magnet insertion hole 11b. That is, the molten resin 84, which is the first resin, is provided at the upper end portion of the core body 11 in the stacking direction.
  • the molten resins 84 and 85 located in the resin passage 41 of the auxiliary plate 40 and the magnet insertion holes 11b are melted while maintaining the state of sandwiching and pressing the core body 11 between the upper mold 21 and the lower mold 22. Allow solidification to proceed.
  • the molten resins 84 and 85 when the molten resin 84, which is the first resin having the fastest solidification speed, solidifies and becomes a solidified resin 87, the extruding part 23 is pulled up from the upper die 21 to return to its original state, The upper die 21 is raised or the lower die 22 is lowered to separate the upper die 21 and the auxiliary plate 40, and the clamping and pressing of the core body 11 by the upper die 21 and the lower die 22 is finished. Thereby, the core body 11, the auxiliary plate 40, and the jig 30 can be carried out from between the upper die 21 and the lower die 22 (see FIG. 4).
  • the solidified resin 87 is positioned above the molten resin 85 in the magnet insertion hole 11b and melts with the upper mold 21. It is located between the resin 85 .
  • the solidified resin 87 can be held even if the molten resin 85 is subjected to expansion stress as the solidification of the molten resin 85 progresses. The force can suppress the influence of expansion of the molten resin 85 due to stress.
  • the molten resin 85 is less likely to be affected by relative movement of the upper die 21 with respect to the core body 11 .
  • the molten resin 85 can be solidified while properly positioned in the magnet insertion hole 11b of the core body 11, and the filler 13 can be obtained without any problem.
  • the solidified resin obtained by solidifying the molten resin 85, which is the second resin, is an example of the second resin portion.
  • the core body 11, the auxiliary plate 40, and the jig 30 are carried out of the core part manufacturing apparatus 1 from between the upper mold 21 and the lower mold 22 by the transfer mechanism.
  • the iron core body 11, the auxiliary plate 40, and the jig 30 carried out from the core part manufacturing apparatus 1 are transferred to the next step by the operation of the transfer mechanism.
  • the molten resin 84 has become the solidified resin 87
  • the core body 11, the auxiliary plate 40, and the jig 30 are transferred to the upper mold 21 and the lower mold 22 by the transfer mechanism without waiting for the molten resin 85 to solidify.
  • the molten resin 85 is solidified by residual heat of the core body 11 while the core body 11, the auxiliary plate 40, and the jig 30 are transferred from the core manufacturing apparatus 1 to the next step.
  • the upper die 21 is separated from the core body 11, and the molten resin 84, which is the first resin having a high solidification speed, is placed in the upper die 21 and the second resin positioned in the magnet insertion hole 11b. Feeding is performed so that it is positioned between a certain molten resin 85, and solidification of the resin proceeds in a state where the molten resin 85 with a slow solidification speed does not contact the upper mold 21, and the molten resin 84 with a fast solidification speed solidifies. do.
  • the core body 11 can be released and taken out from between the upper die 21 and the lower die 22 . Even if the molten resin 85 is not solidified, if the molten resin 84 is solidified to form a solidified resin 87, the core body 11 can be moved between the upper mold 21 and the lower mold 21 without affecting the filling state of the molten resin 85. It can be removed from between the molds 22 .
  • the time during which the core body 11 is restrained between the upper die 21 and the lower die 22 is equal to the difference between the solidification times of the molten resins 84 and 85. can be shortened, the manufacturing efficiency of the core portion 10 is improved.
  • one resin is defined as the first resin
  • the other resin is defined as the second resin. type is used.
  • the first resin which is one of these resins, solidifies from a molten state at a predetermined solidification speed faster than that of the second resin.
  • one resin and another resin may be composed of a plurality of types of resin. For example, even if a third resin is included in addition to the second resin as other resins other than the first resin, which is one resin, the first resin is the second resin and the third resin.
  • the third resin may be lower in cost than the second resin as long as there is no problem with the quality at the time of delivery or after solidification. In this case, the cost of the core portion can be reduced, and if the solidification speed of the third resin is faster than that of the second resin, the manufacturing efficiency of the core portion can be improved.
  • the second resin can be considered to have better properties such as fluidity than the low-cost third resin, the second resin is arranged in a lower layer than the third resin in the resin holding part, and the second resin is It is desirable to feed the resin before the third resin so as to position it in the deep part of the space.
