Patent Publication Number: US-2022216749-A1

Title: Device for manufacturing rotor core, method for manufacturing rotor core, and rotor structure

Description:
This application is a Divisional of U.S. patent application Ser. No. 16/780,493 filed on Feb. 3, 2020, which is is based on and claims the benefit of priority from Japanese Patent Application No. 2019-018604, filed on Feb. 5, 2019, the content of which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates to a device for manufacturing a rotor core, a method for manufacturing a rotor core, and a rotor structure. 
     Related Art 
     For example, a rotor (rotor structure) of an electric rotating machine, such as a motor of an automobile or an electric appliance, is configured such that a plurality of rotor cores is integrally combined in the axis line direction while inserting a shaft into a center hole (shaft hole) of each of the rotor cores. Furthermore, as the rotor core, an IPM-type rotor core (interior permanent magnet type rotor core) or an SPM-type rotor core (surface permanent magnet type rotor core) is frequently used. 
     For example, as shown in  FIG. 2 , the IPM-type rotor core  1  is configured to include: a laminated iron core  2  in which a plurality of core members (thin plate-shaped members) formed by punching an electromagnetic steel sheet is laminated, permanent magnets  3  that are each inserted into and accommodated in a magnet insertion hole  2   c  formed to penetrate from one end  2   a  to the other end  2   b  in an axis line O 1  direction of the laminated iron core  2 , and a resin material  4  for embedding and fixing the permanent magnets  3  by injecting the resin material  4  into the magnet insertion hole  2   c.    
     For example, as shown in  FIG. 3 , the SPM-type rotor core  5  is configured to include a laminated iron core  2 , permanent magnets  3  which are arranged at equal intervals in the circumferential direction on the outer peripheral surface side of the laminated iron core  2 , a cylindrical exterior member  6  which surrounds and covers the laminated iron core  2  with the permanent magnets  3 , and a resin material  4  for embedding and fixing the permanent magnets  3  by injecting the resin material  4  between the exterior member  6  and the laminated iron core  2 . 
     A center hole (shaft hole)  2   d  that is formed to penetrate from one end  2   a  to the other end  2   b  on its axis line O 1  and is used for fitting the shaft is provided in the laminated iron core  2 . 
     On the other hand, for example, as shown in  FIG. 9 , a device for manufacturing the rotor cores  1  and  5  is configured to include: a first mold  7  having a fitting recess  7   a  that fits and holds the laminated iron core  2  mounted by inserting the permanent magnet  3  into the magnet insertion hole  2   c  (or a laminated iron core  5  to which the permanent magnet  3  and the exterior member  6  are mounted) in the axis line O 1 ; a second mold  8  that is engaged with the first mold  7  and clamps/seals the laminated iron core  2  within a mold cavity with the first mold  7 ; and a resin injection unit  9  that is provided in the second mold  8  (or the first mold  7 ) and injects the resin material  4  in the magnet insertion hole  2   c  of the laminated iron core  2  within the mold cavity (or between the exterior member  6  and the laminated iron core  2 )(for example, refer to Patent Document 1). When fitting the laminated iron core  2  in the fitting recess  7   a , the first mold  7  is provided with a core rod  10  integrally for positioning and holding by being fit in the center hole (shaft hole)  2   d.    
     When manufacturing the rotor cores  1  and  5 , as shown in  FIGS. 9 and 10 , after clamping the first mold  7  and the second mold  8  and sealing the laminated iron core  2 , as shown in  FIG. 11 , the resin material  4  is injected into the magnet insertion hole  2   c  from the resin injection unit  9  (or between the exterior member  6  and the laminated iron core  2 ) by using an injection molding machine. As shown in  FIG. 12 , the molds  7  and  8  are opened at the appropriate timing, thereby removing the rotor core  1  ( 5 ) by form removal. The rotor core  1  ( 5 ) in which the permanent magnet  3  is embedded and fixed by the resin material  4  is thereby manufactured.
