Mitsui High-tec Incorporated

Toyota Jidosha Kabushiki Kaisha

Other

Nippon Pneumatics/fluidics System Co., Ltd.

Katsumi Amano

Kazutoshi Ueda

Takashi Fukumoto

Taketo Takeuchi

Hirotoshi Mabu

Satoshi Matsubayashi

Kentaro Haruno

Atsushi Shiraishi

Atsushi Watanabe

Kenichiro Fukumaru

Tashiro Arai

Hisatomo Ishimatsu

Migaku Ishida

Akikazu Higuchi

Shuho Kai

Yukiya Fukunaga

Yuji Takeda

Shuhei Kotani

There are provided a method for manufacturing a core product, a method for removing a residual resin, and device for removing a residual resin including: supplying a molten resin; placing a conveying jig on a collection unit by conveying the conveying jig from a resin supply device to the collection unit together with a core body; splitting the resin solidified in a resin forming region from the resin solidified inside a resin flow path by removing the core body from the conveying jig; forming the residual resin which is a residue of the solidified resin inside the resin flow path and acquiring the core product including the core body and solidified resin formed in the resin forming region; and dropping the residual resin from the resin flow path into the collection unit by causing an extrusion unit to abut against the residual resin from above.

Method of manufacturing a core product

There are provided a core unit manufacturing apparatus and a core unit manufacturing method including: a molding device that fills a resin into a space portion in a core body; a resin transfer unit that transfers a resin material to the molding device to supply the resin material thereto; and a core transfer unit that carries the core body in and out of a part between a pair of dies of the molding device. The resin transfer unit and the core transfer unit are arranged such that: the resin transfer unit supplies the resin to the molding device from one side position of side surfaces of the molding device; and the core transfer unit carries the core body in and out of the molding device from the other side position of the side surfaces of the molding device, the other side position being different from one side position.

Core unit manufacturing method

A method for manufacturing a laminated iron core includes preheating a laminated body in which a plurality of iron core pieces are laminated and which includes a resin filling hole, measuring a temperature of the laminated body after preheating the laminated body, determining whether or not the temperature measured is within a predetermined range, feeding the laminated body into a molding device in a case where it is determined that the temperature is within the predetermined range, and filling the resin filling hole of the laminated body with a resin material in the molding device.

Method for manufacturing laminated iron core

A laminated rotor core () wherein permanent magnets () are inserted in respective magnet insertion holes () is disposed between and pressed by an upper die () and a lower die (). The upper die () has resin reservoir pots () provided above the laminated rotor core () and at positions corresponding to the respective magnet insertion holes (). Raw resin material put in the resin reservoir pots () is heated by the upper die (). Subsequently, the resin material in a liquefied state is ejected from the resin reservoir pots () by plungers () that are inserted and moves vertically in the resin reservoir pots () and is directly filled in the magnet insertion holes (). Consequently, the respective magnet insertion holes () are filled with the resin material more evenly and highly reliable products can be supplied at low cost.

Method of resin sealing permanent magnets in laminated rotor core

An apparatus for inserting a magnet into a rotor iron core includes a magnet inserting unit configured to insert a permanent magnet into a magnet-insert hole formed along a lamination direction of a rotor iron core body in which a plurality of iron core pieces are laminated, and a guide member to be attached to the magnet inserting unit, and arranged in a space formed between the magnet inserting unit and the rotor iron core body and configured to communicate the magnet-insert hole of the rotor iron core body to a supply part for the permanent magnet formed in the magnet inserting unit.

Apparatus for inserting magnet into rotor iron core

A rotor includes a rotor core fixedly attached to a rotational shaft and having a plurality of hole portions arranged in the circumferential direction, a magnet inserted into a plurality of hole portions each, and a filling portion injected into the hole portion. The filling portion is injected into the hole portion from a gate facing a central part in the width direction of the magnet in the opening of the hole portion.

Method of manufacturing a rotor

A method comprising: a first process of placing a laminated rotor core in a preheating device to preheat the laminated core; a second process of removing the preheated laminated core from the preheating device and disposing the laminated core between upper and lower dies of a resin sealing apparatus; a third process of pressing the laminated core by the upper and lower dies and liquefying resin material in resin reservoir pots by heating; and a fourth process of ejecting the liquefied resin material from the pots into the magnet insertion holes by plungers inserted and moving vertically in the pots and thermally curing the resin material. The method improves efficiency of resin sealing the permanent magnets in the laminated core.

A rotor includes: a rotor core fixedly attached to a rotational shaft and having a magnet-inserted hole portion; a magnet inserted into the magnet-inserted hole portion; and a resin portion injected into the magnet-inserted hole portion. The rotor core is constructed by axially stacking a plurality of electromagnetic steel sheets. The electromagnetic steel sheets include: an electromagnetic steel sheet having the magnet-inserted hole portion and a weight-reducing-purpose hole portion provided separately from the magnet-inserted hole portion; and an electromagnetic steel sheet located on at least one axial end of the rotor core and having a portion covering the hole portion formed in the electromagnetic steel sheet.

Rotor and method of manufacturing the same and electric vehicle

An object is to provide a rotor manufacturing method capable of reducing a rotor unbalance amount by controlling a magnet arrangement position in a rotor core and improving work efficiency when fixing a magnet to the rotor core by using resin. A lower surface of a rotor core is arranged in a lower mold. A magnet is arranged in a lower mold. A magnet is contained in each of magnet containing holes formed in the rotor core in such a manner that a predetermined space is assumed between an upper surface of the rotor core and an upper surface of the magnet. An upper mold is arranged on the upper surface of the rotor core. The upper mold and the lower mold apply a pressure to the rotor core and a molten resin is supplied with pressure from an internal diameter side via the predetermined space into the plurality of magnet containing holes from respective cylinder arranged in the upper mold. Thus, the magnets are molded by resin while pressing the magnets toward the outer diameter side of the magnet containing holes.

Rotor manufacturing method

The present invention has an object to propose a method of producing a rotor, capable of reliably fixing a magnet to a rotor core with resin and preventing breakage of the rotor core. The present invention includes a step of fixing a permanent magnet to a rotor core by injecting molten resin into a slot by injection molding on the condition that, assuming that: a dimension between an end surface of the rotor core and an end surface of the permanent magnet is a core end surface-magnet interval; and a minimum value of a dimension between an inner surface of the slot and a side surface of the permanent magnet, allowing the molten resin to fully fill a clearance between the inner surface of the slot and the side surface of the permanent magnet by injecting the resin into the slot through a cylinder, is a minimum slot-magnet interval value, and a value of the core end surface-magnet interval is equal to or larger than the minimum slot-magnet interval value.

Production method of a rotor

A method comprising: a first process of placing a laminated rotor core () in a preheating device () to preheat the laminated core (); a second process of removing the preheated laminated core () from the preheating device () and disposing the laminated core () between upper and lower dies () of a resin sealing apparatus (); a third process of pressing the laminated core () by the upper and lower dies () and liquefying resin material () in resin reservoir pots () by heating; and a fourth process of ejecting the liquefied resin material () from the pots () into the magnet insertion holes () by plungers () inserted and moving vertically in the pots () and thermally curing the resin material (). The method improves efficiency of resin sealing the permanent magnets () in the laminated core ().

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Kitakyushu, Japan

Katsumi Amano