  • the layers of the molten resin 85 and the layers of the molten resin 84 are formed.
  • the boundary is located near the upper end of the core body 11 in the magnet insertion hole 11b as a space, and the molten resin 84, which is the first resin, is arranged above the magnet insertion hole 11b.
  • the boundary between the layer of the molten resin 85 that is the second resin and the layer of the molten resin 84 that is the first resin is positioned in the resin passage 41 and is not limited to the example of this embodiment, and the magnet insertion hole 11b is formed. can be filled with only the molten resin 85.
  • the filler 13 since the boundary of the molten resin layer is not positioned within the magnet insertion hole 11b, only one type of resin can be used as the filler 13 within the core body 11 after the molten resin is solidified. Since the filler 13 is composed of a homogeneous single resin, the filler 13 is superior in terms of strength.
  • the molten resins 84 and 85 are fed into the magnet insertion hole 11b from the housing hole 21a of the upper die 21 with the auxiliary plate 40 attached to the upper side of the core body 11. be done. Without being limited to this, as shown in FIG. It is also possible to adopt a configuration in which the resin is fed into the magnet insertion hole 11 b of the core body 11 from the resin holding portion 21 .
  • the resin materials 81 and 82 are held in a layered state in which the resin material 81 is the upper layer and the resin material 82 is the lower layer in each accommodation hole 21a forming the resin holding portion in the upper die 21, and these resin materials are held at appropriate timings. to obtain molten resins 84 and 85.
  • the lower layer molten resin 85 that is the second resin and the upper layer molten resin 84 that is the first resin are fed in this order.
  • a layer of molten resin 84, which is the first resin, is positioned on the upper side of the layer of molten resin 85, which is the second resin. do.
  • the solidified resin 87 is positioned on the upper end side of the molten resin 85 in the magnet insertion hole 11b, and the upper die 21 and the molten resin 85 are positioned. It will be interposed like a lid between them. As a result, even if the upper die 21 and the upper end surface of the core body 11 are separated from each other at a stage where the molten resin 85 is not yet solidified, the solidified resin 87 interposed between the upper die 21 and the molten resin 85 is not solidified. , the influence of the relative movement of the upper die 21 with respect to the core body 11 on the molten resin 85 can be suppressed.
  • the molten resin 85 can form the filler 13 together with the solidified resin 87 without any problem by being solidified while being properly positioned in the magnet insertion hole 11b of the core body 11 .
  • the molten resins 84 and 85 are fed into the magnet insertion hole 11b in a predetermined order, so that the molten resin 85, which is the second resin, is A layer of molten resin 84, which is the first resin, is positioned above the layers.
  • the solidification process proceeds with the molten resin 84 interposed between the upper mold 21 and the molten resin 85 .
  • an unmelted tablet-like, granular, or powdery resin material is fed into the magnet insertion hole 11b, and then the permanent magnet is inserted into the magnet insertion hole 11b. 12 may be inserted and the resin material may be melted so that the melted resin is properly positioned in each part of the magnet insertion hole 11b and then solidified.
  • resin materials such as tablets, granules, powders, etc.
  • they are composed of two types, for example, a first resin with a fast solidification speed and a second resin with a slower solidification speed. It is desirable that the resin materials are fed in the order of the second resin and the first resin.
  • the layer of the molten resin 84 which is the first resin, is positioned above the layer of the molten resin 85, which is the second resin. That is, in the solidification step, solidification progresses in a state in which the molten resin 84 is interposed between the upper mold 21 and the molten resin 85 through which the magnet insertion holes 11b are communicated.
  • the molten resin 84 that solidifies quickly is provided between the upper mold 21 and the molten resin 85, so that regardless of whether the solidification of the molten resin 85 is complete or incomplete,
  • the molten resin 84 is solidified, the upper die 21 and the core body 11 are separated from each other.
  • the completion of solidification of the molten resin 85 which is the second resin, when the core body 11 needs to be separated from the jig 30 below it at an early stage and the core body 11 needs to be transferred.
  • the molten resin may be fed such that the molten resin of the first resin is also positioned below the layer of molten resin made of the second resin.
  • the resin material 81 which is the first resin
  • the resin material 82 which is the second resin
  • the resin materials 81 and 82 are held in a stacked state (see FIG. 7).
  • the molten resin 84, 85 melted from the resin material is melted in the order of the molten resin 84 of the lower layer, the molten resin 85 of the intermediate layer, and the molten resin 84 of the upper layer while maintaining the laminated state.
