JP5751102B2 - Rotor manufacturing method and manufacturing apparatus - Google Patents

Description

  The present invention relates to a method for manufacturing a rotor in an electric motor, and more particularly to a method and apparatus for manufacturing a rotor in a permanent magnet embedded synchronous motor having a permanent magnet built into the rotor.

  As a method for manufacturing this type of rotor, for example, as described in Patent Documents 1 and 2, a slot that penetrates the rotor core made of a laminated body such as an electromagnetic steel sheet in the axial direction thereof is provided along the circumferential direction of the rotor core. In order to fill the gap between the slot portion and the permanent magnet after inserting a permanent magnet into each slot portion, a resin is inserted from one end of the slot portion where the permanent magnet is inserted. It is known that each permanent magnet is positioned and fixed in the form of a so-called resin mold by filling and curing the material.

JP 2008-125353 A JP 2010-158164 A

  When positioning and fixing the permanent magnet in the form of such a so-called resin mold, whether or not the resin material is fully filled up to the end portion (terminal portion) in the resin material flow direction of each slot portion as part of quality assurance It is necessary to check whether. However, since the exposed area of the resin material filling portion is extremely small, relying on the visual confirmation for the confirmation work may cause quality variations due to individual differences, and improvement in productivity cannot be expected. In addition, since the rotor core itself is preheated, it must be troublesome in handling such as handling.

  The present invention has been made paying attention to such problems, and when positioning and fixing a permanent magnet in the form of a so-called resin mold, the resin material is fully filled up to the end portion of each slot in the resin material flow direction. It is an object of the present invention to provide a method and an apparatus for manufacturing a rotor, which can save labor or automate the operation of checking whether or not the rotor has been checked.

  The present invention inserts a magnet into a plurality of slot portions formed along the axial direction of the rotor core and fills the slot portions with a resin material to position and fix the magnets. Based on the knowledge that the filling state has a correlation with the resin filling pressure, the resin filling pressure in each slot is monitored by a pressure detecting means such as a pressure sensor. Then, the peak value of the resin filling pressure of each slot portion within a predetermined time set in advance from the start of filling is individually detected, and when the peak value is equal to or greater than a predetermined allowable lower limit value, the resin filling pressure is appropriate. Judgment.

  According to the present invention, quality assurance of the filling state of the resin material in each slot portion can be performed accurately without relying on human hands, and it is possible to improve productivity and productivity, as well as to prevent variations in quality. Occurrence can also be eliminated.

Explanatory drawing which shows an example of the rotor manufactured by this invention method. The enlarged view of the principal part of FIG. Cross-sectional explanatory drawing which follows the AA line of FIG. Explanatory drawing which shows the manufacturing procedure of the rotor shown in FIG. Sectional explanatory drawing of the metal mold | die used for manufacture of the rotor under the procedure shown in FIG. The characteristic view which shows the change of the resin filling pressure at the time of the casting of FIG. The figure which shows the example of acquisition of the peak value of the resin filling pressure acquired by the pressure sensor of FIG. 6 is a flowchart of a processing procedure executed by the sequencer of FIG. It is a figure which shows the 2nd Embodiment of this invention, and is operation | movement explanatory drawing of the metal mold | die according to the manufacturing procedure of FIG. Plane explanatory drawing of (A) of FIG. The functional block diagram which shows the relationship between each pressure sensor in FIG. 9, and a sequencer. 12 is a flowchart of a processing procedure executed by the sequencer of FIG. FIG. 12 is a diagram illustrating a third embodiment of the present invention, and a flowchart illustrating another example of a processing procedure executed by the sequencer of FIG. 11. 12 is a flowchart showing another example of a processing procedure executed by the sequencer of FIG. 11.

  1 to 8 show a more specific first embodiment for carrying out the present invention. In particular, FIG. 1 shows a structure of a rotor (rotor) of an embedded permanent magnet synchronous motor, for example, and FIG. 1 is a plan view of the main part of FIG. 1, and FIG. 3 is a sectional view taken along the line AA of FIG.

  As shown in FIG. 1, the rotor 1 is composed mainly of a cylindrical rotor core 2 made of a laminated electromagnetic steel plate, more specifically, a silicon steel plate, and the circumference of the rotor core 2. A plurality (six in the present embodiment) of slot portions 3 having a flat rectangular shape are formed as holes for accommodating the magnets at equal positions in the direction. Each slot 3 penetrates the rotor core 2 in the axial direction and opens at both end faces of the rotor core 2. Each slot 3 has a plate or bar shape slightly smaller than the shape of the slot 3. The permanent magnet 4 is inserted. As shown in FIGS. 2 and 3, each permanent magnet 4 is positioned and fixed in the form of a so-called resin mold by a thermosetting resin material 5 that is injected or filled in a gap between the slot portion 3 and the permanent magnet 4. It is. The resin material 5 is interposed in the four circumferences between the slot portion 3 and the permanent magnet 4, and at the same time, the height of the permanent magnet 4 is set slightly smaller than the height of the slot portion 3 as shown in FIG. Therefore, the upper surface of the permanent magnet 4 is also covered with the resin material 5.

