阅读说明：本技术 转子铁芯的保持工具、磁铁埋入型铁芯的制造装置及制造方法 (Rotor core holding tool, and device and method for manufacturing magnet-embedded core ) 是由 池田正信 福山修 村山友章 于 2018-10-11 设计创作，主要内容包括：能够避免作用于转子铁芯的轴线方向上的压缩力不必要地变大,并且能够高效地制造高品质的磁铁埋入型铁芯。一种转子铁芯(2)的保持工具(10),该转子铁芯(2)包含磁铁插入孔(4),该磁铁插入孔(4)形成为在转子铁芯(2)的轴线方向的两个端面上具有开口的贯通孔,其中,所述转子铁芯(2)的保持工具(10)具有：第1板(12),其与转子铁芯(2)的一个端面抵接,并且包含与磁铁插入孔(4)的开口连通的浇口(20)；第2板(14),其与转子铁芯(2)的另一个端面对置；封闭部件(26),其通过压缩弹簧部件(28)与第2板(14)连结,并且构成为能够封闭磁铁插入孔(4)在另一个所述端面侧的所述开口；以及连结部件(30),其将第1板(12)和第2板(14)互相连结,使得封闭部件(26)封闭所述开口并且压缩弹簧部件(28)的弹簧力成为规定的值。(It is possible to efficiently manufacture a high-quality embedded magnet core while avoiding an unnecessary increase in the compression force acting on the rotor core in the axial direction. A holding tool (10) for a rotor core (2), the rotor core (2) comprising magnet insertion holes (4), the magnet insertion holes (4) being formed as through holes having openings on both end faces in an axial direction of the rotor core (2), wherein the holding tool (10) for the rotor core (2) has: a 1 st plate (12) which abuts against one end surface of the rotor core (2) and includes a gate (20) that communicates with an opening of the magnet insertion hole (4); a 2 nd plate (14) that faces the other end face of the rotor core (2); a closing member (26) which is coupled to the 2 nd plate (14) by a compression spring member (28) and configured to be capable of closing the opening of the magnet insertion hole (4) on the other end surface side; and a connecting member (30) that connects the 1 st plate (12) and the 2 nd plate (14) to each other such that the closing member (26) closes the opening and the spring force of the compression spring member (28) has a predetermined value.)

1. A tool for holding a rotor core, the rotor core including magnet insertion holes formed as through holes having openings at both end surfaces in an axial direction of the rotor core,

the rotor core holding tool comprises:

a 1 st plate abutting against one of the end surfaces of the rotor core and including a gate communicating with the opening of the magnet insertion hole;

a 2 nd plate opposed to the other end surface of the rotor core;

a closing member coupled to the 2 nd plate by a compression spring member and configured to be capable of closing the opening of the magnet insertion hole on the other end surface side; and

and a coupling member that couples the 1 st plate and the 2 nd plate to each other such that the closing member closes the opening and a spring force of the compression spring member has a predetermined value.

2. The rotor core holding tool according to claim 1,

the rotor core includes a plurality of the magnet insertion holes,

the sealing member is divided into a plurality of parts corresponding to at least one of the magnet insertion holes, and the compression spring is provided for each sealing member.

3. The rotor core holding tool according to claim 1 or 2,

the connecting member includes a rod-shaped portion and flange portions provided at both ends of the rod-shaped portion,

the 1 st and 2 nd plates include cutout portions that open at outer edges of the 1 st and 2 nd plates and that define shoulders against which the flange portions abut.

4. An apparatus for manufacturing a magnet-embedded core, comprising: a rotor core having magnet insertion holes formed as through holes having openings at both end surfaces in an axial direction of the rotor core; a magnet piece disposed in the magnet insertion hole; and a resin filled in the magnet insertion hole, wherein,

the device for manufacturing the magnet embedded type iron core comprises:

a holding tool for a rotor core according to any one of claims 1 to 3;

a 1 st member abutting against the 1 st plate of the rotor core holding tool and having a resin pot communicating with the gate;

a 2 nd member which is opposed to the 1 st member with a holding tool of the rotor core interposed therebetween and which is relatively movable toward and away from the 1 st member;

a resin introducing device for introducing molten resin from the resin pot into the magnet insertion hole via the gate; and

and a pressing member which is positioned between the 2 nd member and the 1 st plate and presses the 1 st plate against the 1 st member by a pressing force transmitted from the 2 nd member to the 1 st plate.

5. The apparatus for manufacturing a buried core for a magnet according to claim 4,

the pressing member is a rod-shaped member including a base end fixed to the 2 nd member and a free end capable of abutting against the 1 st plate.

6. The apparatus for manufacturing a buried core for a magnet according to claim 4,

the pressing member is a rod-shaped member including a base end fixed to the 1 st plate and a free end capable of abutting against the 2 nd member.