  • Resins 84, 85 are fed.
  • a layer of molten resin 84 which is the first resin
  • the second resin respectively (see FIG. 8).
  • the solidified resin 87 is positioned at the upper and lower ends of the molten resin 85 within the magnet insertion hole 11b (see FIG. 9). That is, the solidified resin 87 is provided between the upper mold 21 and the molten resin 85 and between the jig 30 and the molten resin 85 . As a result, even if the upper die 21 and the core body 11 are separated from each other or the core body 11 and the jig 30 are further separated at a stage where the molten resin 85 is not yet solidified, the upper die 21 and the molten resin 85 do not melt.
  • the solidified resin 87 interposed between the resin 85 and between the jig 30 and the molten resin 85 suppresses the influence of the relative movement of the upper die 21 and the jig 30 with respect to the core body 11 on the molten resin 85. be able to. Since the molten resin 85 is solidified while being properly positioned in the magnet insertion hole 11b of the core body 11, the filler 13 can be formed together with the solidified resin 87 without any problem.
  • the accommodation hole 21a and the extrusion part 23 in the upper die 21 constitute the resin holding part 24, and the resin holding part 24 is integrally incorporated into the upper die 21.
  • the resin holding portion that holds and feeds the resin may be independent of the upper mold or the lower mold.
  • it may be configured such that the resin holding portion positioned above the core body feeds the resin from above into the core body before it is positioned between the upper die and the lower die.
  • the resin holding portion is positioned above the core body and below the upper mold with respect to the core body positioned between the upper and lower molds but before being sandwiched between the upper and lower molds, and feeds the resin into the core body. After that, the resin holding portion can be retracted from the upper side of the core body so that the core body can be sandwiched between the upper mold and the lower mold.
  • a resin holder independent of the upper and lower molds continuously feeds the molten resin to the core body side. It may also have a mechanism that allows it to be inserted.
  • a resin that is excellent in continuous supply such as a thermoplastic or thermosetting hot-melt adhesive, may be used.
  • the resin fed into the magnet insertion hole 11b as the space portion is mainly a thermosetting resin, but not limited to this, a thermoplastic resin may also be used. good too. If a predetermined thermoplastic resin with a higher melting point or glass transition point than the thermoplastic resins used as the other resins is used as one resin with a fast solidification speed, it can be adjusted to the temperature drop in the solidification process after feeding. Since one of the resins is completely solidified first, it is possible to suppress external influences such as molds on other resins that have not yet been completely solidified.
  • the one resin and the other resin have substantially the same fluidity.
  • the greater the difference in fluidity between one resin and the other resin the more the one resin will overtake the other resin and the resin will flow in, making it easier for the one resin and the other resin to mix.
  • the resin can be flowed into the magnet insertion hole 11b in a state where the order of the other resin and the first resin is not disturbed.
  • the resin is injected into the core body 11 from the upper die 21 side of the core part manufacturing apparatus 1.
  • the present invention is not limited to this and the second embodiment.
  • the core manufacturing apparatus 2 is constructed such that resin is injected from the lower die 27 side of the core manufacturing apparatus 2 in the feeding step.
  • the method for manufacturing the core part according to the present embodiment has the feeding step and the solidifying step, as in the first embodiment, and in the feeding step, the resin holding part 29 located on the lower mold 27 side is The retained resin is fed into the space of the core body 11 from below.
  • the core part manufacturing apparatus 2 to which the core part manufacturing method according to the present embodiment is applied includes an upper die 26 and a lower die 27 as a filling mechanism part, while the lower die 27 is the core body. 11 is provided with a resin holding portion 29 for holding the resin so as to be able to be fed thereinto.
  • An upper mold 26 and a lower mold 27 forming a filling mechanism part of the core part manufacturing apparatus 2 hold the core body 11 in a molten state in the magnet insertion hole 11b as a space part, as in the first embodiment.
  • a certain resin is pressurized and the solidification of the resin is advanced.
  • the iron core body 11 is supported by the jig 35 before and after the resin feeding step by the core manufacturing apparatus 2, and is handled integrally with the jig 35.
  • An auxiliary plate 45 is attached to the end face opposite to the side facing 35 .
  • the shapes of the tool 35 and the auxiliary plate 45 also correspond to resin feeding from the lower die 27 side.
  • the resin is injected into the magnet insertion hole 11 b through the jig 35 from the side of the lower end surface of the iron core body 11 that contacts the jig 35 .