     Patent Document 1: Re-publication of WO2016/147211   

     SUMMARY OF THE INVENTION 
     However, in the manufacturing device for the conventional rotor cores  1  and  5  and the manufacturing method for the rotor cores  1  and  5  as shown in  FIGS. 11 and 12 , there is a case in which, by injecting the resin material  4  in the magnet insertion hole  2   c  from the resin injection unit  9  (or between the exterior member  6  and the laminated iron core  2 ) by using an injection molding machine, the permanent magnet  3  disposed in the magnet insertion hole  2   c  (or between the exterior member  6  and the laminated iron core  2 ) is pressed against the inner surface side of the first mold  7 , and an end  3   a  of the permanent magnet  3  is exposed on the one end  2   a  side of the laminated iron core  2  (rotor core). 
     Then, as shown in  FIG. 13 , when manufacturing the rotor  12  by mounting a plurality of rotor cores  1 ( 5 ) manufactured in this way to the shaft  11 , there is a problem in that the ends  3   a  of the magnets  3  of the pair of rotor cores  1  adjacent to each other in the axis line O 1  direction abut against each other and are brought into contact with each other, or adjoined to each other, a result of which magnetic flux leakage occurs at this portion. In particular, as shown in  FIG. 13 , there is inconvenience in that the magnetic flux leakage often occurs at the location where one of the rotor cores of the pairs of rotor cores  1  adjacent to each other is reversed and step-skewed, and the ends  3   a  of the magnets  3  are brought in contact with each other. 
     An aspect of a device for manufacturing a rotor core according to the present disclosure includes: a first mold including a fitting recess that fits and holds a laminated iron core in which a magnet is inserted into a magnet insertion hole or a laminated iron core in which a magnet and an exterior member are mounted on an outer circumferential side; a second mold that engages with the first mold and clamps and seals the laminated iron core together with the first mold; a resin injection unit that is provided to the first mold or the second mold and injects a resin material in the magnet insertion hole or between the exterior member and the laminated iron core by using a molding machine; and a protrusion that is inserted into the magnet insertion hole or between the exterior member and the laminated iron core by a predetermined insertion amount, and positions and holds the magnet by an end of the magnet being brought into contact with the protrusion, in a state of the first mold and the second mold being clamped. 
     An aspect of a method for manufacturing a rotor core according to the present disclosure includes: a first mold mounting step of inserting a protrusion by a predetermined insertion amount into a magnet insertion hole that penetrates from one end to an other end in an axis line direction of a laminated iron core in which a magnet is inserted into a magnet insertion hole, or between a laminated iron core in which a magnet and an exterior member are mounted on an outer circumferential side and the exterior member, and fitting and arranging the laminated iron core in a fitting recess of a first mold from a side of the one end; a second mold mounting step of engaging a second mold with the first mold, and clamping and sealing the laminated iron core together with the first mold; and a resin injecting step of injecting a resin material into the magnet insertion hole or between the exterior member and the laminated iron core through a resin injection unit provided in the first mold or the second mold. 
     An aspect of a rotor structure according to the present disclosure is a rotor structure provided by integrally combining a plurality of rotor cores manufactured by using the device for manufacturing the rotor core according to the abovementioned aspect, or by method for manufacturing the rotor core, in an axis line direction while inserting a shaft into a center hole of the rotor core, in which, among at least some pairs of rotor cores that are adjacent in the axis line direction, one of the rotor cores is reversed and step-skewed. 
     In the abovementioned aspect, the resin material is injected in a state in which the protrusion is inserted by a predetermined insertion amount into the magnet insertion hole, or between the laminated iron core in which the magnet and the exterior member are mounted on the outer circumferential side and the exterior member. Therefore, it is possible to arrange the end of the magnet in the axis line direction inwardly from the end of the laminated iron core (rotor core) by an amount corresponding to the insertion amount of the protrusion. 
     With such a configuration, when mounting a plurality of rotor cores to the shaft, and when one of the adjacent rotor cores is reversed and step-skewed, it becomes possible for the ends of the magnetics of the adjacent rotor cores to be arranged away from each other. 