7. A method for manufacturing a magnet-embedded core, the magnet-embedded core comprising: a rotor core having magnet insertion holes formed as through holes having openings at both end surfaces in an axial direction of the rotor core; a magnet piece disposed in the magnet insertion hole; and a resin filled in the magnet insertion hole, wherein,

the method for manufacturing the magnet embedded type iron core comprises the following steps:

a rotor core mounting step of mounting the rotor core on the 1 st plate of the rotor core holding tool according to any one of claims 1 to 3 such that the magnet insertion hole is aligned with the gate;

a plate mounting step of mounting the 2 nd plate on the rotor core so that the opening of the magnet insertion hole is closed by the closing member;

a plate connecting step of connecting the 1 st plate and the 2 nd plate to each other by the connecting member in a state where the rotor core is sandwiched by the 1 st plate and the 2 nd plate;

a tool mounting step of mounting a holding tool of the rotor core on a 1 st member having a resin pot so that the gate communicates with the resin pot;

a plate pressing step of pressing the 1 st plate against the 1 st member by a pressing member provided between the 1 st member and a 2 nd member relatively movable toward and away from the 1 st member by a movement of the 2 nd member toward and away from the 1 st member; and

and a resin introducing step of introducing a molten resin from the resin tank into the magnet insertion hole through the gate.

8. The method of manufacturing a buried iron core for a magnet according to claim 7,

the method for manufacturing the magnet-embedded core includes a resin charging step of charging a solid resin into the resin tank before the plate mounting step,

the resin introduction step includes: a melting step of melting the solid resin charged into the resin tank in the resin tank; and a pressurizing step of pressurizing the molten resin to introduce the resin into the magnet insertion hole.

Technical Field

The invention relates to a rotor core holding tool, a device and a method for manufacturing a magnet embedded core.

Background

As a magnet embedded core used in a rotating electrical machine such as a motor, there is known a magnet embedded core including: a rotor core having a magnet insertion hole formed as a through hole having openings at both end surfaces in an axial direction of the rotor core; a magnet piece disposed in the magnet insertion hole; and resin filled in the magnet insertion holes, the magnet pieces being fixed to the rotor core via the resin.

As a manufacturing apparatus for such a magnet-embedded core, there is known a manufacturing apparatus including: an upper die and a lower die that press the rotor core in the axial direction; and an intermediate mold including a gate communicating with one opening of the magnet insertion hole and disposed between the upper mold and the rotor core or between the lower mold and the rotor core, wherein the manufacturing apparatus is provided with a resin pot on the upper mold side or the lower mold side, and the resin in a molten state of the resin pot is pressurized in a state where the other opening of the magnet insertion hole is closed by the upper mold or the lower mold, and the resin is filled from the resin pot into the magnet insertion hole through the gate (for example, patent documents 1 to 3).

Disclosure of Invention

Problems to be solved by the invention

In the above apparatus for manufacturing a magnet-embedded core, it is necessary to press the upper mold or the lower mold against the end face of the rotor core so as to prevent the resin from leaking to the outside from the other opening of the magnet insertion hole, and to press the rotor core against the intermediate mold so as to prevent the resin from leaking to the outside from the connecting portion between the gate and the magnet insertion hole.

In the conventional apparatus for manufacturing a magnet-embedded core, since the upper mold and the lower mold sandwich the intermediate mold and the rotor core so as to sandwich the rotor core therebetween and press them in the axial direction, both the force pressing the upper mold or the lower mold against the end face of the rotor core and the force pressing the rotor core against the intermediate mold are determined by the pressing forces of the upper mold and the lower mold, and these pressing forces cannot be set independently.

In the conventional apparatus for manufacturing the magnet embedded core, the compression force acting in the axial direction of the rotor core is unnecessarily increased, and thus the rotor core may be deformed such as warped, thereby deteriorating the quality of the magnet embedded core.

The present invention has been made in view of the above problems of the prior art, and an object of the present invention is to efficiently manufacture a high-quality embedded magnet core while avoiding an unnecessary increase in the compression force acting on the rotor core in the axial direction.

Means for solving the problems

In a holding tool for manufacturing a rotor core of a magnet embedded core according to an embodiment of the present invention, the rotor core includes magnet insertion holes formed as through holes having openings at both end surfaces in an axial direction of the rotor core, wherein the holding tool for the rotor core includes: a 1 st plate abutting against one of the end surfaces of the rotor core and including a gate communicating with the opening of the magnet insertion hole; a 2 nd plate opposed to the other end surface of the rotor core; a closing member coupled to the 2 nd plate by a compression spring member and configured to be capable of closing the opening of the magnet insertion hole on the other end surface side; and a coupling member that couples the 1 st plate and the 2 nd plate to each other such that the closing member closes the opening and an elastic force of the compression spring member becomes a predetermined value.