  • the upper die 26 is positioned above the lower die 27 and sandwiches the core body 11, the auxiliary plate 45 and the jig 35 together with the lower die 27, as in the first embodiment.
  • the upper mold 26 has the same configuration as that of the first embodiment, except that no holes (receiving holes 21a, extruding portions 23) passing through the upper mold 26 are provided. omitted.
  • the lower die 27 supports the core body 11 and the jig 35 to which the auxiliary plate 45 is attached, as in the first embodiment.
  • the lower mold 27 is provided with a plurality of accommodation holes 27a capable of accommodating and holding resin.
  • the lower die 27 has an accommodation hole 27a into which a resin material such as a tablet-like or powdery first resin and a second resin can be inserted, and a resin can be extruded into the magnet insertion hole 11b of the core body 11. and an extrusion portion 28 .
  • the accommodation hole 27a and the extrusion portion 28 in the lower die 27 form the resin holding portion 29. As shown in FIG. That is, the resin holding portion 29 is integrated with the lower mold 27 .
  • the housing holes 27a as part of the resin holding portion 29 are positioned at locations corresponding to the magnet insertion holes 11b of the core body 11 in a state in which the core body 11 is sandwiched between the upper die 26 and the lower die 27. , are arranged side by side at predetermined intervals.
  • Each accommodation hole 27a can accommodate a resin material supplied in the form of a resin tablet, powder, or the like. As in the first embodiment, two types of resin materials are used: a resin material 81 that is a first resin and a resin material 82 that is a second resin. Each accommodation hole 27a holds a laminated state in which the resin material 81 is the lower layer and the resin material 82 is the upper layer.
  • the lower die 27 also has a mechanism for heating and melting the resin materials 81 and 82 to obtain molten resins 84 and 85 as a function of the resin holding portion 29 .
  • the lower mold 27 is provided with heaters (not shown) capable of heating the resin materials 81 and 82 accommodated in the accommodation holes 27a. When the resin materials 81 and 82 are heated, they are melted in the accommodation holes 27a and become molten resins 84 and 85. As shown in FIG.
  • the extruding portion 28 can extrude the molten resins 84 and 85 into the magnet insertion hole 11b of the core body 11.
  • the pushing part 28 is, for example, a plurality of plungers that can be vertically moved by being driven by a predetermined driving source.
  • Each extruding part 28 may be driven by a corresponding drive source for each extruding part and can move up and down, or a plurality of extruding parts can be driven together by one drive source and can move up and down as a unit. may be
  • the molten resins 84 and 85 held in the accommodation hole 27a are pushed out from the accommodation hole 27a of the lower mold 27 by the extrusion part 28 in the feeding process, and arranged between the lower mold 27 and the lower end surface of the core body 11.
  • the resin passes through the resin passage 36 a in the plate portion 36 of the jig 35 and flows into each magnet insertion hole 11 b of the core body 11 .
  • the upper molten resin is fed first, that is, the upper molten resin 85 that is the second resin and the lower molten resin 84 that is the first resin are fed in this order.
  • the jig 35 includes a plate portion 36 and a post portion 37 as in the first embodiment. It is The plurality of resin passages 36a of the plate portion 36 are holes that are continuous in the height direction of the plate portion 36, and are arranged at positions corresponding to the plurality of magnet insertion holes 11b of the core body 11 and the accommodation holes 27a of the lower die 27. be done.
  • the auxiliary plate 45 is a plate-like member and is attached to the end surface of the core body 11 on the side not in contact with the jig 35. However, the difference is that resin is inserted into the auxiliary plate 45 for each magnet. A resin passage for leading to the hole 11b is not provided.
  • the core body 11 is obtained by laminating a plurality of thin plates 11a in advance.
  • the iron core body 11 is preheated to an appropriate temperature by inserting the permanent magnets 12 into the magnet insertion holes 11b. It is transferred toward the core part manufacturing apparatus 2 by .
  • Two types of resin materials 81 and 82 are supplied to the lower die 27 of the core manufacturing apparatus 2 between loading and unloading of the core body 11 to and from the core manufacturing apparatus 2 .
  • the resin materials 81 and 82 are accommodated and held in the accommodation hole 27a of the lower mold 27 in a laminated state in which the resin material 81 is the lower layer and the resin material 82 is the upper layer.
