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

Abstract

Provided is a device for manufacturing a rotor core with less magnetic flux leakage, a method for manufacturing the rotor core, and a rotor structure. Included are 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; a second mold that clamps and seals the laminated iron core together with the first mold; a resin injection unit that is provided to the second mold and injects a resin material in the magnet insertion hole by using a molding machine; and a protrusion that is inserted into the magnet insertion hole 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.

What is claimed is: 
     
         1 . A rotor structure provided by integrally combining a plurality of rotor cores manufactured by using a device for manufacturing the rotor core in an axis line direction while inserting a shaft into a center hole of the rotor core, the device comprising:
 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,   wherein, 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.   
     
     
         2 . A rotor structure provided by integrally combining a plurality of rotor cores manufactured by using the device for manufacturing the rotor core according to  claim 1  in an axis line direction while inserting a shaft into a center hole of the rotor core,
 wherein the protrusion is provided to a manufacturing jig that is provided between an inner surface of either one of the first mold and the second mold and an end in an axis line direction of the laminated iron core in a clamped state, or provided to the mold. 
 
     
     
         3 . A rotor structure provided by integrally combining a plurality of rotor cores manufactured by using the device for manufacturing the rotor core according to  claim 1  in an axis line direction while inserting a shaft into a center hole of the rotor core,
 wherein the protrusion is provided such that an insertion amount into the magnet insertion hole or between the exterior member and the laminated iron core is adjustable. 
 
     
     
         4 . A rotor structure provided by integrally combining a plurality of rotor cores manufactured by using the device for manufacturing the rotor core according to  claim 2  in an axis line direction while inserting a shaft into a center hole of the rotor core,
 wherein the protrusion is provided such that an insertion amount into the magnet insertion hole or between the exterior member and the laminated iron core is adjustable.