According to the holding tool for the rotor core, it is possible to avoid an unnecessary increase in the compression force acting in the axial direction of the rotor core.

The rotor core holding tool according to the above-described embodiment is used for holding a rotor core including a plurality of magnet insertion holes, and the sealing members are distributed in a plurality corresponding to at least one of the magnet insertion holes, and the compression spring is provided for each sealing member.

According to the rotor core holding tool, the respective closing members appropriately close the respective magnet insertion holes.

In the rotor core holding tool according to the above-described embodiment, it is preferable that the coupling member includes a rod-shaped portion and flange portions provided at both ends of the rod-shaped portion, and the 1 st plate and the 2 nd plate include notch portions that are open at outer edges of the 1 st plate and the 2 nd plate and define shoulder portions against which the flange portions abut.

According to the holding tool for the rotor core, the attachment of the coupling member to the 1 st plate and the 2 nd plate is facilitated.

In an apparatus for manufacturing a magnet-embedded core according to an embodiment of the present invention, the magnet-embedded core includes: a rotor core having magnet insertion holes formed as through holes having openings at both end surfaces in an axial direction of the rotor core; a magnet piece disposed in the magnet insertion hole; and a resin filled in the magnet insertion hole, wherein the apparatus for manufacturing the magnet-embedded core includes: the rotor core holding tool according to the above embodiment; a 1 st member abutting against the 1 st plate of the rotor core holding tool and having a resin pot communicating with the gate; a 2 nd member which is opposed to the 1 st member with a holding tool of the rotor core interposed therebetween and which is relatively movable toward and away from the 1 st member; a resin introducing device for introducing molten resin from the resin pot into the magnet insertion hole via the gate; and a pressing member that is positioned between the 2 nd member and the 1 st plate, and presses the 1 st plate against the 1 st member by a pressing force transmitted from the 2 nd member to the 1 st plate.

According to this apparatus for manufacturing a magnet-embedded core, it is possible to efficiently manufacture a high-quality magnet-embedded core while avoiding an unnecessary increase in the compression force acting in the axial direction of the rotor core.

In the apparatus for manufacturing an embedded magnet core according to the above-described embodiment, it is preferable that the pressing member is a rod-shaped member including a base end fixed to the 2 nd member and a free end capable of coming into contact with the 1 st plate.

According to the apparatus for manufacturing the magnet-embedded core, the pressing member can easily and reliably press the 1 st plate.

In the apparatus for manufacturing an embedded magnet core according to the above-described embodiment, it is preferable that the pressing member is a rod-shaped member including a base end fixed to the 1 st plate and a free end capable of coming into contact with the 2 nd member.

According to the apparatus for manufacturing the magnet-embedded core, the 1 st plate can be easily and reliably pressed by the pressing member, and the 1 st plate can be miniaturized.

In a method for manufacturing a magnet-embedded core according to an embodiment of the present invention, the magnet-embedded core includes: a rotor core having magnet insertion holes formed as through holes having openings at both end surfaces in an axial direction of the rotor core; a magnet piece disposed in the magnet insertion hole; and a resin filled in the magnet insertion hole, wherein the method for manufacturing the magnet-embedded core includes: a rotor core mounting step of mounting the rotor core on the 1 st plate of the rotor core holding tool according to the above embodiment so that the magnet insertion hole is aligned with the gate; a plate mounting step of mounting the 2 nd plate on the rotor core so that the opening of the magnet insertion hole is closed by the closing member; a plate connecting step of connecting the 1 st plate and the 2 nd plate to each other by the connecting member in a state where the rotor core is sandwiched by the 1 st plate and the 2 nd plate; a tool mounting step of mounting a holding tool of the rotor core on a 1 st member having a resin pot so that the gate communicates with the resin pot; a plate pressing step of pressing the 1 st plate against the 1 st member by a pressing member provided between the 1 st member and a 2 nd member relatively movable toward and away from the 1 st member by a movement of the 2 nd member toward and away from the 1 st member; and a resin introducing step of introducing molten resin from the resin tank into the magnet insertion hole through the gate.

According to this method for manufacturing a magnet-embedded core, it is possible to efficiently manufacture a high-quality magnet-embedded core while avoiding an unnecessary increase in the compression force acting in the axial direction of the rotor core.

In the method of manufacturing a magnet-embedded core according to the above-described embodiment, it is preferable that the method of manufacturing a magnet-embedded core includes, before the plate placement step, a resin injection step of injecting a solid resin into the resin tank, and the resin introduction step includes: a melting step of melting the solid resin charged into the resin tank in the resin tank; and a pressurizing step of pressurizing the molten resin to introduce the resin into the magnet insertion hole.

According to the method for manufacturing the magnet-embedded core, the useless waste of the resin is reduced by using the solid resin.

