CN112217354A

CN112217354A - Method and apparatus for manufacturing laminated core of rotating electrical machine

Info

Publication number: CN112217354A
Application number: CN202010646115.3A
Authority: CN
Inventors: 大桥直树; 中野正嗣; 中野圣士
Original assignee: Mitsubishi Electric Corp
Current assignee: Mitsubishi Electric Corp
Priority date: 2019-07-12
Filing date: 2020-07-07
Publication date: 2021-01-12
Anticipated expiration: 2040-07-07
Also published as: CN112217354B; JP2021016254A; JP6780905B1

Abstract

Provided are a method and an apparatus for manufacturing a laminated core for a rotating electrical machine, which can realize the manufacturing of punching a plurality of plate-shaped stator core elements from an electrical steel plate after rolling at high precision through one process, and can suppress the distortion and the reduction of rigidity of the electrical steel plate caused by punching. In a method for manufacturing a laminated core for a rotating electrical machine, prior to a step of punching a plate-like rotor core element (21) from a rolled strip-like magnetic steel sheet (4), a plate-like stator core element (11) is punched in a region of a second region (42) located on the inner side of a first region (41) of the punched plate-like rotor core element, and a plurality of guide pins (501, 502) are arranged in the first region (41) and the second region (42), respectively, prior to punching the plate-like stator core element (11) from the strip-like magnetic steel sheet.

Description

Method and apparatus for manufacturing laminated core of rotating electrical machine

Technical Field

The present application relates to a method and an apparatus for manufacturing a laminated core for a rotating electrical machine.

Background

In a conventional method for manufacturing a laminated core for a rotating electrical machine, a method is known in which a space inside an annular rotor core is effectively used, and therefore, a rotor core is manufactured after divided cores are manufactured in advance using a material of a part of the space (generally referred to as "co-material") (for example, patent documents 1 and 2).

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2013-

Patent document 2: japanese patent laid-open No. 2002-186227

In the conventional art, the material is distorted due to the cutting resistance when manufacturing the plate-shaped stator core elements constituting the stator core. Further, since the plate-shaped stator core elements are cut in advance, holes are opened in the material, so that the material rigidity is lowered. The rotor core is usually produced by laminating plate-shaped stator core elements positioned by guide pins, and therefore, it is desirable that the material is uniform all the time. That is, the use of a distorted material is not preferable because it affects the positional accuracy of the rotor core during lamination.

Further, it is preferable that the material has a certain rigidity or more. That is, normally, the material is quantitatively conveyed and laminated by the guide pin, but if the rigidity of the material is insufficient, the material may be twisted or distorted, and a desired conveyance amount may not be secured, and the material may be inclined.

In particular, since the guide pin is usually disposed only at an end portion in a direction orthogonal to the material conveying direction, if the rigidity of the material is low, the material may twist, which is not preferable.

As described above, in the conventional manufacturing method, the dimensional accuracy and the attitude accuracy of the rotor core are degraded, and the cogging torque, the torque pulse, and the like of the motor are increased, thereby increasing the vibration and the noise.

Disclosure of Invention

The present application discloses a technique realized in view of the above circumstances, and an object thereof is to enable manufacturing of a plurality of plate-shaped stator core elements by punching out a magnetic steel plate after rolling at high accuracy in one step, and to suppress distortion and a decrease in rigidity of the magnetic steel plate due to punching out.

The application discloses a method for manufacturing a laminated iron core of a rotating electrical machine, the rotating electrical machine comprises: a stator core configured by annularly connecting stator core element lamination blocks in a circumferential direction, the stator core element lamination blocks configured by laminating plate-shaped stator core elements formed in a T shape by a pole tooth portion and a core back portion in an axial direction; and a rotor core that is formed by laminating annular plate-like rotor core elements in an axial direction and is surrounded by the stator core, wherein the plate-like stator core elements are punched out by a punching step by a punching mechanism in a region of a second region of a strip-like electromagnetic steel plate that is located more inward than a first region where the plate-like rotor core elements are punched out, prior to a step of punching out the plate-like rotor core elements from the strip-like electromagnetic steel plate formed by rolling, and wherein a plurality of guide pins are arranged in the first region and the second region, respectively, prior to the step of punching out the plate-like stator core elements from the strip-like electromagnetic steel plate by the punching mechanism.

According to the method for manufacturing a laminated core for a rotating electrical machine disclosed in the present application, the rotating electrical machine includes: a stator core configured by annularly connecting stator core element lamination blocks in a circumferential direction, the stator core element lamination blocks configured by laminating plate-shaped stator core elements formed in a T shape by a pole tooth portion and a core back portion in an axial direction; and a rotor core that is formed by laminating annular plate-like rotor core elements in an axial direction and is surrounded by the stator core, wherein the plate-like stator core elements are punched out by a punching step by a punching mechanism in a region of a second region of a strip-like electromagnetic steel plate that is located more inside than a first region where the plate-like rotor core elements are punched out, before a step of punching out the plate-like rotor core elements from the strip-like electromagnetic steel plate formed by rolling, and a plurality of guide pins are arranged in the first region and the second region, respectively, before the plate-like stator core elements are punched out from the strip-like electromagnetic steel plate by the punching step by the punching mechanism, so that it is possible to realize manufacturing by which a plurality of plate-like stator core elements are punched out from the rolled electromagnetic steel plate with high accuracy by one step at a time, and distortion and reduction in rigidity of the electrical steel sheet due to punching can be suppressed.

Drawings

Fig. 1 is a diagram illustrating embodiment 1 of the present application, and is a plan view illustrating an example of a rotating electric machine that is a target of a method and an apparatus for manufacturing a laminated core of the rotating electric machine.

Fig. 2 is a plan view showing embodiment 1 of the present application, illustrating a concept of a laminated core manufacturing method.

Fig. 3 is a view showing embodiment 1 of the present application, which is a plan view showing an example of a plate-shaped stator core element.

Fig. 4 is a view showing embodiment 1 of the present application, and is a perspective view showing an example of a laminated stator core element block.

Fig. 5 is a diagram showing embodiment 1 of the present application, which is a front view schematically illustrating a laminated core manufacturing apparatus.

Fig. 6 is a view showing embodiment 1 of the present application, which is a schematic plan view illustrating a laminated core manufacturing apparatus.

Fig. 7 is a plan view showing embodiment 1 of the present application, which is a method for punching a plurality of plate-shaped stator core elements at a time in a plurality of punching steps.

Fig. 8 is a plan view showing embodiment 2 of the present application, which is an example of the concept of a laminated core manufacturing method.