     Accordingly, it becomes possible to eliminate the inconvenience in that the magnetic flux leakage occurs at this portion where the ends of the magnets of the pair of rotor cores adjacent to each other in the axis line direction abut against each other and are brought into contact or adjoined with each other conventionally. In other words, it becomes possible to realize a high-performance rotor (rotor structure). 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional view showing a rotor (rotor structure) of an embodiment; 
         FIG. 2  is a perspective view showing a rotor core (an IPM-type rotor core) of one embodiment; 
         FIG. 3  is a perspective view showing a rotor core (an SPM-type rotor core) of one embodiment; 
         FIG. 4  is a cross-sectional view showing a manufacturing device and a manufacturing method for a rotor core (an IPM-type rotor core) of one embodiment; 
         FIG. 5  is a cross-sectional view showing a manufacturing device and a manufacturing method for a rotor core (an IPM-type rotor core) of one embodiment; 
         FIG. 6  is an enlarged view showing a manufacturing jig and a protrusion of a manufacturing device for a rotor core (an IPM-type rotor core) of one embodiment; 
         FIG. 7  is a cross-sectional view showing a manufacturing device and a manufacturing method for a rotor core (an-IPM type rotor core) of one embodiment; 
         FIG. 8  is a cross-sectional view showing a modified example of a manufacturing device and a manufacturing method for a rotor core (an IPM-type rotor core) of one embodiment, and an enlarged view showing a protrusion; 
         FIG. 9  is a cross-sectional view showing a manufacturing device and a manufacturing method for a conventional rotor core (an IPM-type rotor core); 
         FIG. 10  is a cross-sectional view showing a manufacturing device and a manufacturing method for a conventional rotor core (an IPM-type rotor core); 
         FIG. 11  is a cross-sectional view showing a manufacturing device and a manufacturing method for a conventional rotor core (an IPM-type rotor core); 
         FIG. 12  is a cross-sectional view showing a manufacturing device and a manufacturing method for a conventional rotor core (an IPM-type rotor core); and 
         FIG. 13  is a cross-sectional view showing a conventional rotor (rotor structure). 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Hereinafter, with reference to  FIGS. 1 to 8 , a description will be given of a device for manufacturing a rotor core, a method for manufacturing a rotor core, and a rotor structure. 
     As shown in  FIG. 1 , a rotor structure (rotor) A of the present embodiment (rotor) is, for example, a rotor of an electric rotating machine such as a motor of an automobile or an electric appliance, and is configured such that a plurality of rotor cores  1 ( 5 ) of the present embodiment is integrally mounted by inserting a shaft  11  into a center hole (shaft hole)  2   d  that is formed to be penetrated around the axis line O 1 , and combined on the same axis. 
     Here, in the present embodiment, the rotor core  1  will be described as an IPM-type rotor core (interior permanent magnet type rotor core). 
     For example, as shown in  FIGS. 1 and 2 , the rotor core  1  of the present embodiment includes: a laminated iron core (core)  2  in which a plurality of core members (thin plate-shaped members) formed by punching an electromagnetic steel sheet is laminated; permanent magnets (magnets)  3  that are each inserted into and arranged in a magnet insertion hole  2   c  formed to penetrate from one end  2   a  to the other end  2   b  in an axis line O 1  direction of the laminated iron core  2 ; and a resin material  4  for embedding and fixing the permanent magnet  3  by injecting the resin material  4  into the magnet insertion hole  2   c.    
     As illustrated in  FIGS. 4 and 5 , a device B for manufacturing the rotor core  1  (a manufacturing device for a rotor core) of the present embodiment including the abovementioned configuration includes: a first mold  7  having a fitting recess  7   a  that fits and holds the laminated iron core  2  in which the permanent magnet  3  is inserted into the magnet insertion hole  2   c , and a columnar core rod  10  that is fit in the center hole  2   d  formed to penetrate in the axis line O 1  of the laminated iron core  2 ; a second mold  8  that is engaged with the first mold  7  and clamps and seals the laminated iron core  2  together with the first mold  7 ; a resin injection unit  9  that is provided in the second mold  8  and injects a resin material  4  in the magnet insertion hole  2   c  by using an injection molding machine; and a manufacturing jig  14  that has a through hole  13  into which the core rod  10  is to be inserted centered on the axis line O 1 , and provided between an inner surface of the first mold  7  and one end (an end)  2   a  in the axis line O 1  direction on the first mold  7  side of the laminated iron core  2  in a state in which the first mold  7  and the second mold  8  are clamped. 