  The height of the permanent magnet 4 may be equal to the height of the rotor core 2. In addition, a rotation shaft (not shown) is inserted and fixed in the shaft hole 2 a at the center of the rotor core 2, and disc-shaped end plates (end plates) may be stacked on both end surfaces of the rotor core 2. Further, a thermosetting adhesive may be used in place of the thermosetting resin material 5.

  As shown in FIG. 2, the method for manufacturing the rotor core 2 generally includes (1) magnet insertion, (2) preheating, (3) mold clamping, (4) resin tablet insertion, (5 ) Casting (injection or filling of resin material), (6) Cure (curing), (7) Mold opening and product removal are included, and after these steps, as shown in FIG. The rotor core 2 is manufactured.

  “Magnet insertion” is an operation of inserting the permanent magnet 4 itself or an unmagnetized magnet material to be the permanent magnet 4 into each slot portion 3 of the rotor core 2. Therefore, in the latter case, magnetization as the permanent magnet 4 is performed in a later process.

  “Preheating” is to heat the rotor core 2 in which the permanent magnets 4 are inserted into the slot portions 3 to, for example, about 170 ° C.

  “Clamping” is an operation in which the rotor core 2 preheated in a state where the permanent magnet 4 is inserted is pressure-restrained with a predetermined mold from both end face sides. In addition, while the rotor core 2 is preheated, the metal mold | die for carrying out pressure restraint of the rotor core 2 is heated by about 180 degreeC, for example.

  “Resin tablet insertion” is an operation of inserting a thermosetting resin material tablet into a pot portion formed in a part of a mold.

  “Casting (resin pouring)” is an operation of softening and melting a resin material tablet inserted into a pot portion of a mold, and pouring or filling each slot portion 3.

  “Cure (curing)” means that the resin material injected or filled in each slot 3 is cured under a predetermined holding pressure, and the permanent magnet 4 inserted in advance in each slot 3 is formed in the form of a resin mold. This is an operation for positioning and fixing.

  “Mold opening / product removal” is an operation of releasing the rotor core 2 from the pressurization restraint state by the mold and taking out the rotor core 2 in which the permanent magnet 4 is positioned and fixed in each slot portion 3 as the name suggests.

  Here, the series of manufacturing steps as described above can be understood as a technique substantially equivalent to the transfer molding method, and details thereof are shown in FIG.

  As shown in FIG. 5, a mold 8 comprising a combination of a lower mold 6 and an upper mold 7 as a mold plate is prepared, and one of the rotor cores 2 in which permanent magnets 4 are inserted in advance in each slot 3. The end surface is placed on the lower mold 6 as a contact surface and positioned. Further, the upper die 7 is lowered to bring the upper die 7 into close contact with the other end surface of the rotor core 2, and the lower die 6 and the upper die 7 are used to press and restrain the rotor core 2 in the axial direction with a predetermined pressure. In this case, the upper die 7 is formed with a gate portion 10 that communicates with a pot portion 9 to be described later, and in the mold clamping state as described above, the gate portion 10 has each slot portion into which the permanent magnet 4 is inserted in advance. You will be in communication with the third person. The steps so far correspond to the steps of “magnet insertion”, “preheating”, and “clamping” in FIG.

  In the pressure restrained state of the rotor core 2 as shown in FIG. 5, the pot portion 9 on the upper die 7 side and the plunger 11 to be press-fitted thereto are independent for each slot portion 3, and the pot portion on the upper die 7 side. After inserting a pellet Pe of thermosetting resin material into the portion 9, the plunger 11 is press-fitted into the pot portion 9. Each plunger 11 is driven by an independent hydraulic cylinder or other actuator 12, and the pressure input to the pot portion 9 can be adjusted. In this case, the rotor core 2 is preheated to about 170 ° C. in advance, and the mold 8 composed of the combination of the lower mold 6 and the upper mold 7 is heated to about 180 ° C. as described above. It is. The actuator 12 may be an electric type as a matter of course.