Fig. 9 is a plan view showing embodiment 3 of the present application, illustrating a concept of a laminated core manufacturing method.

Fig. 10 is a diagram showing embodiment 4 of the present application, in which (a) is a plan view illustrating a concept of a laminated core manufacturing method, and (b) and (c) are diagrams illustrating technical problems of a strip-shaped electrical steel sheet formed by rolling.

Fig. 11 is a view showing embodiment 4 of the present application, in which (a) and (b) are perspective views of a stator core element laminated block for explaining a technical problem of a stator core element laminated block in which plate-shaped stator core elements, which are punched and sheared from a strip-shaped electromagnetic steel sheet formed by rolling and formed in a T shape by a pole tooth portion and a core back portion, are laminated in an axial direction.

Fig. 12 is a plan view showing embodiment 5 of the present application, which is an example of the concept of a laminated core manufacturing method.

Fig. 13 is a view showing embodiment 5 of the present application, which is a perspective view of a stator core element laminated block for explaining the flow of magnetic flux in the stator core element laminated block.

Fig. 14 is a plan view showing embodiment 6 of the present application, which is an example of the concept of a laminated core manufacturing method.

Fig. 15 is a plan view showing embodiment 7 of the present application, which is a method for punching a plurality of plate-shaped stator core elements at a time in a double punching step.

Fig. 16 is a plan view of a stator core illustrating a first feature of the stator core according to the manufacturing method of the present application.

Fig. 17 is a plan view of a stator core illustrating a second feature of the stator core according to the manufacturing method of the present application.

(symbol description)

1 a stator core; 11 a plate-shaped stator core element; 11T pole tooth parts; 11CB core back; 11LB stator core element lamination block; 12 a frame; 2 a rotor core; 21 a plate-shaped rotor core element; 211 a hole for a magnet; 3, rotating a shaft; 4 a strip-shaped electromagnetic steel sheet; 41 a first region; 42 a second region; a4 belt-like electromagnetic steel sheet feeding direction; 5 manufacturing the device; a 50-strip-shaped electromagnetic steel plate flattening mechanism; 501 outer guide pins; 502 inboard guide pins; 51 a first stamping mechanism; 511 a first stator core element blanking punch; 512 a first plate-like stator core element blanking die; 513 a first plate-like stator core element storage chamber; 514 a first stator core element lamination block discharge port; 515 a stator core element lamination block axial length adjustment mechanism; 52 secondA stamping mechanism; 521 blanking male die of the second stator core element; 522 a second plate-like stator core element blanking negative die; 523 a second plate-like stator core element storage chamber; 524 a second stator core element lamination block exhaust port; 525 a stator core component lamination block axial length adjustment mechanism; 53 third stamping mechanism; 531 blanking male die of the third stator core element; 532 a third sheet stator core element blanking cavity die; 533 a third plate-like stator core element storage chamber; 534 a third stator core component lamination block exhaust port; 535 stator core element lamination block axial length adjustment mechanism; 54 a fourth stamping mechanism; 541 a fourth stator core element blanking punch; 542 a fourth plate-like stator core element blanking die; 543 a fourth plate-like stator core element storage chamber; 544 a fourth stator core element lamination block exhaust port; 545 stator core element lamination block axial length adjustment mechanism; 55 a fifth stamping mechanism; 551 a fifth plate-like rotor core element blanking punch; 552 fifth plate-like rotor core element blanking cavity die; 553 a fifth plate-like rotor core element storage chamber; 554 rotor core element lamination stack exhaust port; 56 a scrap severing mechanism; 561 electromagnetic steel plate scrap cutting male die; 562 a cutting female die for electromagnetic steel plate waste; 563 a scrap stocker for cutting the electromagnetic steel sheet; 564 cutting the electromagnetic steel sheet scrap discharge port; 525. 535, 545 stator core element lamination block axial length adjustment mechanism; A4M rolling direction of the strip-shaped electromagnetic steel plate; t is_1-1、T_1-2、T_1-3、T_1-4、T_1-5、T_1-6、T_1-7、T_1-8、T_1-9、T_1-10、T_P-1、T_P-2Plate-shaped stator core elements are punched out of objects.

Detailed Description

Embodiments of a method and an apparatus for manufacturing a laminated core for a rotating electrical machine and a rotating electrical machine according to the present invention will be described below with reference to the drawings. The present invention is not limited to the following description, and can be appropriately modified within a scope not departing from the gist of the present invention. In the drawings shown below, for convenience of understanding, the proportional dimensions of the respective members may be different from those of the actual members, or the structures not related to the features of the present application may be omitted from illustration.

Embodiment mode 1

Hereinafter, a method for manufacturing a laminated core for a rotating electrical machine, an apparatus for manufacturing a laminated core, and embodiment 1 of a rotating electrical machine having a laminated core will be described with reference to fig. 1 to 7 and 12. Fig. 1 is a plan view showing an example of a rotating electric machine which is a target of a method and an apparatus for manufacturing a laminated core of the rotating electric machine. Fig. 2 is a plan view illustrating a concept of a laminated core manufacturing method, fig. 3 is a plan view illustrating an example of a plate-shaped stator core element, fig. 4 is a perspective view illustrating an example of a laminated block of stator core elements, fig. 5 is a front view schematically illustrating a laminated core manufacturing apparatus, fig. 6 is a plan view schematically illustrating a laminated core manufacturing apparatus, fig. 7 is a plan view illustrating a method of punching a plurality of plate-shaped stator core elements at a time in a plurality of punching steps, and fig. 12 is a plan view of a stator core illustrating features of the stator core.

A rotating electrical machine which is a target of a method and an apparatus for manufacturing a laminated core for a rotating electrical machine includes, as an example illustrated in fig. 1, 3, and 4: a stator core portion configured by annularly connecting stator core component laminated blocks 11LB (see fig. 4) in a circumferential direction as illustrated in fig. 1, the stator core component laminated blocks 11LB being configured by laminating plate-shaped stator core components 11 (see fig. 3) formed in a T-shape by a tooth portion 11T and a core back portion 11CB in an axial direction of a rotating shaft 3; and a rotor core that is configured by laminating annular plate-shaped rotor core elements 21 in the axial direction and that is surrounded by the stator core.

The stator core element lamination blocks 11LB connected annularly in the circumferential direction are strongly fitted into the inner periphery of the annular frame 12. By the above-described strong fitting, the stator core element laminated block 11LB group annularly connected in the circumferential direction maintains a state annularly connected in the circumferential direction, that is, the state of fig. 1.