Effects of the invention

As described above, according to the present embodiment, the compression force acting in the axial direction of the rotor core is not unnecessarily increased, and a high-quality embedded magnet core can be efficiently manufactured.

Drawings

Fig. 1 is a perspective view showing an example of a magnet-embedded core manufactured by using a manufacturing method and a manufacturing apparatus according to an embodiment of the present invention.

Fig. 2 is a longitudinal sectional view showing the magnet embedded core.

Fig. 3 is a longitudinal sectional view of a rotor core holding tool according to an embodiment of the present invention.

Fig. 4 is a plan view of the rotor core holding tool according to the present embodiment.

Fig. 5 is an explanatory view showing a rotor core holding process of the rotor core holding tool according to the present embodiment.

Fig. 6 is a vertical cross-sectional view showing a state after a lower movable member of the apparatus for manufacturing an embedded magnet core according to the embodiment of the present invention is lowered.

Fig. 7 is a vertical cross-sectional view showing a state where the lower movable member of the manufacturing apparatus is lifted.

Fig. 8 is a vertical cross-sectional view showing a resin pressurized state of the manufacturing apparatus.

Fig. 9 is a vertical cross-sectional view showing a state of being pushed up (object) of the manufacturing apparatus.

Fig. 10 is a vertical sectional view showing a rotor core holding jig and a magnet embedded core manufacturing apparatus according to another embodiment.

Fig. 11 is a plan view showing a rotor core holding tool according to another embodiment.

Detailed Description

Preferred embodiments of the present invention will be described with reference to the accompanying drawings.

First, a magnet-embedded core 1 manufactured by using the manufacturing method and manufacturing apparatus according to the embodiment of the present invention will be described with reference to fig. 1 and 2.

The embedded magnet core 1 is a component of a rotating electrical machine such as a motor, and includes a rotor core 2. The rotor core 2 is a laminated core in which a plurality of electromagnetic steel plates are laminated in a state of being bonded to each other by a known bonding method (caulking bonding, laser welding, bonding, or the like), and the rotor core 2 has a substantially annular shape in plan view and has a shaft hole 3 penetrating in the axial direction at the center.

A plurality of magnet insertion holes 4 are formed in the rotor core 2. Each magnet insertion hole 4 is formed as a substantially rectangular parallelepiped space, penetrates the rotor core 2 in the axial direction, and is open at both end faces of the rotor core 2. In the illustrated example, the magnet insertion holes 4 are arranged at equal intervals at four locations in the circumferential direction of the rotor core 2, but the present invention is not limited thereto, and the shape, number, arrangement, and the like of the magnet insertion holes 4 can be variously changed.

Each magnet insertion hole 4 accommodates a substantially rectangular parallelepiped magnet piece 5. The magnet piece 5 can be made of a permanent magnet (including a magnet piece before magnetization) such as a ferrite-based sintered magnet piece or a neodymium magnet piece. The dimensions of each part of the magnet piece 5 are set smaller than those of each part of the magnet insertion hole 4. Thereby, a gap can be formed between the rotor core 2 and the magnet piece 5 in the magnet insertion hole 4. The gap is filled with a resin 6. Each magnet piece 5 is fixed to the rotor core 2 via the resin 6 filled in the gap. As the resin 6, a thermosetting resin such as an epoxy resin can be used.

For example, as shown in fig. 1, each magnet piece 5 is disposed in the magnet insertion hole 4 so as to be biased inward (toward the center of the rotor core 2), and the outer surface of each magnet piece 5 facing the center of the rotor core 2 abuts against the inner surface of the magnet insertion hole 4 facing the outer surface. Thus, the arrangement positions of the magnet pieces 5 in the radial direction of the rotor core 2 are determined to be the same, and the magnet insertion holes 4 are provided at equal intervals in the circumferential direction of the rotor core 2, so that the magnet pieces 5 do not cause an imbalance in the rotational direction of the rotor core 2. Each magnet piece 5 may be disposed so as to be biased to the opposite side (the outer peripheral side of the rotor core 2) to the position shown in fig. 1.

Next, the rotor core holding tool 10 used for manufacturing the embedded magnet core will be described with reference to fig. 3 and 4.

The rotor core holding tool 10 has a lower 1 st plate 12 and an upper 2 nd plate 14 facing each other.

The 1 st plate 12 is formed by stacking a rectangular flat plate-based gate plate 16 and a knockout plate (カルプレート)18 on each other. The gate plate 16 and the knockout plate 18 may be integrated by bolts (not shown) in a detachable manner. The tundish plate 16 comprises: an upper surface 16A that abuts against the lower end surface 2A of the rotor core 2; and gates 20 communicating with the openings 4A on the lower side of the magnet insertion holes 4, respectively. The stripper plate 18 is located below the gate plate 16 and includes a stripper opening 22(カル open/open) that communicates with each gate 20 and each resin tank 80 of the magnet-embedded core manufacturing apparatus 60 described later.