  Accordingly, the pellet Pe of the thermosetting resin material inserted into the pot portion 9 is immediately softened and melted (plasticized) into a molten resin material 5 (see FIGS. 1 to 3), and the pushing pressure of the plunger 11 as it is. Each slot 3 is filled or filled with That is, as shown in FIGS. 2 and 3, the resin material 5 is fully injected or filled into the four-round gaps between the permanent magnet 4 and the slot portion 3, and this is also applied to the upper surface side of the permanent magnet 4. Injected or filled to coat. If the curing of the resin material 5 is waited for a predetermined curing time in this state, the permanent magnet 4 is firmly positioned and fixed at a predetermined position in the slot portion 3 in the form of a so-called resin mold. The steps so far correspond to the steps of “resin tablet insertion”, “casting (resin injection)”, and “curing (curing)” in FIG.

  If the resin material 5 is cured after a predetermined curing time has elapsed, the lower mold 6 and the upper mold 7 are opened, the plunger 11 is pulled up, and the rotor core 2 is taken out, as shown in FIG. Such a rotor core 2 is manufactured. When a non-magnetized magnet is used instead of the permanent magnet 4, the magnet is magnetized by a known method in a later process to be converted into a permanent magnet. This process corresponds to the “mold opening / product removal” process of FIG.

  In this case, as shown in FIG. 5, a pressure sensor 13 is provided as a pressure detecting means at a position corresponding to each slot portion 3 in the lower mold 6, and the pressure receiving surface of each pressure sensor 13 is set to each slot portion 3. It is facing. In FIG. 5, only two pressure sensors 13 are shown. As described above, the rotor core 2 is filled with the resin material 5 from the upper end surface side of each slot portion 3 in a state where the rotor core 2 is pressed and restrained by the upper and lower molds 6 and 7. 3, the pressure sensors 13 individually face the flow direction terminal (terminal) side of the resin material 5 at the position opposite to the filling side of the resin material 5. Each of these pressure sensors 13 constantly monitors the resin filling pressure in each slot 3 during the “casting” process of FIG. 4 described above, and the detection output of each pressure sensor 13 is the mold 8. In addition to the mold clamping and mold opening operations, the sequencer 14 serving as a control means for controlling the operation of the plunger 11 driven by the actuator 12 is incorporated.

  The sequencer 14 is composed mainly of a microcomputer including at least a CPU, a RAM, a ROM, and the like. The sequencer 14 receives various outputs from the pressure sensors 13 as described above and executes various arithmetic processes. Such a determination process and a correction process are executed.

  When the resin material 5 is filled in each slot portion 3 based on the filling operation of the plunger 11 during the “casting” process of FIG. 4 described above, the resin filling pressure in each slot portion 3 is filled before the filling is completed. It changes as shown in FIG.

  That is, when filling of the resin material 5 is started from the upper end surface of each slot portion 3 in the casting step, the resin material 5 flows from the upper end surface of each slot portion 3 toward the flow direction terminal. Thereafter, the filling pressure detected by the pressure sensor 13 increases from the time when the resin material 5 is filled up to the flow direction end of each slot portion 3 provided with the pressure sensor 13, and the resin material is placed in each slot portion 3. The filling pressure detected by the pressure sensor 13 at the time when 5 is completely filled becomes a peak value. After that, as the resin material 5 is cured as the temperature decreases (cured to such an extent that the fluidity is lowered), the pressure applied by the plunger 11 becomes difficult to be transmitted to the flow direction terminal, and the filling detected by the pressure sensor 13. Pressure decreases.

However, when the resin material 5 is filled from the upper end surface of each slot portion 3 in the casting step, the resin material 5 flowing from the upper end surface of each slot portion 3 is not filled to the flow direction end (in each slot portion 3). When the resin is not sufficiently filled), the peak value of the pressure detected by the pressure sensor 13 is low. For this reason, the peak value of the pressure detected by the pressure sensor 13 provided at the flow direction terminal of each slot portion 3 is measured, and the measured peak value is equal to or greater than a predetermined reference value P ₀ previously obtained by experiments or the like By detecting this, it becomes possible to detect that the resin material 5 is filled in the slot portion 3.

However, this reference value P ₀ varies somewhat depending on the resin filling conditions (dimensional variations of the slot 3, dimensional variations of the permanent magnet 4, ambient temperature, etc.). Therefore, in addition to the reference value P _0, it is assumed to preset the area up allowable lower limit value P _B and the allowable upper limit value P _A where the range of ± beta of the reference value P ₀ as the primary tolerance Q . Further, preset as a reference value P ₀ where a range of ± alpha secondary allowable lower limit value P _D from the secondary allowable upper limit of the region of up to P _C narrower area than the primary tolerance Q secondary tolerance R Shall be kept. The allowable lower limit value P _B and the allowable upper limit value P _A (that is, ± β) are compared with the peak value of the pressure detected by the pressure sensor 13 as will be described later. It is a threshold value for determining whether or not filling has been performed, and is a value predetermined by design or experiment. The secondary allowable lower limit value P _D and the secondary allowable upper limit P _C (i.e. ± alpha), by comparing the peak value of pressure detected by the pressure sensor 13 as will be described later, the output of the plunger 11 It is a threshold value for determining whether or not adjustment is necessary, and is a value determined in advance by design or experiment.