  • the resin materials 81 and 82 held in the accommodation holes 27a are heated at appropriate timings and melted in the accommodation holes 27a to form molten resins 84 and 85, respectively.
  • the core main body 11 and the jig 35 on which the core main body 11 is placed are transferred toward the core manufacturing apparatus 2 by the operation of the transfer mechanism, and when they reach the core manufacturing apparatus 2, the core main body 11 and the jig 35 are transferred. is carried in between the upper mold 26 and the lower mold 27 of the core manufacturing apparatus 2 through an opening for carrying in and out of the core manufacturing apparatus 2 .
  • the jig 35 with the core body 11 placed thereon is placed on the lower die 27 by the transfer mechanism, the loading of the core body 11 and the jig 35 into the core manufacturing apparatus 2 is completed.
  • the upper die 26 is lowered or the lower die 27 on which the core body 11 is placed is raised, so that the upper die 26 and the lower die 27
  • the iron core body 11 is sandwiched and pressed (see FIG. 10).
  • the auxiliary plate 45 and the jig 35 are brought into contact with both end surfaces of the core body 11 in the stacking direction and pressed, so that the magnet insertion holes 11b are formed at the ends of the core body 11 in the stacking direction. blocked.
  • each extrusion part 28 is driven and inserted into each accommodation hole 27a of the lower mold 27 from below.
  • the molten resins 84, 85 are extruded upward in the order of the upper molten resin 85 and the lower molten resin 84 from the accommodation hole 27a.
  • the extruded resin is injected and filled into the magnet insertion holes 11b of the upper core body 11 through the resin passages 36a of the plate portion 36 of the jig 35 in order from the upper molten resin 85 (see FIG. 11).
  • the molten resins 84 and 85 existing in the resin passage 36a and the magnet insertion hole 11b of the plate portion 36 are spread under the layer of the molten resin 85, which is the second resin, with the first resin. It is in a laminated state in which a layer of a certain molten resin 84 is positioned.
  • the boundary between the layer of molten resin 85 and the layer of molten resin 84 located on the lower die 27 side, that is, below the molten resin 85 is below the core body 11 in the magnet insertion hole 11b as a space.
  • Both the molten resin 85 and the molten resin 84 are filled in the magnet insertion hole 11b positioned near the side end. That is, the molten resin 84, which is the first resin, is provided at the lower end portion of the core body 11 in the stacking direction.
  • the molten resin 84 which is the first resin that solidifies faster, solidifies to become a solidified resin 87 (an example of the first resin portion). It is located on the lower end side of the molten resin 85 in the hole 11 b and is located between the molten resin 85 and the jig 35 .
  • the extruding part 28 is lowered with respect to the lower mold 27 to return to the original state, and the upper mold 26 is raised or the lower mold 27 is lowered. , the upper die 26 and the core body 11 are separated, and the clamping and pressing of the core body 11 by the upper die 26 and the lower die 27 are completed.
  • the core body 11 and the jig 35 can be moved from above the lower die 27 and can be unloaded from the core manufacturing apparatus 2 (see FIG. 12).
  • the solidified resin 87 is positioned below the molten resin 85 in the magnet insertion hole 11b, and is between the lower mold 27 and the molten resin 85. positioned.
  • the molten resin 85 is less likely to be affected by relative movement of the lower die 27 with respect to the core body 11 .
  • the molten resin 85 can be solidified while properly positioned in the magnet insertion hole 11b of the core body 11, and the filler 13 can be obtained without any problem.
  • the solidified resin obtained by solidifying the molten resin 85, which is the second resin, is an example of the second resin portion.
  • the iron core body 11 and the jig 35 are transported out of the core part manufacturing apparatus 2 by the transport mechanism and further transported to the next step, as in the first embodiment.
  • the molten resin 84 has become the solidified resin 87
  • the iron core body 11 and the like are transported out of the core manufacturing apparatus 2 by the transfer mechanism without waiting for the molten resin 85 to solidify.
  • the molten resin 85 is solidified by residual heat of the core body 11 while the core body 11, the auxiliary plate 45, and the jig 35 are transferred from the core manufacturing apparatus 2 to the next step. Thereby, the time for restraining the core body 11 between the upper mold 26 and the lower mold 27 can be further shortened.