As shown in fig. 2, before a strip-shaped magnetic steel sheet raw ingot is punched by a punching mechanism to punch out a plate-shaped rotor core element 21 from a first region of a strip-shaped magnetic steel sheet 4 rolled and formed in a strip-shaped magnetic steel sheet rolling direction A4M by punching rollers not shown in the drawing, plate-shaped stator core elements 11, … (10 in the example of fig. 2) connected annularly in the circumferential direction are sequentially punched out so as to be punched out by the punching mechanism in a plurality of steps, not at once, but in a plurality of steps, from a second region 42 located on the inner side of the first region, before the plate-shaped rotor core element 21 is punched out from the first region of the strip-shaped magnetic steel sheet 4 rolled and formed in the strip-shaped magnetic steel sheet rolling direction A4M. Specifically, fig. 5 and 6 illustrating the manufacturing apparatus 5, and fig. 7 illustrating a method of punching a plurality of plate-shaped stator core elements at a time in a plurality of punching steps will be described in detail below.

When a strip-shaped magnetic steel sheet 4 rolled in a rolling direction A4M (hereinafter also referred to as "strip-shaped magnetic steel sheet rolling direction") is fed toward a manufacturing apparatus 5 in a direction of an arrow A4 (hereinafter also referred to as "strip-shaped magnetic steel sheet feeding direction"), irregular bending, deflection, or the like of the strip-shaped magnetic steel sheet 4 is first flattened by a strip-shaped magnetic steel sheet flattening mechanism 50.

Specifically, by inserting the outer guide pins 501 into the four corners outside the punched region of the plate-like rotor core member 21 of the strip-like magnetic steel plate 4, that is, the first region 41, by the strip-like magnetic steel plate flattening mechanism 50, tension is applied to the strip-like magnetic steel plate 4 at the four corners of the region 41, so that the region surrounded by the outer guide pins 501 of the four corners of the strip-like magnetic steel plate 4 (including the second region 42) is flattened.

Further, at any plural places in the second region 42 (region surrounded by the region where the plate-shaped rotor core member 21 is punched) of the strip-shaped electromagnetic steel plate 4, the inner guide pins 502 are inserted by the strip-shaped electromagnetic steel plate flattening mechanism 50 at positions not overlapping with the punched portions of the plate-shaped stator core member 11. By inserting the inner guide pins 502 into the strip-shaped magnetic steel sheet 4, the occurrence of distortion in the second region 42 of the strip-shaped magnetic steel sheet 4 due to punching by the punching mechanism of the plate-shaped stator core member 11 is suppressed.

In the manufacturing apparatus 5, a first press mechanism 51 is disposed downstream of the flattening mechanism 50 of the strip-shaped magnetic steel sheet in the feeding direction a4 of the strip-shaped magnetic steel sheet 4, a second press mechanism 52 is disposed downstream of the first press mechanism 51, a third press mechanism 53 is disposed downstream of the second press mechanism 52, a fourth press mechanism 54 is disposed downstream of the third press mechanism 53, a fifth press mechanism 55 is disposed downstream of the fourth press mechanism 54, and a scrap cutting mechanism 56 is disposed downstream of the fifth press mechanism 55.

The first press mechanism 51 has a plurality of (3 in embodiment 1) first stator core element blanking punches 511, and has a first plate-like stator core element blanking die 512 formed in the die plate in correspondence with the first stator core element blanking punches 511.

The first stator core member blanking male die 511 is caused to cooperate with the first plate-like stator core member blanking female die 512 by the punching action of the first stator core member blanking male die 511 to blank the plate-like stator core members 11 from the strip-like electromagnetic steel sheets 4.

Corresponding to each of the plurality of first plate-like stator core element blanking female dies 512, a first plate-like stator core element storage chamber 513, a plurality of first stator core element lamination block discharge ports 514 are provided, respectively.

The second press mechanism 52 has a plurality of (2 in embodiment 1) second stator core element punching male dies 521, and has a second plate-like stator core element punching female die 522 formed in the die plate in correspondence with the second stator core element punching male dies 521.

The second stator core element blanking male die 521 is caused to cooperate with the second plate-like stator core element blanking female die 522 by the punching action of the second stator core element blanking male die 521 to blank the plate-like stator core elements 11 from the strip-like electromagnetic steel sheets 4.

Corresponding to each of the plurality of second plate-shaped stator core element blanking female dies 522, a second plate-shaped stator core element storage chamber 523 and a plurality of second stator core element lamination block discharge ports 524 are provided, respectively.

The third press mechanism 53 has a plurality of (3 in embodiment 1) third stator core element blanking punches 531, and has a third plate-like stator core element blanking die 532 formed in the die plate in correspondence with the third stator core element blanking punches 531.

The third stator core element blanking male die 531 cooperates with the third plate-shaped stator core element blanking female die 532 to blank the plate-shaped stator core element 11 from the strip-shaped electromagnetic steel plates 4 by the punching action of the third stator core element blanking male die 531.

A third plate-shaped stator core element storage chamber 533, a plurality of third stator core element stacked block discharge ports 534 are provided, respectively, corresponding to each of the plurality of third plate-shaped stator core element blanking female dies 532.

The fourth press mechanism 54 has a plurality of (2 in embodiment 1) fourth stator core element blanking punches 541, and has fourth plate-like stator core element blanking female dies 542 formed in the die plate in correspondence with the fourth stator core element blanking punches 541.

The fourth stator core element blanking punch 541 cooperates with the fourth plate-like stator core element blanking die 542 by the punching action of the fourth stator core element blanking punch 541 to blank the plate-like stator core elements 11 from the strip-like electromagnetic steel sheet 4.

Corresponding to each of the plurality of fourth plate-like stator core element blanking dies 542, a fourth plate-like stator core element storage chamber 543, a plurality of fourth stator core element lamination block discharge openings 544 are provided, respectively.

The fifth press mechanism 55 has a fifth plate-like rotor core element blanking male die 551, and has a fifth plate-like rotor core element blanking female die 552 formed in the die plate in correspondence with the fifth plate-like rotor core element blanking male die 551.

The fifth plate-like rotor core element blanking male die 551 cooperates with the fifth plate-like rotor core element blanking female die 552 by the punching action of the fifth plate-like rotor core element blanking male die 551 to blank the plate-like rotor core elements 21 from the strip-like electromagnetic steel sheet 4.

Corresponding to the fifth plate-like rotor core element blanking female die 552, a fifth plate-like rotor core element storage chamber 553 and a rotor core element lamination block discharge port 554 are provided, respectively.