  After that, an elapsed time from the start of filling of the resin material 5 into each slot portion 3 is set in advance as a predetermined time t1 (sec), and each pressure sensor is started together with the start of filling of the resin material 5 for each shot. Based on the detection output from 13, the actually measured pressure value is monitored by the sequencer 14. Similarly, the peak hold function of the sequencer 14 is used to hold the peak at a predetermined sampling period, and finally the peak value P of the actually measured pressure value from each pressure sensor 13 until the predetermined time t1 elapses is detected. Then, the data is held or specified, and the data of the peak value P for each slot 3 (each pressure sensor 13) is sequentially collected and accumulated. This processing is executed for each shot, and an example of the collected and accumulated data is shown in FIG.

FIG. 8 shows a flowchart of the processing procedure in the sequencer 14, and when the cycle starts, the peak value P of the actually measured value of the resin filling pressure is initially set within a predetermined time t1 (sec). Whether or not it is detected is determined for each slot portion 3 (step S1), and in the next step S2, whether or not each peak value P for each slot portion 3 is within the primary tolerance Q of FIG. That is, it is determined whether or not the relationship of P _A ≧ peak value P ≧ P _B is satisfied. In the previous step S2, when the peak value P of the resin filling pressure is not detected within a predetermined time t1 (sec) for any one of the slot portions 3, and in step S3, for any slot portion 3, P _A ≧ In the case where the relationship of the peak value P ≧ P _B is not satisfied, the abnormal process, that is, the equipment stop process is executed by assuming that all are in trouble such as the filling condition as the process of step S4 in FIG. Note that when this equipment stop process is executed, all the data collected and accumulated so far are erased and reset.

  Here, when it is assumed that the rotor 1 as shown in FIG. 1 is continuously manufactured, the specified number of shots (the number of manufactured rotors 1) for minimum data collection is M (however, continuous If the number of rotors 1 to be manufactured is N, N> M.), And the subsequent processing is not executed until the current shot exceeds the specified number of shots, and the process returns to step S1 The processes after step S1 are repeated. For example, if the first rotor 1 is manufactured as the first shot and the specified number of shots is set to “10”, the process after step S5 is not executed until the 10th shot, and the process returns to step S1 to return to that step. The processes after S1 are repeated.

In step S3 of FIG. 8, when the current shot N exceeds the prescribed shot count M (if the prescribed shot count is set to “10” as in the previous example, the 11th and subsequent shots are applicable. In the next step S5, the average value of the peak values P for all past shots including the current shot, that is, the average value of the peak values P for each slot 3 (for each pressure sensor 13). Are respectively calculated as P _{1 to} P ₆ . For example, assuming that the specified shot number M is “10” and the current shot being molded is the 11th shot, the peak value P data for 11 shots is obtained for each slot 3 (each pressure). In this case, all the peak values P corresponding to the total number of shots (11 shots in the above example) are added and then divided by the total number of shots. averaged, thereby obtaining the average value of the peak value P to past all shots total content including the current shot to the slot portions every 3 as P ₁ to P ₆ (the pressure sensors per 13). In other words, the average value of the total number of data acquisition for each horizontal row in the data acquisition example shown in FIG. 7 is set as the average value of the peak value P for each slot unit 3 (for each pressure sensor 13) as P _{1 to} P _6. Will be asked.

Then, at the next step S6, whether or not the average value P ₁ of the peak value P in an lowermost pressure sensor 13 out of the total number six pressure sensors 13 are accommodated in the secondary tolerance R in FIG. 6, i.e. It is determined whether or not the relationship of P _C ≧ P ₁ ≧ P _D is satisfied. If the relationship of P _C ≧ P ₁ ≧ P _D is satisfied, the process returns to step S1 and the subsequent processing is repeated. . That is, the reference value P ₀ is an ideal value in design, and when the average value P ₁ of the peak values is included in the secondary tolerance R considering the variation ± α, the average of the peak values P It is determined that the value P ₁ substantially matches the ideal value in design, and the process returns to step S1 and the subsequent processing is repeated.