  • the core body 11 and the jig 35 below it may be separated early and the core body 11 may be transferred. If the molten resin 84 is solidified to become a solidified resin 87, the solidified resin 87 is provided between the molten resin 85 and the jig 35, so the core body 11 and the jig 35 are separated from each other. Even so, the solidified resin 87 can suppress the influence of the relative movement of the jig 35 with respect to the core body 11 on the molten resin 85 . As a result, the molten resin 85 is solidified while being properly positioned in the magnet insertion hole 11b of the core body 11, so that the filler 13 can be formed together with the solidified resin 87 without any problem.
  • the molten resin 84 which is the first resin having a high solidification speed, is placed in the lower mold 27 and the second resin positioned in the magnet insertion hole 11b, while the lower mold 27 is separated from the core body 11 after the resin is solidified.
  • the solidification of the resin progresses in a state where the molten resin 85 with a slow solidification speed does not come into contact with the lower mold 27, and the molten resin 84 with a fast solidification speed is solidify.
  • the core body 11 can be released and taken out from between the upper die 26 and the lower die 27 . Even if the molten resin 85 is not solidified, if the molten resin 84 is solidified and becomes a solidified resin 87, the core body 11 can be moved between the upper mold 26 and the lower mold 26 without affecting the filling state of the molten resin 85. It can be taken out from between the molds 27 .
  • the time during which the core body 11 is constrained between the upper mold 26 and the lower mold 27 is equal to the difference between the solidification times of the molten resins 84 and 85. can be shortened, the manufacturing efficiency of the core portion 10 is improved.
  • the auxiliary plate 45 is arranged on the upper side of the core body 11 in the core part manufacturing apparatus 2, so that the resin filled in the magnet insertion hole 11b does not come into contact with the upper mold 26.
  • the auxiliary plate is not arranged on the upper side of the core body 11, and in the core part manufacturing apparatus 2, the upper die 21 and the upper end surface of the core body 11 are in direct contact, and the resin of the lower die 27 Resin may be fed into the magnet insertion hole 11b of the core body 11 from the holding portion.
  • the resin material 81 which is the first resin
  • the resin material 82 which is the second resin
  • the resin materials 81 and 82 may be held in a stacked state (see FIG. 13).
  • the molten resin 84 is melted from the resin material, and the melted resin 84 and the melted resin 85 are melted in the order of the upper layer melted resin 84, the intermediate layer melted resin 85, and the lower layer melted resin 84 while maintaining the laminated state. , 85 are input.
  • a layer of molten resin 84 which is the first resin
  • the layer of molten resin 85 which is the second resin, respectively (see FIG. 14).
  • the solidified resin 87 is positioned on the upper and lower end sides of the molten resin 85 within the magnet insertion hole 11b (see FIG. 15). That is, the solidified resin 87 is provided between the upper mold 21 and the molten resin 85 and between the lower mold 27 and the molten resin 85 .
  • the boundary between the layers is located near the lower end of the core body 11 in the magnet insertion hole 11b as a space, and the molten resin 84, which is the first resin, is arranged in the lower part of the magnet insertion hole 11b.
  • the boundary between the layer of the molten resin 85 and the layer of the molten resin 84 is positioned within the resin passage 36a of the plate portion 36, and the magnet insertion hole 11b is filled only with the molten resin 85, not limited to the example of this embodiment. You can also make it so that
  • the filler 13 is superior in terms of strength.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

La présente invention comprend une étape de distribution dans laquelle de la résine est distribuée à un espace dans un corps de noyau (11) positionné entre des moules. Dans l'étape de distribution, une première résine à vitesse de solidification rapide est distribuée de façon à être intercalée entre les moules et une seconde résine située dans l'espace, et la première résine est d'abord solidifiée dans un état dans lequel la seconde résine à vitesse de solidification lente n'entre pas en contact avec les moules.
PCT/JP2022/031419 2021-08-20 2022-08-19 Procédé de fabrication d'un noyau de machine électrique rotative, dispositif de fabrication de noyau et noyau WO2023022232A1 (fr)

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JP2021134762A JP2023028833A (ja) 2021-08-20 2021-08-20 回転電機のコア部製造方法及びコア部製造装置
JP2021-134762 2021-08-20

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WO2023022232A1 true WO2023022232A1 (fr) 2023-02-23

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Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2016171648A (ja) * 2015-03-12 2016-09-23 トヨタ自動車株式会社 樹脂モールド方法及び樹脂モールド装置

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2016171648A (ja) * 2015-03-12 2016-09-23 トヨタ自動車株式会社 樹脂モールド方法及び樹脂モールド装置

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