Kuroda Precision Industries Ltd.

Osamu Fukuyama

Tomoaki Murayama

Masanobu Ikeda

Hironobu Okudaira

Tetsuya Nishizawa

Kazuo Nakamura

In a method of manufacturing a magnet embedded core (), creation of unnecessary resin from the resin for fixedly securing the magnet is prevented. The method includes a resin charging step of charging resin material () in solid form into the magnet insertion hole; a melting step of melting the resin material () in the magnet insertion hole, and a pressurization step of pressurizing an interior of the magnet insertion hole (). The melting step includes melting the resin material () at least partly by preheating and inserting the magnet () into the magnet insertion hole ().

Method of manufacturing magnet embedded core

To prevent the axial compressive force that acts on the rotor core from becoming unnecessarily large and to enable a high-quality magnet embedded core to be manufactured efficiently, a retaining jig () for a rotor core () including a magnet insertion hole () forming a through hole defining openings on end surfaces in an axial direction includes: a first plate () configured to contact against one of the end surfaces of the rotor core () and including a gate () configured to communicate with the corresponding opening of the magnet insertion hole (); a second plate () configured to oppose another of the end surfaces of the rotor core (); a closure member () coupled to the second plate () via a compression spring member () and configured to be capable of closing the opening of the magnet insertion hole () on the other of the end surfaces; and a coupling member () that couples the first plate () and the second plate () to each other such that the closure member () closes the opening and a spring force of the compression spring member () becomes a prescribed value.

Rotor core retaining jig, manufacturing device and manufacturing method for magnet embedded core

To automate setting of coupling rods when using a rotor core retaining jig and thereby to improve the production efficiency of a magnet embedded core, a setting device includes: a support base () on which the rotor core retaining jig () is to be placed; an opposing base () joined to the support baseto oppose the support base (); a pressurizing device () provided on the opposing base () and configured to pressurize an upper plate () of the rotor core retaining jig () on the support base () toward a lower plate (); chuck devices () provided on the support base () to releasably grip the coupling rods () and capable of moving between a separated position where the coupling rods () are separated from engagement grooves () and an engaged position where the coupling rods () engage the engagement grooves (); and a fluid pressure cylinder device () provided on the support base () to drive each chuck device () between the separated position and the engaged position.

Setting device for rotor core retaining jig

To allow necessary movement of a magnet in a magnet insertion hole during a manufacturing process so that a magnet embedded core in which the magnet is positioned as designed can be manufactured efficiently, a lower plate () and an upper plate () configured to contact against the end surfaces of a rotor core () are provided with pin members () configured to enter a magnet insertion hole () to allow movement of a magnet () in a first direction, which is a separation direction of two mutually opposing inner surfaces (C,D) of a magnet insertion hole (), and to restrict movement of the magnet in a second direction orthogonal to the first direction as viewed in the axial direction of the magnet insertion hole (), in a state where the magnet insertion hole is not filled with resin.

Manufacturing device for magnet embedded core

A magnet embedded core is manufactured in a stable manner even when using a die clamping device having a large rated clamping force by preventing an excessive pressurizing force from being applied to a laminated iron core, performing the clamping with an appropriate pressurizing force so to minimize leakage of the resin out of magnet insertion holes, and suppressing a reduction in the geometric and dimensional precision of the laminated iron core. A die clamping device for driving a moveable platen in a direction toward and away from a fixed lower platen is configured to include a toggle link mechanism. In a fully extended state of the toggle link mechanism, an upper die abuts an end surface of the laminated iron core to close openings of the magnet insertion holes and pressurize the laminated iron core in a laminating direction.

Resin sealing device and resin sealing method for manufacturing magnet embedded core

To prevent creation of unnecessary resin when fixing a magnet with resin, a manufacturing method for manufacturing a magnet embedded core comprises: a placing step of placing the rotor core on a mounting table such that an end surface of the rotor core is in contact with the mounting table; a resin charging step of charging the resin in solid state into the magnet insertion hole; a melting step of inciting the resin in the magnet insertion hole; a magnet inserting step of inserting the magnet into the magnet insertion hole; a closure step of closing the opening of the magnet insertion hole remote from the mounting table; and a resin pressurizing step of pressurizing the molten resin that has flowed into a buffer chamber formed in the mounting table from the opening of the magnet insertion hole on a side of the mounting table following the closure step.

Device, method, and jig for manufacturing magnet embedded core

A magnet embedded core is manufactured in a stable manner by preventing an excessive pressurizing force from being applied to the laminated iron core and performing the clamping with an appropriate pressurizing force so that the leakage of the resin out of the magnet insertion holes can be minimized, and the reduction in the geometric and dimensional precision of the laminated iron core may be suppressed. An electric die clamping device is used, such that a laminated iron core is placed on one of a fixed die and a moveable die and upon clamping by the die clamping device, the other of the fixed die and the moveable die is caused to abut onto an end surface of the laminated iron core to close openings of magnet insertion holes and pressurize the laminated iron core in a laminating direction.

To prevent the creation of unnecessary resin from the resin used for fixing the magnet, a device for manufacturing a magnet embedded core including a magnet embedded in resin filling a magnet insertion hole () extending axially in a motor core comprises a resin charging device () configured to charge the resin () in solid form into the magnet insertion hole (), a magnet insertion device () configured to insert the magnet () into the magnet insertion hole (), and a heating device () configured to heat the motor core () to melt the resin () in solid form received in the magnet insertion hole ().

Method for manufacturing magnet embedded core

A resin filling method for a magnet embedded core includes: a fixing step of sandwiching the laminated iron core at axial ends thereof between a first mold and a second mold provided to face each other; and a resin injecting step of injecting a resin into the magnet insertion hole from a resin injecting portion provided in the first mold or the second mold, wherein in the resin injecting step, an end portion of the resin injecting portion is inserted into the magnet insertion hole beyond an axial end surface of the permanent magnet inserted in the magnet insertion hole.

Resin filling method and resin filling device for magnet embedded core

A resin filling device includes: a first mold and a second mold provided so as to face each other to sandwich therebetween a laminated iron core and thereby to fix the laminated iron core; a flow path forming member provided to the first mold so as to be engageable with one of the axial ends of the laminated iron core and forming a resin flow path through which a resin flows; and a fitting member provided to the second mold to be fitted into an opening portion of the flow path forming member that is in communication with the resin flow path, wherein the fitting member is provided with a vent portion for discharging air in the resin flow path to outside.

Growing community of inventors

Kanagawa, Japan

Osamu Fukuyama