On the other hand, when the average value P ₁ of the peak values P does not satisfy the relationship of P _C ≧ P ₁ ≧ P _D , in the next step S7, the average value P ₁ of the peak values P is the second order tolerance shown in FIG. It is determined whether or not the allowable upper limit value P _C of R is exceeded, that is, whether or not the average value P ₁ of the peak value P is P ₁ ≧ P _C.

When the average value P ₁ of the peak value P is P ₁ ≧ P _C , the average value P ₁ of the peak value P is nothing other than the secondary tolerance R in FIG. in step S8, the actuator 12 of the plunger 11 that calculates and sets, showing the pressure adjustment amount in FIG what average value P ₁ of the peak value P obtained by subtracting the reference value P ₀ in FIG. 6 as a pressure adjustment amount Among them, the correction command is given to the actuator 12 of the plunger 11 corresponding to the first pressure sensor 13 (step S9). That is, the pressure adjustment allowance is converted into the output adjustment allowance of the actuator 12 of the plunger 11 corresponding to the specific slot portion 3, and this is given as the output DOWN command of the actuator 12 of the plunger 11 in the specific slot portion 3. . As a result, at the next shot (N + 1 shot), the output of the plunger 11 driven by the actuator 12 is suppressed, and as a result, the resin filling in which the specific slot portion 3 is filled by the plunger 11 is performed. The pressure is reduced by a predetermined amount, and the average value P ₁ of the peak values P is approximately within the secondary tolerance R in FIG.

On the other hand, when the average value P ₁ of the peak value P is not P ₁ ≧ P _C in step S7, so that the average value P ₁ of the peak value P is not accommodated in the second tolerance R in FIG. 6 since, at the next step S10, and calculates and sets the minus the mean value P ₁ of the peak value P from the reference value P ₀ in FIG. 6 as an output adjustment value, 5 the pressure adjustment amount in the same manner as described above The correction command is given to the actuator 12 of the plunger 11 corresponding to the first pressure sensor 13 among the actuators 12 of the plunger 11 shown in FIG. That is, the pressure adjustment allowance is converted into the output adjustment allowance of the actuator 12 of the plunger 11 corresponding to the specific slot portion 3, and this is given as the output UP command of the actuator 12 of the plunger 11 in the specific slot portion 3. . As a result, at the next shot (N + 1 shot), the output of the plunger 11 driven by the actuator 12 increases, and as a result, the resin filling pressure at which the specific slot portion 3 is filled by the plunger 11 Is increased by a predetermined amount, and the average value P ₁ of the peak values P is substantially within the secondary tolerance R of FIG.

Then, based on the average values P _{2 to} P ₆ of the remaining five peak values P, the processing from step S6 to step S11 is the same for the remaining five actuators 12 (slot portion 3) after step S12. Run individually. Note that processing may be performed up to step S1~S11 simultaneously to average P ₁ to P ₆ of the six peak value P.

  By performing such control for each slot part 3 for each shot, quality assurance of the filling state of the resin material 5 in each slot part 3 can be accurately performed without relying on human hands, and labor saving is achieved. Productivity can be improved and quality variations can be eliminated.

  9 to 12 show a second embodiment of the present invention, and the same reference numerals are given to the parts common to the first embodiment.

  In the second embodiment, as shown in FIGS. 9 and 10, the pot portion 19 on the upper mold 17 side and the plunger 21 driven by the actuator 22 to be press-fitted thereto are provided independently for each slot portion 3. The first embodiment is different from the first embodiment in that a single pot portion 19 to be shared by a plurality of slot portions 3 and a plunger 21 to be press-fitted thereto are prepared. Is different. The resin material is supplied to the gate portion 10 located above each slot portion 3 through the runner portion 15 so as to be distributed radially from the single pot portion 19.

  9A shows the step of “magnet insertion” in FIG. 4, FIG. 9B shows the steps of “clamping” and “resin tablet insertion” in FIG. 4, and FIG. Each of the steps of “casting” in FIG. 4 is shown. 9D shows the “cure” step in FIG. 4, and FIG. 9E shows the “mold opening / product removal” step in FIG. Similarly to FIG. 5, pressure sensors 13 are provided as pressure detection means at positions corresponding to the slot portions 3 in the lower mold 6, and the pressure receiving surfaces of the pressure sensors 13 face the slot portions 3. . The output of each pressure sensor 13 is taken into a sequencer 14 as a control means as shown in FIG.

  In the second embodiment, the processing procedure in the sequencer 14 is as shown in FIG.