As illustrated in fig. 5, a stator core element lamination block axial

length adjustment mechanism

515, 525, 535, 545 is provided in the manufacturing apparatus 5 in front of each of the stator core element lamination

block discharge ports

514, 524, 534, 544, and the stator core element lamination block axial

length adjustment mechanism

515, 525, 535, 545 adjusts the length tllb of the stator core element lamination block 11LB in the axial direction of the rotating electrical machine, which is punched out from the strip-shaped electromagnetic steel plate 4 and stored in the plate-shaped stator core

element storage chambers

513, 523, 533, 543, before the stator core element lamination

block discharge ports

514, 524, 534, 544 are taken out, that is, before the stator core 1 is assembled.

When all the punching by the first punching mechanism 51 to the fifth punching mechanism 55 is completed, the surplus material of the strip-shaped magnetic steel sheet 4 is scrap, and therefore, the scrap cut by the magnetic steel sheet scrap cutting male die 561 and the magnetic steel sheet scrap cutting female die 562 is stored in the cut magnetic steel sheet scrap storage chamber 563 and then taken out from the cut magnetic steel sheet scrap discharge port 564.

Next, referring to fig. 7 and 5, description will be made in order of a punching step of punching out a plurality of plate-shaped stator core elements at a time so that the extending directions of the pole teeth portions in the radial direction of the rotating electrical machine are the same in a plurality of punching steps in a second region of a strip-shaped magnetic steel sheet on the inner side of a first region where the plate-shaped rotor core elements are punched out, prior to a step of punching out the plate-shaped rotor core elements from the strip-shaped magnetic steel sheet formed by rolling by a punching mechanism.

As illustrated in fig. 7, in the first punching step, three plate-shaped stator core element punching objects T of the strip-shaped electromagnetic steel plate 4 are punched in the second region 42 by the first punching mechanism 51 of fig. 5 and 6_1-1、T_1-2、T_1-3The strip-shaped magnetic steel sheet 4 is advanced in the strip-shaped magnetic steel sheet feeding direction A4And feeding the blank to a second blanking process of the next process.

The three plate-shaped stator core elements 11 blanked in the first blanking process are individually stored in the three first plate-shaped stator core

element storage chambers

513, 513 of the manufacturing apparatus 5 of fig. 5 and 6.

As illustrated in fig. 7, in the second punching step, in the second region 42, the two plate-shaped stator core element punching targets T of the strip-shaped electromagnetic steel plate 4 are punched by the second punching mechanism 52 of fig. 5 and 6_1-4、T_1-5The strip-shaped magnetic steel sheet 4 is fed in the strip-shaped magnetic steel sheet feeding direction a4, and is fed to the third blanking step in the next step.

The two plate-shaped stator core elements 11 punched out in the second punching process are individually stored in the two second plate-shaped stator core

element storage chambers

523, 523 of the manufacturing apparatus 5 of fig. 5 and 6.

As illustrated in fig. 7, in the third punching step, three plate-shaped stator core element punching objects T of the strip-shaped electromagnetic steel plate 4 are punched in the second region 42 by the third punching mechanism 53 shown in fig. 5 and 6_1-6、T_1-7、T_1-8The strip-shaped magnetic steel sheet 4 is fed in the strip-shaped magnetic steel sheet feeding direction a4, and is fed to the fourth blanking step in the next step.

The three plate-shaped stator core elements 11 punched out in the third punching process are individually stored in the three third plate-shaped stator core

element storage chambers

533, 533 of the manufacturing apparatus 5 of fig. 5 and 6.

As illustrated in fig. 7, in the fourth punching step, in the second region 42, the two plate-shaped stator core element punching targets T of the strip-shaped electromagnetic steel plate 4 are punched by the fourth punching mechanism 54 of fig. 5 and 6_1-9、T_1-10The strip-shaped magnetic steel sheet 4 is fed in the strip-shaped magnetic steel sheet feeding direction a4, and is fed to the fifth blanking step in the next step.

The two plate-shaped stator core elements 11 punched out in the fourth punching step are individually stored in the two fourth plate-shaped stator core

element storage chambers

543, 543 of the manufacturing apparatus 5 of fig. 5 and 6.

At the punching end time point of the fourth punching step, all the plate-shaped stator core elements 11 … 11 used for the plate-shaped rotor core elements 21 at the time of assembling the rotating electrical machine (10 plate-shaped stator core element punching objects T for punching the strip-shaped electromagnetic steel plates 4 in the second region 42) are punched_1-1To T_1-10And a plate-shaped fixed core member).

In the first to fourth punching steps, all of the plate-shaped stator core elements 11 … 11 used with respect to the plate-shaped rotor core elements 21 at the time of assembling the rotary electric machine (10 plate-shaped stator core element punching objects T for punching the strip-shaped electromagnetic steel plates 4 in the second region 42) are punched from the second region 42_1-1To T_1-10And the formed plate-shaped stator core element) is followed by a fifth blanking process.

As illustrated in fig. 6, the fifth punching step is a step of punching the plate-like rotor core element 21 from the first region 41 of the strip-like electromagnetic steel plate 4 by the fifth punching mechanism 55.

One plate-shaped rotor core member 21 blanked in the fifth blanking process is individually stored in the plate-shaped rotor core member storage chamber 553 of the manufacturing apparatus 5 of fig. 5 and 6.

When the blanking in the first blanking step is completed, the strip-shaped magnetic steel sheet 4 is fed in the strip-shaped steel sheet feeding direction a4, and the area to be blanked in the first blanking step is moved to the second blanking step to perform the blanking in the second blanking step, but the strip-shaped magnetic steel sheet 4 that is not blanked in the first blanking step is blanked in the first blanking step while the blanking in the second blanking step is performed. Similarly, while the punching in the fifth punching step is performed, punching in the first punching step, the second punching step, the third punching step, and the fourth punching step is performed.

In this way, when the first press mechanism 51, the second press mechanism 52, the third press mechanism 53, the fourth press mechanism 54, and the fifth press mechanism 55 are continuously operated, and when a predetermined number of plate-shaped stator core components 11 are stored in the corresponding first plate-shaped stator core component storage chamber 513, the second plate-shaped stator core component storage chamber 523, the third plate-shaped stator core component storage chamber 533, and the fourth plate-shaped stator core component storage chamber 543, the plate-shaped stator core components 11 stored in the predetermined number are automatically extruded from the first plate-shaped stator core component storage chamber 513, the second plate-shaped stator core component storage chamber 523, the third plate-shaped stator core component storage chamber 533, and the fourth plate-shaped stator core component storage chamber 543 by the extrusion mechanism inside the manufacturing apparatus 5, and the stator core component laminated block axial length adjustment mechanism 515, 525, 535, 545 adjusts the length T11LB of the stator core component laminated block 11LB in the axial direction of the rotary electric machine, thereafter, the stator core element lamination block 11LB is discharged from the first stator core element lamination block discharge port 514, the second stator core element lamination block discharge port 524, the third stator core element lamination block discharge port 534, and the fourth stator core element lamination block discharge port 544 (see fig. 4).