The 2 nd plate 14 is a rectangular flat plate and faces the upper end face 2B of the rotor core 2. The 2 nd plate 14 supports the closing member 26 movably in the vertical direction by means of bolts 24 in a suspended manner corresponding to each magnet insertion hole 4. Each of the closing members 26 includes a lower surface 26A that can be brought into contact with the upper end surface 2B of the rotor core 2, and the lower surface 26A has an area larger than the opening 4B on the upper side of the magnet insertion hole 4. The lower limit position of each closing member 26 is determined by the abutment of the head 24A of the bolt 24 against the shoulder-shaped bottom of the bolt insertion hole 14A formed in the 2 nd plate 14.

A compression coil spring 28 is installed between the 2 nd plate 14 and each of the closing members 26. The compression coil springs 28 are provided for each of the closing members 26, and each of the compression coil springs 28 biases the closing member 26 toward the 1 st plate 12. That is, the closing member 26 and the compression coil spring 28 are provided for each magnet insertion hole 4. As shown in fig. 4, the closing members 26 are supported by two bolts 24, and two compression coil springs 28 are provided side by side for each closing member 26.

The 1 st plate 12 is larger than the 2 nd plate 14, and the 1 st plate 12 includes a rectangular frame-shaped projecting portion 17 projecting outward from the outer edge of the 2 nd plate 14 in a plan view.

The 1 st plate 12 and the 2 nd plate 14 are connected to each other by the connecting members 30 at four positions, front, rear, left, and right, respectively, with the rotor core 2 sandwiched between the 1 st plate 12 and the closing member 26.

The details of the connection structure of the 1 st plate 12 and the 2 nd plate 14 by the connection member 30 will be described. Each coupling member 30 includes a rod-shaped portion 30A and flange portions 30B and 30C provided at upper and lower ends of the rod-shaped portion 30A. Notches 32 and 34 are formed in the 1 st plate 12 and the 2 nd plate 14, respectively, to open to the left and right outer edges of the plates 12 and 14, and the notches 32 and 34 linearly extend in the left-right direction. The cutout portions 32 and 34 are provided in front, rear, left, and right positions so as to be aligned vertically, and as shown in the partially enlarged perspective views (a) and (B) of fig. 3, the cutout portions 32 and 34 include slit-shaped openings 32B and 34B, respectively, the openings 32B and 34B are provided at the bottoms of the groove 32A and the groove 34A, respectively, into which the flange portions 30B and 30C can be engaged, the rod-shaped portion 30A can be inserted, and the shoulder portions 32C and 34C formed at the bottoms of the groove 32A and the groove 34A, respectively, which are left on both sides of the openings 32B and 34B, respectively, are abutted by the flange portions 30B and 30C.

As described above, the coupling members 30 engage with the 1 st plate 12 and the 2 nd plate 14, whereby the coupling members 30 couple the 1 st plate 12 and the 2 nd plate 14 to each other so that the elastic force of the compression coil springs 28 has a predetermined value. Thus, each of the closing members 26 is pressed against the upper end surface 2B of the rotor core 2 by the spring force of the compression coil spring 28, and closes the upper opening 4B of the corresponding magnet insertion hole 4.

The flanges 30B and 30C are entirely accommodated in the concave grooves 32A and 34A, and do not protrude below the 1 st plate 12 or above the 2 nd plate 14.

The rotor core 2 can be set to the rotor core holding tool 10 by using the core setting device 40 shown in fig. 5. The core setting device 40 includes: a flat plate-like base 42; a flat plate-like upper member 46 disposed above the base 42 so as to face each other via a plurality of column members 44 erected from the base 42; a fluid pressure type pressurizing device (cylinder piston device) 48 attached to the lower surface of the upper member 46; and a flat plate-shaped pressurizing plate 52 attached to the piston rod 50 of the pressurizing device 48.

In the setting of the rotor core 2 with respect to the rotor core holding jig 10 using the core setting device 40, first, the 1 st plate 12 is placed on the base 42, the magnet pieces 5 are put into the magnet insertion holes 4, and then the 2 nd plate 14 is placed on the rotor core 2 so that the respective closing members 26 are aligned with the magnet insertion holes 4.

Next, the pressing device 48 is driven to press the pressing plate 52 against the 2 nd plate 14, and the compression coil springs 28 are compressed and deformed. In this state, flange portions 30B and 30C of connecting member 30 are inserted into respective cutout portions 32 and 34 from both the left and right sides. Then, after the pressing of the 2 nd plate 14 by the pressing plate 52 is released, the respective flange portions 30B, 30C are pressed against the shoulder portions 32C, 34C by the elastic force of the compression coil spring 28.