In the second embodiment shown in FIG. 12, the processing from step S1 to step S4 is the same as that in FIG. 8, but the processing after step S5 is different from that in FIG. In step S5, average values P1 to _P6 of peak values P for all past shots including the current shot are calculated. For example, as in the first embodiment, assuming that the specified shot number M is “10” and the current shot being shot is the eleventh shot, “total shot number × Since the peak value P data corresponding to “the total number of pressure sensors” is accumulated, the peak value P corresponding to “the total number of shots × the total number of pressure sensors” is added as an average value. The arithmetic average obtained by dividing “the total number of shots × the total number of pressure sensors” is obtained as the average value of the peak values P for all the past shots including the current shot as P ₁ to ₆ .

Then, in the next step S6, whether or not the average values P1 to _P6 of the peak value P are within the secondary tolerance R in FIG. 6, that is, the relationship of P _C ≧ P _{1 to 6} ≧ P _D is satisfied. It is determined whether or not the relationship is satisfied, and if the relationship of P _C ≧ P _{1 to 6} ≧ P _D is satisfied, the process returns to step S1 and the subsequent processing is repeated.

On the other hand, when the average values P ₁ to P ₆ of the peak value P do not satisfy the relationship of P _C ≧ P _{1 to 6} ≧ P _D , in the next step S7, the average values P ₁ to P _{6 of the} peak value P are It is determined whether or not the allowable upper limit value P _C of the secondary tolerance R in FIG. 6 is exceeded, that is, whether or not the average values P ₁ to P _{6 of the} peak value P are P _{1 to 6} ≧ P _C. .

When the average value P _1-6 of the peak value P is P _1-6 ≧ P _C , the average value P _1-6 of the peak value P is not within the secondary tolerance R of FIG. because nothing but, Figure in the next step S8, those from the average value P _{1 to 6} of the peak value P obtained by subtracting the reference value P ₀ in FIG. 6 and the register number assignments for pressure adjustment amount, the pressure adjustment amount 5 Is given as a correction command to the actuator 12 of the specific plunger 11 shown in FIG. That is, the pressure adjustment allowance is converted into an output adjustment allowance for the actuator 12 of the plunger 11 and then given as an output DOWN command for the actuator 12 of the plunger 11. Thereby, at the time of the next shot (N + 1 shot), the output of the plunger 11 driven by the actuator 12 is suppressed, and as a result, the resin filling pressure filled by the plunger 11 decreases by a predetermined amount, The average values P ₁ to P ₆ of the peak value P are approximately within the secondary tolerance R of FIG.

On the other hand, if the average value P _1-6 of the peak value P is not P _1-6 ≧ P _C in step S7, the average value P _1-6 of the peak value P is within the secondary tolerance R of FIG. since that will not fall, in the next step S10, and calculates and sets the minus the mean value P _{1 to 6} of the peak value P from the reference value P ₀ in FIG. 6 as an output adjustment value, as described above The pressure adjustment allowance is given as a correction command to the actuator 12 of the specific plunger 11 shown in FIG. 5 (step S11). That is, this pressure adjustment allowance is converted into an output adjustment allowance for the actuator 12 of the plunger 11 and then given as an output UP command for the actuator 12 of the plunger 11. As a result, at the next shot (N + 1 shot), the output of the plunger 11 driven by the actuator 12 increases, and as a result, the resin filling pressure filled by the plunger 11 increases by a predetermined amount. Become.

  And the process from said step S6 to step S10 is similarly performed separately about the five actuators 12 which remain in step S12.

  By performing such control for each shot, quality assurance of the filling state of the resin material 5 in each slot portion 3 can be performed accurately without relying on human hands. Therefore, in the second embodiment, In this case, the same effect as in the first embodiment can be obtained.

  13 and 14 show the third embodiment of the present invention, and show another example of the processing procedure in the sequencer 14 shown in FIG.

  In the third embodiment shown in FIGS. 13 and 14, the processing from step S1 to S8 and the processing in step S10 are the same as those in FIG. Is different from that of FIG.

If the output adjustment allowance is calculated and set in step S8 of FIG. 14, in the next step S9, the pressure adjustment allowance corresponding to the output adjustment allowance is subtracted from the average value _P1-6 of the peak value P obtained previously. Then, the peak value Pn when it is assumed that the output of the plunger 21 of FIG. The conversion from the output adjustment allowance to the pressure adjustment allowance is performed, for example, by referring to a map stored in the sequencer 14 in which the correlation between the output adjustment allowance and the pressure adjustment allowance is calculated and stored in advance through experiments or the like. And Here, the latest peak value P for each slot unit 3 is called out from the data related to the peak value P stored in the storage unit of the sequencer 14, and then the latest peak value for each slot unit 3 called. By subtracting the pressure adjustment allowance from P, the peak value Pn when assuming that the output of the actuator 22 of the plunger 21 is adjusted / changed with the output adjustment allowance is estimated for each slot portion 3 individually.