Similarly, when a predetermined number of the plate-shaped rotor core components 21 are stored in the fifth plate-shaped rotor core component storage chamber 553, the plate-shaped rotor core components 21 stored in the predetermined number are automatically extruded from the fifth plate-shaped rotor core component storage chamber 553 by the extrusion mechanism inside the manufacturing apparatus 5, and are discharged from the rotor core component stacked block discharge port 554.

As is apparent from the above description, embodiment 1 exemplifies a method for manufacturing a laminated core of a rotating electrical machine including: a stator core 1 configured by annularly connecting stator core element lamination blocks 11LB in a circumferential direction of a rotary electric machine, the stator core element lamination blocks 11B being configured by laminating plate-shaped stator core elements 11 in an axial direction of the rotary electric machine, the plate-shaped stator core elements 11 being formed in a T-shape by tooth portions 11T and a core back portion 11 CB; and a rotor core 2 formed by laminating annular plate-like rotor core elements 21 in an axial direction of a rotary electric machine, the rotor core 2 being surrounded by the stator core 1, wherein, prior to a step (a fifth punching step in the present embodiment) of punching out the plate-like rotor core elements 21 from a strip-like electromagnetic steel plate 4 formed by rolling by a punching mechanism 55, a plurality of plate-like stator core elements 11 are punched out at a time so that the extending directions of the pole teeth portions in a radial direction of the rotary electric machine are the same in a plurality of punching steps (a first punching step to a fourth punching step in the present embodiment) in a second region 42 on an inner side than a first region 41 of the strip-like electromagnetic steel plate 4 where the plate-like rotor core elements 21 are punched out.

In the present embodiment, as illustrated in fig. 2 and 7, two punched objects T21 of the plate-shaped rotor core elements 21 are punched out in parallel with the rolling-press conveying direction a5 (i.e., the rolling direction A4M of the strip-shaped magnetic steel sheet, i.e., the feeding direction A4 of the strip-shaped magnetic steel sheet) except for the center axis CH21 of the punched objects_1-2、T_1-7In addition, the number of plate-shaped stator core element punching objects for punching the plate-shaped stator core elements out of the 10 plate-shaped stator core elements 11 is symmetrical to the center axis CH21 of the punching object of the plate-shaped rotor core element 21 parallel to the rolling press conveyance direction a5 (i.e., the strip-shaped electromagnetic steel plate rolling direction A4M, i.e., the strip-shaped electromagnetic steel plate feeding direction A4) and the center axis CV21 of the punching object of the plate-shaped rotor core element 21 perpendicular to the rolling press conveyance direction a5 (i.e., the strip-shaped electromagnetic steel plate rolling direction A4M, i.e., the strip-shaped electromagnetic steel plate feeding direction A4), so that the punching pressure of the stator core element punching punch applied to the second region 42 of the strip-shaped electromagnetic steel plate 4 is uniformly dispersed when the punching object of the plate-shaped stator core element in the second region 42 surrounded by the region, i.e., the first region 41, from which the plate-shaped electromagnetic steel plate 4 is, therefore, the dimensional accuracy of each of the plate-shaped stator core elements 11 is improved.

Further, since the orientations of the strip-shaped electromagnetic steel sheet rolling directions A4M of the plate-shaped stator core elements 11 arranged in the circumferential direction of the rotating electrical machine are all in the same direction, i.e., in the radial direction, as illustrated in fig. 12, it is possible to reduce the cogging torque, the torque pulses, and the like caused by the difference in magnetic anisotropy due to the difference in the angle of the plate-shaped stator core elements 11 arranged in the circumferential direction of the rotating electrical machine in the direction perpendicular to the strip-shaped electromagnetic steel sheet rolling direction A4.

Further, since the strip-shaped electromagnetic steel sheet rolling directions A4M of the plate-shaped stator core elements 11 arranged in the circumferential direction of the rotating electrical machine are all oriented in the same direction, i.e., in the radial direction, as illustrated in fig. 12, the direction of the magnetic flux passing through the plate-shaped stator core elements 11 when the rotating electrical machine is operated is the same as the strip-shaped electromagnetic steel sheet rolling direction A4M, and therefore, the magnetic properties in the strip-shaped electromagnetic steel sheet rolling direction A4M are good, and therefore, an effect of realizing a high-torque rotating electrical machine can be obtained.

As a feature of embodiment 1, guide pins are arranged not only at the ends (four corners) of the first region 41 of the material (rolled strip-shaped electrical steel sheet 4) but also in the region of the second region 42 surrounded by the annular plate-shaped rotor core elements 21 in the region of the first region 41. Thus, even a material (the strip-shaped electromagnetic steel sheet 4) having reduced rigidity after punching the plate-shaped stator core elements 11 can be fed and positioned at equal intervals to the next step without twisting, and the accuracy of the plate-shaped rotor core elements punched in the subsequent step can be ensured, so that cogging torque and torque pulses can be suppressed, and vibration and noise reduction effects can be obtained.

In embodiment 1, the diameter of the guide pin 502 disposed in the second region 42 is made smaller than the diameter of the guide pin 501 disposed in the first region 41. Thereby, the guide pin 502 can be disposed in a space in the region of the second region 42 surrounded by the first region 41.

As illustrated in fig. 2, the guide pins 502 in the region of the second region 42 are disposed one at each of substantially four corners in the region of the second region 42, and the total number thereof is four. This is effective in improving positioning accuracy and suppressing twisting and distortion of a material (the strip-shaped electromagnetic steel sheet 4) by uniformly arranging four corners in punching of a product (the plate-shaped stator core element 11), but may be at any position or in any number.

The guide pin 502 of the second region 42 and the guide pin 501 of the first region 41 are arranged at positions shifted in the direction of feeding the strip-shaped electrical steel sheet 4 to the manufacturing apparatus 5. This is because the positioning accuracy is improved and the twisting and distortion of the material are effectively suppressed, compared to the case where the positioning is arranged at the same position without being shifted in the feeding direction.

Further, as a feature of embodiment 1, one roll-shaped strip-shaped magnetic steel sheet 4 is sequentially conveyed and supplied to the die of the first punching mechanism 51, and punching is started from the plate-shaped stator core element 11 first, but in embodiment 1, the plate-shaped stator core element 11 is punched in four steps as illustrated in fig. 6. This reduces or suppresses the cutting resistance (i.e., material distortion), and ensures the accuracy of the plate-like rotor core element 21 in the subsequent step.