     Furthermore, the manufacturing jig  14  is not particularly limited, and for example, is composed of stainless steel, aluminum, or the like. The manufacturing jig  14  is formed to include a protrusion  15  that is inserted into the magnet insertion hole  2   c  by a predetermined insertion amount, and positions and holds the permanent magnet  3  by an end  3   a  of the permanent magnet  3  being brought into contact with the protrusion  15  in a state in which the first mold  7  and the second mold  8  are clamped. 
     The resin material  4  is delivered to the resin injection unit  9  provided in the second mold  8  from an injection molding machine, and the resin injection unit  9  includes a resin flow channel through which the resin material  4  is delivered and injected to the magnet insertion hole  2   c  of the laminated iron core  2  clamped by the first mold  7  and the second mold  8 . 
     Next, a description will be given of a method for manufacturing a rotor core  1  by using a manufacturing device B for the rotor core  1  of the present embodiment including the above configuration (a method for integrally embedding and fixing the permanent magnet  3  to the laminated iron core  2  by injecting the resin material  4 ). 
     In the manufacturing method for the rotor core of the present embodiment, as shown in  FIGS. 4 and 5 , the core rod  10  of the first mold  7  is inserted into the center hole  2   d  of the laminated iron core  2  from the through hole  13  of the manufacturing jig  14 , thereby fitting and arranging the laminated iron core  2  (and the manufacturing jig  14 ) (first mold mounting step). 
     At this time, for example, the manufacturing jig  14  is installed in advance in the fitting recess  7   a  of the first mold  7 . With such a configuration, the laminated iron core  2  is fit and arranged in the fitting recess  7   a  of the first mold  7 , and the manufacturing jig  14  is provided between the inner surface of the first mold  7  and the one end  2   a  of the laminated iron core  2 . 
     Furthermore, the laminated iron core  2  is fit and arranged in the fitting recess  7   a  of the first mold  7 , and the protrusion  15  provided in the manufacturing jig  14  is inserted into the magnet insertion hole  2   c  of the laminated iron core  2  from the one end  2   a  by a predetermined insertion amount. 
     Next, as shown in  FIG. 5 , the second mold  8  is engaged with the first mold  7 , thereby clamping and sealing the laminated iron core  2  together with the first mold  7  (second mold mounting step). 
     Thereafter, the resin material  4  is injected to the magnet insertion hole  2   c  by an injection molding machine through the resin injection unit  9  provided in the second mold  8  (resin injecting step). 
     At this time, as shown in  FIGS. 5 and 6 , the resin material  4  is inserted from the other end  2   b  side of the magnet insertion hole  2   c , and the permanent magnet  3  inside the magnet insertion hole  2   c  is pressed against the protrusion  15 , and thus, the end  3   a  of the permanent magnet  3  abuts with the protrusion  15 , thereby positioning and holding the permanent magnet  3 . 
     Next, as shown in  FIG. 7 , the molds  7  and  8  are opened at the appropriate timing, and the rotor core  1  is removed by form removal. Thus, the protrusion  15  is also withdrawn from the interior of the magnet insertion hole  2   c , and the permanent magnet  3  is spaced apart in the axis line O 1  direction by a predetermined amount from the one end  2   a  of the laminated iron core  2 , whereby the rotor core  1  that is embedded and fixed by the resin material  4  is manufactured. It should be noted that the manufacturing jig  14  is adopted to manufacture another rotor core  1 . 
     Here, as shown in  FIG. 7  ( FIG. 1 ), if the dimension obtained by adding the protrusion amount of the protrusion  15  to the length along the axis line O 1  direction of the permanent magnet  3  is made smaller than the length dimension along the axis line O 1  direction of the magnet insertion hole  2   c , it is possible for one end of the permanent magnet  3  to be spaced apart from the one end  2   a  of the laminated iron core  2  by the protrusion  15 , and the rotor core  1  is formed in such a manner that the other end  3   b  of the permanent magnet  3  is spaced apart from the other end  2   b  of the laminated iron core  2 . 