Then, in the next step S11, whether or not the estimated peak value Pn is within the primary tolerance Q shown in FIG. 6, that is, whether or not the relationship of P _A ≧ estimated peak value Pn ≧ P _B is satisfied. Is determined for each slot portion 3, and when all the slot portions 3 satisfy the relationship of P _A ≧ estimated peak value Pn ≧ P _B , the output adjustment allowance previously obtained in the next step S12 is calculated. 9 is given as a correction command to the actuator 22 of the plunger 21 shown in FIG. 9, that is, as an output DOWN command of the plunger 21 in FIG. Thereby, in the next shot (N + 1 shot), the output of the plunger 21 driven by the actuator 22 is suppressed, and as a result, the resin filling pressure at which each slot portion 3 is filled by the plunger 21 is reduced. It will drop by a predetermined amount.

On the other hand, if it is determined in step S11 in FIG. 14 that at least one of the slot portions 3 does not satisfy the relationship of P _A ≧ estimated peak value pn ≧ P _B , even if the process is executed as it is, the control limit is reached. As a result, a defective product exceeding the range will be generated, resulting in a decrease in the material yield. Therefore, the process proceeds to step S13 and the facility stop process is immediately executed.

  In addition, when the equipment stop process in step S13 in FIG. 14 is executed, all the data collected and accumulated so far are erased and reset as in step S4 in FIG.

Similarly, if the output adjustment allowance is calculated and set in step S10 of FIG. 14, in the next step S14, the pressure adjustment corresponding to the output adjustment allowance is obtained from the average value _P1-6 of the peak value P obtained previously. The peak value Pn when the output of the plunger 21 is assumed to be adjusted / changed with the output adjustment allowance is estimated for each slot portion 3. Note that the conversion from the output adjustment allowance to the pressure adjustment allowance is performed with reference to, for example, a map stored in the sequencer 14 as described above. Here, the latest peak value P for each slot unit 3 is called out from the data related to the peak value P stored in the storage unit of the sequencer 14, and then the latest peak value for each slot unit 3 called. By adding the pressure adjustment allowance to P, the peak value Pn when it is assumed that the output of the actuator 22 of the plunger 21 is adjusted / changed with the output adjustment allowance is estimated for each slot 3 individually.

Then, in the next step S15, whether or not the estimated peak value Pn is within the primary tolerance Q shown in FIG. 6, that is, whether or not the relationship of P _A ≧ estimated peak value Pn ≧ P _B is satisfied. Is determined for each slot part 3, and when all the slot parts 3 satisfy the relationship of P _A ≧ estimated peak value Pn ≧ P _B , the output adjustment allowance previously obtained in the next step S16 is calculated. 9 is given as a correction command to the actuator 22 of the plunger 21 shown in FIG. 9, that is, as an output UP command of the plunger 21 in FIG. Thereby, in the next shot (N + 1 shot), the output of the plunger 21 driven by the actuator 22 increases, and as a result, the resin filling pressure at which each slot portion 3 is filled by the plunger 21 is increased. It will rise by a predetermined amount.

On the other hand, if it is determined in step S15 that at least one of the slot portions 3 does not satisfy the relationship of P _A ≧ estimated peak value Pn ≧ P _B , management is performed even if the processing is executed as it is. Since a defective product exceeding the limit is generated and the yield of the material is reduced, the process proceeds to step S13 and the facility stop process is immediately executed.

  According to the third embodiment, in addition to the same effects as those of the first embodiment, there are the following advantages. That is, according to the third embodiment, the peak value Pn of the resin filling pressure in each slot portion 3 at the time of the next shot when it is assumed that the output of the actuator 22 of the plunger 21 is adjusted is estimated. Since the output of the actuator 22 of the plunger 21 is adjusted after predicting whether or not the peak value Pn is within a predetermined tolerance, there is no possibility of producing a defective product outside the control limit. The material yield does not deteriorate.