On the other hand, since punching is performed in a plurality of punching steps, positioning accuracy in each punching step becomes important. When the plate-shaped stator core element 11 is manufactured using the manufacturing method and the manufacturing apparatus of the present application, the guide pins 502 can be arranged at positions close to the product (the plate-shaped stator core element 11) as compared with the conventional construction method, and the positioning accuracy per punching step can be improved, and further, the effect of improving the dimensional accuracy can be obtained.

In addition, in order to reduce the cutting resistance, the plate-shaped stator core elements 11 may be cut in at least two steps.

Further, in the case where the number of the plate-shaped stator core elements 11 is small, the plate-shaped stator core elements 11 can be punched out simultaneously in one step, but in order to reduce the cutting resistance, it is preferable that all the plate-shaped stator core elements 11 are punched out not simultaneously but in a plurality of times.

In the present embodiment, as shown in fig. 7, 10 plate-shaped stator core elements 11 are produced four times in the first to fourth blanking steps. In each of the first to fourth blanking steps, the number of the plate-shaped stator core elements 11 to be blanked is 3, 2, respectively, and a plurality of the plate-shaped stator core elements 11 are not simultaneously blanked in a direction a6 perpendicular to a feeding direction a4 of the strip-shaped electromagnetic steel sheet (a 5 parallel to the feeding direction a4 of the strip-shaped electromagnetic steel sheet). Thus, as shown in FIG. 7As exemplified, the object T to be punched is punched out of each plate-shaped stator core element_1-1、T_1-2、T_1-3、T_1-4、T_1-5、T_1-6、T_1-7、T_1-8、T_1-9、T_1-10On the other hand, since the manufactured plate-shaped stator core elements are accumulated individually in each of the corresponding plate-shaped stator core

element storage chambers

513, 523, 533, 543 without being mixed with each other as indicated by arrow D13, the stator core element lamination blocks 11LB of the plate-shaped stator core elements manufactured in the first to fourth punching steps are taken out from the respective discharge ports of the first stator core element lamination block discharge port 514, the second stator core element lamination block discharge port 524, the third stator core element lamination block discharge port 534, and the fourth stator core element lamination block discharge port 544 of the manufacturing apparatus 5 without being mixed with each other, and the method of collecting the stator core element lamination blocks 11LB is facilitated, and the production efficiency is improved.

In each of the first to fourth punching steps, as illustrated in fig. 6 and 7, the adjacent plate-shaped stator core members are punched to have a spacing L16 in the strip-shaped electromagnetic steel sheet feeding direction a4 equal to or greater than the plate-shaped stator core member width L14 (see fig. 3) in the strip-shaped electromagnetic steel sheet feeding direction a4 and a spacing L17 in the direction perpendicular to the strip-shaped electromagnetic steel sheet feeding direction a4 and equal to or greater than the plate-shaped stator core member width L15 (see fig. 3) in the direction perpendicular to the strip-shaped electromagnetic steel sheet feeding direction a4, so that the die plate receiving the punching load by the punching mechanism can be kept rigid, and the dimensional accuracy of each of the plate-shaped stator core members 11 constituting the stator core member laminated block 11LB (see fig. 4) can be further improved.

The number of plate-shaped stator core elements 11 punched in the punching step can be generalized as follows. That is, if the number of plate-shaped stator core elements 11 punched inside the plate-shaped rotor core elements 21 is a natural number a and the number of punching steps for punching the plate-shaped stator core elements 11 is b, if c > a/b > d, which are adjacent natural numbers c and d, is set when a/b is not a natural number, the number of plate-shaped stator core elements 11 punched in the punching step of the plate-shaped stator core elements 11 can be represented by c or d.

The present invention further provides a large-diameter permanent magnet embedded motor. As an example of application of a large-diameter permanent magnet embedded motor, there is a hybrid system in which a motor is disposed between an engine and a transmission of an automobile, the engine is started using the motor, and kinetic energy of the automobile is regenerated into electric energy by power generation or torque is generated to assist the engine. In the above application example, it is needless to say that the efficiency of the motor is strictly required to be reduced in vibration and noise. In addition, in the large-diameter motor, if the inner region (second region 42) of the punched plate-shaped rotor core element in the strip-shaped electromagnetic steel plate is not effectively used, the material yield is deteriorated. When the plate-shaped stator core element and the plate-shaped rotor core element are manufactured by using the manufacturing method and the manufacturing apparatus of the present application, an effect that the dimensional accuracy can be improved as compared with the conventional one can be obtained. Further, since the accuracy of the stator core portion is also increased, the vibration and noise of the motor due to the deterioration of the shape accuracy can be suppressed.

In embodiment 1, since the direction of each pole tooth of the plate-shaped stator core element of the divided core is the same direction as the rolling direction A4M (see fig. 7 and 12), it is possible to reduce the cogging torque, the torque pulse, and the like caused by the difference in magnetic anisotropy due to the difference in the angle of the plate-shaped stator core element in the direction orthogonal to the rolling direction of each pole tooth. Further, there are effects as follows: the electromagnetic excitation force with low space dimension is reduced through the magnetic anisotropy performance, and the low vibration and the low noise of the motor can be realized. In particular, in a so-called "magnet embedded motor" in which permanent magnets are embedded in a core of a rotor, there are problems in particular in reducing vibration and noise, and therefore, the structure of the present application further exhibits effects. Since the direction having good magnetic properties can be used, the torque of the motor can be improved, and the efficiency can be improved.

Although the permanent magnet embedded motor is described here, it is needless to say that the same effect can be obtained even in other motor systems such as a surface magnet type motor.

Further, in embodiment 1, in the example of fig. 5 and 6, as the punching mechanism for punching the plate-like stator core element 11 from the strip-shaped electromagnetic steel sheet 4 and as the punching mechanism for punching the plate-like rotor core element 21 from the strip-shaped electromagnetic steel sheet 4, five punching mechanisms of the first punching mechanism 51, the second punching mechanism 52, the third punching mechanism 53, the fourth punching mechanism 54, and the fifth punching mechanism 55 are arranged in series in the strip-shaped electromagnetic steel sheet feeding direction a4, but the first stator core element punching male die 511, the second stator core element punching male die 521, the third stator core element punching male die 531, the fourth stator core element punching male die 541, the fifth stator core element punching male die 551, and the first plate-like stator core element punching female die 512, the second plate-like stator core element punching female die 522, the first punching mechanism 52, the second punching mechanism 52, the third punching mechanism 54, and the fifth punching mechanism 55 may be arranged in series in the strip-shaped electromagnetic steel sheet feeding direction a4, The third, fourth, and fifth plate-like stator core element blanking dies 532, 542, and 552 are associated with a single punching mechanism, and the first, second, third, fourth, and fifth stator core element blanking male dies 511, 521, 531, 541, and 551 are operated with time shifts. In the above case, the first punching step to the fifth punching step may be performed by moving one punching mechanism in the strip-shaped magnetic steel sheet feeding direction a 4.