Then, the 1 st plate 12 and the 2 nd plate 14 are coupled to each other by the coupling member 30 in a state where the spring force of each compression coil spring 28 has a predetermined value. Thus, as shown in fig. 3, the rotor core 2 is used as the following components together with the rotor core holding tool 10: the opening 4B of each magnet insertion hole 4 is closed by the corresponding closing member 26 with a pressing force based on the elastic force of the compression coil spring 28.

Next, an apparatus 60 for manufacturing an embedded magnet core will be described with reference to fig. 6 to 9.

The magnet-embedded core manufacturing apparatus 60 includes: a plurality of column members 62 extending in the up-down direction; a fixed platen 64 fixed to an upper end of the column member 62; and a movable platen 66 that is guided by the column member 62 so as to be movable up and down. The movable platen 66 is driven in the vertical direction by a driving device (not shown) based on fluid pressure or the like, and can be moved closer to or farther from the fixed platen 64.

The 1 st member 70 is attached to the movable platen 66. The 1 st member 70 is an assembly of a lower member 72, an intermediate member 74, and an upper member 76 that are stacked. The components of the rotor core 2 are mounted on the upper member 76 together with the rotor core holding jig 10.

A plurality of resin pots 80 corresponding to the magnet insertion holes 4 of the rotor core 2 are formed in the upper member 76. Each resin tank 80 is opened in the upper surface of the upper member 76 and communicates with the corresponding reject opening 22. A plunger chamber 82 and a push rod chamber 84 that communicate with the respective resin tanks 80 are formed in the intermediate member 74. As a resin introducing means for introducing the molten resin from the resin tank 80 into the magnet insertion hole 4 through the gate 20, a plunger 86 is provided in the plunger chamber 82 so as to be movable up and down, and a pushrod 88 is provided in each pushrod chamber 84 so as to be movable up and down. The resin tank 80, the plunger chamber 82, and the reject opening 22 are holes having the same inner diameter, and the plunger 86 can enter the reject opening 22 from the plunger chamber 82.

A block-shaped solid resin 6 is placed on the plunger 86 of each resin pot 80.

Each push rod 88 is brought into contact with the corresponding plunger 86 at its upper end, and moves the plunger 86 upward. Each push rod 88 has a pressure receiving flange 90 at a lower end thereof, and hydraulic pressure is applied to each pressure receiving flange 90 by hydraulic oil in a manifold oil passage 92 formed in the intermediate member 74. A cylinder chamber 94 is formed in the lower member 72. A piston 96 is provided in the cylinder chamber 94 so as to be movable up and down. The piston 96 defines an upper oil chamber 98 communicating with the manifold oil passage 92 on the upper side and a lower oil chamber 100 on the lower side. The upper oil chamber 98 and the lower oil chamber 100 are connected to a hydraulic pressure source (not shown) via oil passages 102, 104 formed in the lower member 72, and the like.

A heater 106 for heating the 1 st block 70 is embedded in the 1 st block 70. The 1 st member 70 is provided with a push rod 108 that can protrude above the upper surface of the upper member 76. The lift rod 108 is projected above the upper surface of the upper member 76 by a driving device (not shown) such as an air cylinder, a hydraulic cylinder, or a servo or by the lowering operation of the movable platen 66.

A 2 nd member 110 is attached to a lower portion of the fixed platen 64. The 2 nd member 110 is opposed to the 1 st member 70 with the rotor core holding jig 10 on the 1 st member 70 interposed therebetween, and the movable platen 66 can approach or separate from the fixed platen 64, whereby the 2 nd member 110 can approach or separate from the 1 st member 70 relatively.

Base ends 112A of a plurality of pressing members 112 as rod-like members are fixed to the 2 nd member 110. Each pressing member 112 extends downward from a base end 112A, is positioned between the 2 nd member 110 and the 1 st plate 12, and includes a free end 112B capable of coming into contact with the upper surface 16A of the gate plate 16 of the 1 st plate 12. As shown in fig. 7, each pressing member 112 abuts on the upper surface 16A of the extension 17 of the gate plate 16 by the upward movement of the movable platen 66, and presses the 1 st plate 12 against the 1 st member 70 by the pressing force transmitted from the 2 nd member 110 to the 1 st plate 12.

Thus, unlike the force with which the closing member 26 is pressed against the rotor core 2, the force with which the 1 st plate 12 is pressed against the 1 st member 70 is determined by the lifting force (mold clamping force) of the movable platen 66, and the connection between the removal opening 22 and the resin tank 80 is performed without a gap based on the force with which the 1 st plate 12 is pressed against the 1 st member 70.