DESCRIPTION OF SYMBOLS 1 ... Rotor 2 ... Rotor core 3 ... Slot part 4 ... Permanent magnet 5 ... Resin material 6 ... Lower mold 7 ... Upper mold 8 ... Mold 9 ... Pot part 10 ... Gate part 11 ... Plunger 12 ... Actuator 13 ... Pressure sensor (pressure) Detection means)
14 ... Sequencer (control means)
17 ... Upper mold 19 ... Pot part 21 ... Plunger 22 ... Actuator

Claims (17)

In the method of manufacturing a rotor in an electric motor in which a magnet is inserted into a plurality of slot portions formed along the axial direction of the rotor core, and the slot portion is filled with a resin material so that the magnet is positioned and fixed.
In continuously manufacturing the rotor, the resin filling pressure in each slot is monitored,
Individually detecting the peak value of the resin filling pressure in each slot within a predetermined time set in advance from the start of filling,
A method for manufacturing a rotor, wherein the resin filling pressure is determined to be appropriate when the peak value is equal to or greater than a predetermined allowable lower limit value.   The resin filling pressure is determined to be appropriate when the peak value is equal to or greater than the allowable lower limit value and within a primary tolerance range defined below a predetermined allowable upper limit value. The manufacturing method of the rotor of description. In addition to the above determination of the resin filling pressure,
The average value of the above peak values for the past multiple shots including the current shot is calculated, and the filling condition at the next shot is corrected based on the comparison result between the average value and a preset reference value. The method for manufacturing a rotor according to claim 2, wherein:   In addition to the primary tolerance, a secondary tolerance having a narrower tolerance than the primary tolerance is set in advance, and when the average value of the peak values deviates from the range of the secondary tolerance, the filling condition at the next shot The rotor manufacturing method according to claim 3, wherein:   The method for manufacturing a rotor according to claim 4, wherein the correction of the filling condition uses a difference between the average value of the peak values and a reference value as a correction allowance.   The resin filling pressure after the correction of the filling condition is estimated, and when the estimated resin filling pressure deviates from the primary tolerance, the abnormality process is executed without correcting the filling condition. 6. The method for producing a rotor according to 5.   7. The method of manufacturing a rotor according to claim 1, wherein pressure detecting means for detecting a resin filling pressure is made to face each slot portion in advance. Filling the slot portion with the resin material is performed by flowing the resin material from one end in the axial direction of the rotor core of the slot portion,
The said pressure detection means has faced the resin flow terminal part side which is an edge part on the opposite side with respect to the said one end into which resin material flows among each slot part, The Claim 7 characterized by the above-mentioned. A method for manufacturing a rotor. The filling of the resin material into the slot part is by a transfer molding method in which the resin tablet inserted in the pot part is heated and softened and then the resin material in the pot part is pressurized and filled with a plunger,
The rotor manufacturing method according to claim 3, wherein the output of the plunger is corrected as the correction of the filling condition.   The filling of the resin material into the slot part is performed so as to be distributed to each slot part using a single pot part and plunger shared by each slot part. A method for manufacturing a rotor.   The method for manufacturing a rotor according to claim 9, wherein the filling of the resin material into the slot portion is performed individually using a pot portion and a plunger that are independent for each slot portion. A magnet is individually inserted into a plurality of slot portions formed along the axial direction of the rotor core, and the rotor core into which the magnet is inserted is pressed and restrained from both end surfaces by a mold, and a part of the mold In an electric motor in which a resin tablet is inserted into a pot portion formed on the top and softened by heating, and a magnet is positioned and fixed by pressurizing and filling each slot portion with a resin material in the pot portion. A rotor manufacturing apparatus,
Pressure detecting means arranged to face each slot,
Control means for taking in the output of the pressure detection means and controlling the plunger;
And having
The control means individually detects a peak value of the resin filling pressure in each slot portion within a predetermined time from the start of filling, and a judging means for determining that the resin filling pressure is appropriate when the peak value is equal to or greater than an allowable lower limit value. An apparatus for manufacturing a rotor, comprising:   The rotor according to claim 12, wherein the determination means determines that the resin filling pressure is appropriate when the peak value is not less than the allowable lower limit value and not more than the allowable upper limit value. apparatus. The determination means individually detects the peak value within the tolerance of the resin filling pressure of each slot portion within a predetermined time set in advance from the start of filling as the detection of the peak value,
In addition to this determination means,
Correction means for calculating the average value of the above peak values for a plurality of past shots including the current shot, and correcting the filling condition at the next shot based on a comparison result between the average value and a preset reference value The rotor manufacturing apparatus according to claim 13, comprising:   In addition to the tolerance, the correction means sets a secondary tolerance having a narrower tolerance than the tolerance in advance, and the average value of the peak values deviates from the range of the secondary tolerance. The rotor manufacturing apparatus according to claim 14, wherein the filling condition is corrected.   16. The rotor manufacturing apparatus according to claim 15, wherein the correction of the filling condition uses a difference between the average value of the peak values and a reference value as a correction allowance.   The correction means estimates the resin filling pressure after the correction of the filling condition, and executes the abnormal process without correcting the filling condition when the estimated resin filling pressure deviates from the tolerance. The rotor manufacturing apparatus according to claim 16.

Images