In the stator core element laminated block 11LB in which the plate-shaped stator core elements 11 are laminated in the axial direction of the rotating electrical machine, the laminated state of the plate-shaped stator core elements 11 of the stator core element laminated block 11LB taken out from the

outlet ports

514, 524 … of the manufacturing apparatus 5 is made less likely to collapse by caulking the laminated plate-shaped stator core elements 11 to each other in a step preceding the first punching step.

Further, fig. 12 illustrates a case where the strip-shaped electromagnetic steel sheet rolling directions A4M of the plate-shaped stator core elements 11 arranged in the circumferential direction of the rotating electrical machine are all oriented in the same direction as the radial direction of the rotating electrical machine, but as illustrated in fig. 13, the strip-shaped electromagnetic steel sheet rolling directions A4M of the plate-shaped stator core elements 11 arranged in the circumferential direction of the rotating electrical machine may be all oriented in the same direction as the circumferential direction of the rotating electrical machine, and if the strip-shaped electromagnetic steel sheet rolling directions A4M of the plate-shaped stator core elements 11 arranged in the circumferential direction of the rotating electrical machine are all oriented in the same direction, a corresponding effect can be achieved.

Embodiment mode 2

Hereinafter, embodiment 2 will be described with reference to fig. 8.

As in embodiment 1 described above, as shown in fig. 8, a plate-like rotor core member 21 constituting a rotor is produced by punching out a strip-like electromagnetic steel plate 4.

The plate-shaped stator core members 11 are collectively taken from the above-described strip-shaped electromagnetic steel plates 4. Although not shown in fig. 8 of the present embodiment, a magnet hole 211 (see fig. 2) for embedding a permanent magnet is formed in the plate-shaped rotor core element 21, as in fig. 2 of embodiment 1.

In a stator core element lamination block 11LB (see fig. 4) configured by laminating plate-shaped stator core elements 11 in the axial direction of the rotary electric machine, caulking is performed to fix the plate-shaped stator core elements 11 to each other.

In the present embodiment, as in embodiment 1, when one strip-shaped magnetic steel sheet 4 is fed to the die of the press mechanism of the manufacturing apparatus 5 by being sequentially conveyed, punching is started from the plate-shaped stator core elements 11, and the rolling direction A4M of the strip-shaped magnetic steel sheet 4 of the plate-shaped stator core elements 11 is the same as the direction of the yoke portion (that is, the extending direction EDT (see fig. 3) of the tooth portion 11T of the plate-shaped stator core elements 11 in the radial direction of the rotating electrical machine is the same direction as the rolling direction A4M of the strip-shaped magnetic steel sheet 4). The extending direction EDCB (see fig. 3) of the core back portion 11CB of the plate-shaped stator core element 11 is the same direction as the circumferential direction of the rotating electrical machine.

Since the yoke portions of the divided core portions constituting the stator core portion 1 are oriented in the same direction, cogging torque and torque pulses caused by a difference in magnetic anisotropy caused by a difference in a direction running straight in the rolling direction from the yoke portion (the pole tooth portion 11T) can be reduced. Further, there are effects as follows: the electromagnetic excitation force with low space dimensionality is reduced through the magnetic anisotropy performance, and low vibration and low noise of the motor can be realized. In particular, in a so-called magnet-embedded motor in which permanent magnets are embedded in the rotor core 2, there are problems in particular in reducing vibration and noise, and therefore, the structure of embodiment 2 is similar to that of embodiment 1, and further advantageous effects are exhibited. Since the direction having good magnetic properties can be used, the effect of increasing the efficiency of the motor can be obtained.

In view of product accuracy, all the plate-shaped stator core elements 11 are not punched at the same time, but the plate-shaped stator core elements 11 are punched in multiple times as in embodiment 1.

After the plate-shaped stator core elements 11 are punched out of the strip-shaped electromagnetic steel sheet 4, the plate-shaped rotor core elements 21 are punched out of the strip-shaped electromagnetic steel sheet 4.

In the case where the stator core 1 is configured by annularly arranging the plurality of stator core element lamination blocks 11LB as illustrated in fig. 1, as in embodiment 1, the accuracy of the stator core element lamination blocks 11LB is required in a large-diameter motor rather than in a small-diameter motor. A very strict management is required for a lamination deflection (japanese: load れ) in which the upper surface and the lower surface of the stator core element lamination block 11LB (see fig. 4) are offset. For example, when the upper surface of one of the adjacent stator core element lamination blocks 11LB is inclined in the outer diameter direction (for example, arrow a7 in fig. 11 b), the lower surface is inclined in the inner diameter direction (for example, arrow A8 in fig. 11 b), the upper surface of the other adjacent stator core element lamination block is inclined in the inner diameter direction in the opposite direction, and the lower surface is inclined in the outer diameter direction in the opposite direction, the management of the stator core element lamination blocks in the arrangement (fig. 11) becomes difficult. When the stator core element lamination blocks 11LB are circumferentially offset, management at the time of alignment becomes difficult as well.

Therefore, in order to prevent the plate-shaped stator core elements 11 from falling toward the manufacturing apparatus installation floor and causing the deviation after punching the plate-shaped stator core elements 11 from the strip-shaped electromagnetic steel sheet 4, when punching the plate-shaped stator core elements 11 from the strip-shaped electromagnetic steel sheet 4 by the punching mechanism, the step of installing the floor in the manufacturing apparatus in which the punched plate-shaped stator core elements 11 fall downward is not employed, and it is preferable that the manufacturing apparatus is provided with a structure for mechanically receiving the punched plate-shaped stator core elements 11. If the directions of the punched plate-shaped stator core elements 11 are not uniform, the machine in the manufacturing apparatus needs to be accepted in accordance with the directions of the respective punched plate-shaped stator core elements 11, and the accepting machine becomes complicated and large in scale, and therefore, the cost becomes high.