The 2 nd member 110 supports the heating block 116 by means of the suspension bolt 114 so as to be vertically displaceable with respect to the 2 nd member 110. A heater 118 is embedded in the heating block 116. As shown in fig. 7, the heating block 116 abuts on the 2 nd plate 14 by the upward movement of the movable platen 66, and heats the resin 6 through the holding tool 10 of the rotor core.

The solid resin 6 in each resin tank 80 is heated and melted by a heater 106 or the like. In this state, as shown in fig. 8, hydraulic pressure is supplied from a hydraulic pressure source (not shown) to the lower oil chamber 100, and the piston 96 is moved upward, whereby the hydraulic oil in the manifold oil passage 92 is transmitted to the pressure receiving flanges 90 and the push rods 88 as the same pressure as each other as a pressure medium. Thereby, the plungers 86 are moved upward, and the molten resin 6 in the resin tanks 80 is pressure-fed through the corresponding ejection openings 22 and gates 20 and is filled in the magnet insertion holes 4.

Since the force pressing the 1 st plate 12 against the 1 st member 70 can be set to an appropriate value that is not excessively large or excessively small by the lifting force of the movable platen 66 alone, the connection of the reject opening 22 and the resin tank 80 is performed based on an appropriate pressing force pressing the 1 st plate 12 against the 1 st member 70. Thus, in the process of pressure-feeding the molten resin 6 from the resin tank 80 to the magnet insertion hole 4, the molten resin 6 is prevented from leaking to the outside from the boundary portion between the 1 st plate 12 and the 1 st member 70, and burrs are prevented from being generated at the boundary portion.

Since the closing member 26 is pressed against the rotor core 2 by the spring force of the compression coil spring 28, which is different from the rising force of the movable platen 66, the force pressing the closing member 26 against the rotor core 2 can be set to an appropriate value, which is not too large or too small, separately from the force pressing the 1 st plate 12 against the 1 st member 70. Accordingly, the closing of the opening 4B of the magnet insertion hole 4 and the connection of the opening 4A of the magnet insertion hole 4 to the gate 20 are performed based on the following circumstances without causing deformation such as warpage of the rotor core 2: the force pressing the closing member 26 against the rotor core 2 is an appropriate pressing force. Thus, in the process of pressure-feeding the molten resin 6 from the resin pot 80 to the magnet insertion hole 4, the molten resin 6 is prevented from leaking to the outside from the opening 4B of the magnet insertion hole 4 or from the boundary portion between the opening 4A of the magnet insertion hole 4 and the gate 20, and burrs are prevented from being generated around the boundary portion or the opening 4B.

As shown in fig. 9, the rotor core 2 after the completion of the filling of the resin 6 is taken out together with the rotor core holding jig 10 as follows: the lift rod 108 is raised, and the rotor core holding tool 10 is thereby lifted upward by the 1 st member 70.

As described above, the method for manufacturing the magnet-embedded core 1 according to the present embodiment includes the steps of: a rotor core mounting step of mounting the rotor core 2 on the 1 st plate 12 of the rotor core holding tool 10 so that the magnet insertion hole 4 is aligned with the gate 20; a plate mounting step of mounting the 2 nd plate 14 of the rotor core holding tool 10 on the rotor core 2 so as to close the opening 4B of the magnet insertion hole 4 by the closing member 26; a plate connecting step of connecting the 1 st plate 12 and the 2 nd plate 14 to each other by the connecting member 30 in a state where the rotor core 2 is sandwiched by the 1 st plate 12 and the 2 nd plate 14; a tool mounting step of mounting a rotor core holding tool 10 on the 1 st member 70 having the resin pot 80 so that the gate 20 communicates with the resin pot 80; a plate pressing step of pressing the 1 st plate 12 against the 1 st member 70 by the pressing member 112 provided between the 1 st member 70 and the 2 nd member 110 through the proximity movement of the 2 nd member 110 with respect to the 1 st member 70; and a resin introducing step of introducing the molten resin from the resin tank 80 into the magnet insertion hole 4 through the gate 20.

The manufacturing method further includes a resin charging step of charging a resin 6 in a solid state into the resin tank 80 before the board mounting step, and the resin introducing step includes: a melting step of melting the solid resin charged into the resin tank 80 in the resin tank 80; and a pressurizing step of pressurizing the molten resin 6 to introduce (pressure-feed) the resin into the magnet insertion hole 4.

Thus, in the method of manufacturing the embedded magnet core 1 according to the present embodiment, the force with which the 1 st plate 12 is pressed against the 1 st member 70 and the force with which the closing member 26 is pressed against the rotor core 2 can be set individually, and the generation of burrs can be suppressed without causing deformation such as warping of the rotor core 2. Further, by using the solid resin 6, wasteful consumption of the resin 6 can be reduced.

Another embodiment of the apparatus 60 for manufacturing an embedded magnet core will be described with reference to fig. 10 and 11. In fig. 10 and 11, the same reference numerals as those used in fig. 4 and 6 are used for the parts corresponding to fig. 4 and 6, and the description thereof is omitted.