     Furthermore, as shown in  FIG. 8 , the protrusion  15  may be provided on the inner surface of the first mold  7 , rather than in the manufacturing jig  14 . In this case, it suffices if the laminated iron core  2  is fit to the fitting recess  7   a  from the one end  2   a  side, and the protrusion  15  of the first mold  7  is configured to be inserted into the magnet insertion hole  2   c  of the laminated iron core  2  without using the manufacturing jig  14 . In this case as well, similarly to the above, the end of the permanent magnet  3  can be spaced apart by a predetermined amount in the axis line O 1  direction from the one end  2   a  of the laminated iron core  2 . 
     Furthermore, the protrusion  15  may be provided so that the protrusion amount and the insertion amount into the magnet insertion hole  2   c  are adjustable by providing the protrusion  15  so as to be slidably moved in the axis line O 1  direction. In this case, it is possible to freely adjust the spacing amount from the permanent magnet  3  and the end  2   a  of the laminated iron core  2 . Furthermore, in this case, for example, in a case of employing a small permanent magnet  3  having strong magnetic force and a large permanent magnet  3  having less magnetic force than that of the small permanent magnet  3  (in a case of achieving torque increasing efficiently by using the permanent magnets  3  having different magnetic forces), it is possible to fit the sizes of the respective permanent magnets  3  by adjusting the protrusion amount of the protrusion  15 , thereby adjusting the arrangement suitably and easily. 
     Then, as shown in  FIG. 1 , when configuring the rotor (rotor structure) A by mounting a plurality of rotor cores  1  manufactured as described above to the shaft  11 , since the ends  3   a ( 3   b ) of the permanent magnets  3  from each of the ends of the rotor cores  1  are spaced apart in the axis line O 1  direction inwardly, it is possible to eliminate the inconvenience in that the ends  3   a  of the magnets  3  of the pair of rotor cores  1  adjacent to each other in the axis line O 1  direction abut against each other and are brought into contact with each other, or adjoin each other conventionally, leading to magnetic flux leakage at this portion. That is, it becomes possible to realize a high-performance rotor A. 
     Furthermore, it is also possible to prevent damage such as cracking in the permanent magnet  3  due to abutting against each other of the ends  3   a ( 3   b ) of the magnets  3  of the pair of adjacent rotor cores  1 . 
     As described above, the description has been given of the manufacturing device for the rotor core, the manufacturing method for the rotor core, and the rotor structure; however, the present invention is not limited to one embodiment described above, and can be modified to the extent that does not deviate from the gist of the present invention. 
     For example, in the present embodiment, the rotor core has been described as an IPM-type rotor core (interior permanent magnet type rotor core); however, it may be an SPM-type rotor core (surface permanent magnet type rotor core). 
     More specifically, as shown in  FIG. 3 , for example, the SPM-type rotor core  5  includes the laminated iron core  2 , the permanent magnets  3  which are arranged at equal intervals in the circumferential direction on the outer peripheral surface side of the laminated iron core  2 , the cylindrical exterior member  6  which surrounds and covers the laminated iron core  2  with the permanent magnets  3 , and the resin material  4  for embedding and fixing the permanent magnets  3  by injecting the resin material  4  between the exterior member  6  and the laminated iron core  2 . 
     When manufacturing the SPM-type rotor core  5 , the protrusion  15  is inserted between the exterior member  6  and the rotor core  5  and, while the permanent magnet  3  between the exterior member  6  and the laminated iron core  2  is positioned by means of the protrusion  15 , the permanent magnet  3  is embedded and fixed using a molding machine by injecting from the resin injection unit  9  between the exterior member  6  and the laminated iron core  2 . With such a configuration, it is possible to obtain the same operational effect as that of the present embodiment. 
     EXPLANATION OF REFERENCE NUMERALS 
     
         
           1  IPM-type rotor core (rotor core) 
           2  laminated iron core 
           2   a  one end 
           2   b  other end 
           2   c  magnet insertion hole 
           2   d  center hole (shaft hole) 
           3  permanent magnet (magnet) 
           3   a  one end (end) 
           3   b  other end (end) 
           4  resin material 
           5  SPM-type rotor core (rotor core) 
           6  exterior member 
           7  first mold 
           7   a  fitting recess 
           8  second mold 
           9  resin injection unit 
           10  core rod 
           11  shaft 
           13  through hole 
           14  manufacturing jig 
           15  protrusion 
         A rotor (rotor structure) 
         B manufacturing device for rotor core 
         O 1  axis line