Method for manufacturing rotor

Patent metadata

Field	Value
Publication number	US-9421609-B2
Application number	US-201414560328-A
Country	US
Kind code	B2
Filing date	Dec 4, 2014
Priority date	Apr 12, 2013
Publication date	Aug 23, 2016
Grant date	Aug 23, 2016

Abstract

In a setting step, a plurality of steel plates configuring a rotor core stacked in an axial direction of a rotor is set in a predetermined position in a mold that is capable of being opened and closed by relative movement in the axial direction. In a casting step, molten metal is fed into a molten metal introduction passage to form a conductive member of the rotor. The molten metal introduction passage has a ring-shaped gate that is opened so as to oppose one axial end surface of the steel plates set in the mold. In a cutoff step, the molten metal is cut off in the molten metal introduction passage so as to be separated into a gate side and a molten metal introduction opening side. In a mold-releasing step, the mold is opened such that a casting configuring the rotor is removed from the mold.

First claim

What is claimed is:

1. A method for manufacturing a rotor,
the rotor comprising:
a rotor core composed of a plurality of steel plates stacked in an axial direction of the rotor, each of the steel plates having a center shaft hole and a plurality of through holes, the center shaft hole passing through the steel plates in the axial direction, the plurality of through holes passing through the steel plates in the axial direction and being arrayed in a circumferential direction of the rotor; and
a conductive member that includes a pair of end rings and a plurality of connection bars, the pair of end rings being disposed on both axial ends of the rotor core in the axial direction, the plurality of connection bars connecting the pair of end rings through the through holes, the conductive member being integrally formed by casting,

the method comprising:
a setting step of setting, in a predetermined position in a mold, the plurality of steel plates configuring the rotor core stacked in the axial direction, the mold being capable of being opened and closed by relative movement in the axial direction;
a casting step of feeding molten metal into a molten metal introduction passage to form the conductive member, the molten metal introduction passage having a ring-shaped gate that is opened so as to oppose one axial end surface of the plurality of steel plates set in the mold;
a cutoff step of cutting off the molten metal in the molten metal introduction passage so as to be separated into a gate side and a molten metal introduction opening side; and
a mold-releasing step of opening the mold such that a casting configuring the rotor is removed from the mold,

wherein the molten metal introduction passage comprises
a cylindrical sloped passage that is tapered so as to gradually increase in diameter towards the gate.

2. The method for manufacturing a rotor according to claim 1 , wherein:
the setting step comprises
holding the plurality of steel plates set in the mold by a holding pin that comprises:
a shaft portion that is inserted into the center shaft hole; and
a blocking portion that is disposed on one axial end portion of the shaft portion and blocks an opening of the center shaft hole on a feeding side of the molten metal.

3. The method for manufacturing a rotor according to claim 2 , wherein:
the holding pin comprises
a positioning portion that performs positioning in a rotation direction of the plurality of steel plates fitted onto the shaft portion.

4. The method for manufacturing a rotor according to claim 2 , wherein:
the cutoff step comprises
cutting off the molten metal by moving the holding pin in the axial direction by a driving unit such that the blocking portion comes into contact with an outer peripheral wall surface of the sloped passage.

5. The method for manufacturing a rotor according to claim 3 , wherein:
the cutoff step comprises
cutting off the molten metal by moving the holding pin in the axial direction by a driving unit such that the blocking portion comes into contact with an outer peripheral wall surface of the sloped passage.

6. The method for manufacturing a rotor according to claim 4 , wherein:
the blocking portion comprises
a cutoff portion that is disposed on an opposing surface of the blocking portion that opposes the outer peripheral wall surface of the sloped passage, the cutoff portion being formed by a corner portion at which two surfaces intersect.

7. The method for manufacturing a rotor according to claim 5 , wherein:
the blocking portion comprises
a cutoff portion that is disposed on an opposing surface of the blocking portion that opposes the outer peripheral wall surface of the sloped passage, the cutoff portion being formed by a corner portion at which two surfaces intersect.

8. The method for manufacturing a rotor according to claim 2 , wherein:
the holding pin is capable of being pressed from both axial sides by an energizing member disposed on one axial end side of the holding pin and a pressing member disposed on the other axial end side of the holding pin;
the casting step comprises
pressing the blocking portion in the axial direction by an energizing force of the energizing member such that, in the plurality of steel plates set in the mold, the opening of the center shaft hole on the feeding side of the molten metal is blocked by the blocking portion; and

the cutoff step comprises
cutting off the molten metal by moving the holding pin in the axial direction by a pressing force of the pressing member such that the blocking portion comes into contact with an outer peripheral wall surface of the sloped passage.

9. The method for manufacturing a rotor according to claim 3 , wherein:
the holding pin is capable of being pressed from both axial sides by an energizing member disposed on one axial end side of the holding pin and a pressing member disposed on the other axial end side of the holding pin;
the casting step comprises
pressing the blocking portion in the axial direction by an energizing force of the energizing member such that, in the plurality of steel plates set in the mold, the opening of the center shaft hole on the feeding side of the molten metal is blocked by the blocking portion; and

the cutoff step comprises
cutting off the molten metal by moving the holding pin in the axial direction by a pressing force of the pressing member such that the blocking portion comes into contact with an outer peripheral wall surface of the sloped passage.

10. The method for manufacturing a rotor according to claim 4 , wherein:
the holding pin is capable of being pressed from both axial sides by an energizing member disposed on one axial end side of the holding pin and a pressing member disposed on the other axial end side of the holding pin;
the casting step comprises
pressing the blocking portion in the axial direction by an energizing force of the energizing member such that, in the plurality of steel plates set in the mold, the opening of the center shaft hole on the feeding side of the molten metal is blocked by the blocking portion; and

the cutoff step comprises
cutting off the molten metal by moving the holding pin in the axial direction by a pressing force of the pressing member such that the blocking portion comes into contact with an outer peripheral wall surface of the sloped passage.

11. The method for manufacturing a rotor according to claim 5 , wherein:
the holding pin is capable of being pressed from both axial sides by an energizing member disposed on one axial end side of the holding pin and a pressing member disposed on the other axial end side of the holding pin;
the casting step comprises
pressing the blocking portion in the axial direction by an energizing force of the energizing member such that, in the plurality of steel plates set in the mold, the opening of the center shaft hole on the feeding side of the molten metal is blocked by the blocking portion; and

the cutoff step comprises
cutting off the molten metal by moving the holding pin in the axial direction by a pressing force of the pressing member such that the blocking portion comes into contact with an outer peripheral wall surface of the sloped passage.

12. The method for manufacturing a rotor according to claim 6 , wherein:
the holding pin is capable of being pressed from both axial sides by an energizing member disposed on one axial end side of the holding pin and a pressing member disposed on the other axial end side of the holding pin;
the casting step comprises
pressing the blocking portion in the axial direction by an energizing force of the energizing member such that, in the p

Assignees

• Denso Corp

Inventors

• Yamaoka Tadashi
• Hirata Yuji
• Aoyama Takashi
• Sasaki Hiroshisa

Classifications

• B22C9/22

  Moulds for peculiarly-shaped castings · CPC title

• B22D29/00

  Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots {(B22D13/10, B22D11/124, B22D17/00 take precedence)} · CPC title

• B22D19/0054 Primary

  rotors, stators for electrical motors · CPC title

• B22D19/04

  for joining parts · CPC title

• B22C9/08

  Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates · CPC title