In the present embodiment, the pressing member 120 based on a rod member includes: a base end 120A fixed to the 1 st plate 12 by a screw 122; and a free end 120B that penetrates through the through hole 36 formed in the 2 nd plate 14 of the rotor core holding tool 10 and can be brought into contact with the lower surface 110A of the 2 nd member 110.

The pressing member 112 abuts against the lower surface 110A of the 2 nd member 110 by the upward movement of the movable platen 66, and presses the 1 st plate 12 against the 1 st member 70 by the pressing force transmitted from the 2 nd member 110 to the 1 st plate 12.

Therefore, in this embodiment, the same operational effects as those of the above-described embodiment can be obtained by using the holding tool 10 using the rotor core similar to those of the above-described embodiment. In the present embodiment, the extension 17 of the 1 st plate 12 in the above embodiment is not necessary, and the 1 st plate 12 can be downsized.

The present invention has been described above based on specific embodiments, but these embodiments are merely examples, and the present invention is not limited to these embodiments.

For example, the magnet embedded core manufacturing apparatus 60 may be arranged upside down. The header plate 16 and the stripper plate 18 may be formed of a single plate-like member.

The solid resin used in the present invention is not limited to a block, and may be pellets, powder or granules. In the above embodiments, the example of using a thermosetting resin as the resin is shown, but the present invention is not limited thereto, and a thermoplastic resin may be used. In the case of using a thermoplastic resin, a hardening step by cooling is performed instead of the thermosetting step of the thermosetting resin.

In the above embodiment, the magnet pieces 5 are disposed in the magnet insertion holes 4 so as to be biased inward, but the positions of the magnet pieces 5 in the magnet insertion holes 4 may be changed as appropriate.

For example, the closing member 26 does not necessarily have to be provided for each magnet insertion hole 4, and the closing member 26 may be distributed for each set of a plurality of adjacent magnet insertion holes 4 or each magnet insertion hole 4 corresponding to each magnetic pole, and the compression coil spring 28 may be provided for each closing member 26. That is, the closing member 26 may be distributed in a plurality corresponding to at least one magnet insertion hole 4, and the compression spring 28 may be provided for each closing member 26. The arrangement and number of the coupling members 30 may be other than those of the above-described embodiments. The driving of the push rod 88, the piston 96, and the like is not limited to the fluid pressure, and may be electrically performed by an electromagnetic mechanism or the like. The magnet piece 5 may be disposed at the center of the magnet insertion hole 4 in a plan view. In addition, the whole device can be turned upside down.

The method for manufacturing a magnet-embedded core according to the present invention described in the above embodiment is not necessarily required for all of the components, and at least can be selected appropriately without departing from the scope of the present invention.

Description of the reference symbols

1: a magnet-embedded iron core; 2: a rotor core; 2A: a lower end face; 2B: an upper end surface; 3: a shaft hole; 4: a magnet insertion hole; 4A: an opening; 4B: an opening; 5: a magnet piece; 6: a resin; 10: a holding tool for the rotor core; 12: a 1 st plate; 14: a 2 nd plate; 14A: a bolt through hole; 16: a gate plate; 16A: an upper surface; 17: an extension portion; 18: a rejection plate; 20: a gate; 22: removing the opening; 24: a bolt; 24A: a head portion; 26: a closure member; 26A: a lower surface; 28: compressing the coil spring; 30: a connecting member; 30A: a rod-shaped portion; 30B: a flange portion; 30C: a flange portion; 32: a cut-out portion; 32A: a groove; 32B: an opening; 32C: a shoulder portion; 34: a cut-out portion; 34A: a groove; 34B: an opening; 34C: a shoulder portion; 40: an iron core setting device; 42: a base station; 44: a column part; 46: an upper member; 48: a pressurizing device; 50: a piston rod; 52: a pressurizing plate; 60: a device for manufacturing a magnet-embedded iron core; 62: a column part; 64: fixing the pressing plate; 66: a movable platen; 70: the 1 st component; 72: a lower part; 74: an intermediate member; 76: an upper member; 80: a resin tank; 82: a plunger chamber; 84: a push rod chamber; 86: a plunger; 88: a push rod; 90: a compression flange; 92: a manifold oil passage; 94: a cylinder chamber; 96: a piston; 98: an upper oil chamber; 100: a lower oil chamber; 102: an oil path; 104: an oil path; 106: a heater; 108: a top rod; 110: a 2 nd component; 110A: a lower surface; 112: a pressing member; 112A: a base end; 112B: a free end; 114: a suspension bolt; 116: a heating block; 118: a heater; 120: a pressing member; 120A: a base end; 120B: a free end; 122: and (4) screws.