In the present embodiment, since the punched plate-shaped stator core elements 11 are all in the same direction and the same shape, the machine acceptance of the manufacturing apparatus may be configured to be a structure in which the plate-shaped stator core

element storage chambers

513, 523 … are provided just below the die of the punching mechanism as illustrated in fig. 5 of embodiment 1, for example, and the manufacturing apparatus can be configured easily and inexpensively. Further, since the number of plate-shaped stator core elements 11 punched out from one strip-shaped electromagnetic steel plate 4 is large, it is not easy to follow after discharge. If the plate-shaped stator core elements 11 can be mechanically received, tracking is facilitated since connection up to subsequent binding packaging becomes easy.

In addition, in the present embodiment, the material can be taken out even from the second region 42 on the inner peripheral side and the first region 41 on the outer peripheral side of the plate-like rotor core element 21 in the strip-like electromagnetic steel sheet 4, and the material can be taken out efficiently. Since the directions of the yoke portions (pole teeth portions) of the plate-shaped rotor core elements 21 punched out from the strip-shaped electromagnetic steel plates 4 are all aligned, the yoke portions of the stator core can match the motor radial direction of the pole tooth centers with the rolling direction, and the magnetic paths can be optimized in all the core portions when the pole tooth width W14 is equal to or less than the core back width W15 × 2.

Subsequently, in order to correct the axial length of the stator core element lamination blocks 11LB in the lamination direction, dimensions are measured in a state after pressurization in the stator core element lamination block axial

length adjustment mechanisms

515, 525, 535, 545 (see fig. 5 and 6), and the number of lamination blocks is adjusted based on the above-described dimension results, thereby adjusting the shape to match the axial length of the rotating electrical machine. In this configuration, since the yoke portion and the material direction are aligned, the axial length deviation in one core portion is constant, and the axial length correction process can be easily managed.

As a feature of embodiment 2, as illustrated in fig. 8, the interval SPN5012 between the guide pins 502 of the second region 42 and the guide pins 501 of the first region 41 in the direction of feeding the strip-shaped electrical steel sheet 4 to the manufacturing apparatus 5 is the same as or close to the interval SPN5022 between the plurality of guide pins 502, 502 of the second region 42 in the direction of feeding. This has an effect of improving the positioning accuracy and suppressing the twisting and distortion of the material (the strip-shaped electrical steel sheet 4).

As illustrated in fig. 8, the guide pins 501 and 502 are arranged substantially symmetrically with respect to the center of the material (strip-shaped magnetic steel sheet 4) in the transport direction. That is, the guide pins 501 and 502 are arranged symmetrically with respect to the central axis CH21 of the plate-like rotor core element 21 parallel to the rolling direction of the strip-like magnetic steel sheet 4. This is also for the purpose of improving positioning accuracy and suppressing twisting and distortion of the material by providing the material in a symmetrical form.

As an example of application of a large-diameter permanent magnet embedded motor, there is a hybrid system in which a motor is disposed between an engine and a transmission of an automobile, the engine is started using the motor, and kinetic energy of the automobile is regenerated into electric energy by power generation or torque is generated to assist the engine. In the above application example, it is needless to say that the efficiency of the motor is strictly required to be reduced in vibration and noise. However, when the core is manufactured by using the manufacturing method and the manufacturing apparatus of the present application, it is possible to achieve not only reduction in efficiency but also reduction in cogging torque, torque ripple, and the like due to a difference in magnetic anisotropy, and the following effects are obtained: the electromagnetic excitation force with low spatial dimension caused by magnetic anisotropy can be reduced, and low vibration and low noise of the motor can be realized. Further, since the accuracy of the core portion also becomes high, the following effects can be obtained: vibration and noise of the motor caused by deterioration of shape accuracy can be suppressed.

Embodiment 3

Hereinafter, embodiment 3 will be described with reference to fig. 9.

As shown in fig. 9, a plate-like rotor core member 21 constituting the rotor is manufactured by punching out a strip-like electromagnetic steel plate 4, and a plate-like stator core member 11 is taken out from the strip-like electromagnetic steel plate 4 in common. Although not shown in the present embodiment, magnet holes for embedding permanent magnets are formed in the plate-shaped rotor core elements 21 (see fig. 2) in the same manner as in embodiment 1. In the plate-shaped stator core elements 11 in the stator core element lamination block 11LB, caulking is performed in order to fix the plate-shaped stator core elements 11 to each other.

In the present embodiment, when one strip-shaped magnetic steel sheet is fed to the die of the press mechanism of the manufacturing apparatus by being sequentially conveyed, punching is started from the plate-shaped stator core elements 11 in the same manner as in embodiment 1, and the rolling direction of the strip-shaped magnetic steel sheet of these plate-shaped stator core elements 11 is the same as the direction of the core back (arrow EDCB in fig. 3). Since the core backs of the divided core portions are oriented in the same direction, the difference in magnetic anisotropy caused by the difference between the rolling direction and the straight running direction, and the cogging torque caused thereby, can be reduced. Since the direction having good magnetic properties can be used, the effect of increasing the efficiency of the motor can be obtained.

In consideration of product accuracy, all the stator cores are not blanked at the same time, but the stator cores are blanked in multiple times. After blanking the stator core, the rotor core is blanked. In the embodiment, the material is all carried out to the week side and the periphery of rotor core and is got, can get the material high-efficiently. Since the direction of the pole teeth is perpendicular to the rolling direction, the influence of the circumferential thickness variation in one core portion is small. In the large diameter motor, since a large number of core portions are arranged side by side, the present embodiment is realized in order to pursue circumferential deviation control.

Embodiment 4

Hereinafter, embodiment 4 will be described with reference to fig. 10 and 11.

As shown in fig. 10, a rotor steel plate constituting the rotor is manufactured by press punching.

Compared to

embodiments

1 and 2 described above, the plate-shaped stator core members 11 are oriented in point symmetry with respect to the center of the plate-shaped rotor core member 21, and therefore, the degree of freedom in product pickup is improved, and the configuration is further improved in favor of pickup.

Since the orientation of the pole teeth is constant as in

embodiments

1 and 2, the cogging torque caused by the difference in magnetic anisotropy between the rolling direction and the rectilinear direction can be reduced. Since the direction having good magnetic properties can be used, the effect of increasing the efficiency of the motor can be obtained.

In the present embodiment, the guide pins are disposed without cutting the stator core from a position that is a center orthogonal to the material conveying direction.

As a feature of embodiment 4, as illustrated in fig. 10, in order to ensure the accuracy of the plate-shaped stator core member 11, the plate-shaped stator core member is cut out so as to be substantially symmetrical with respect to a central axis orthogonal to the direction in which the material (the strip-shaped electromagnetic steel plate 4) is conveyed, so that load balance is obtained, thereby improving the accuracy. The guide pins 501 and 502 are also arranged symmetrically in the same manner. Therefore, the central portion of the second region 42 does not contribute much to the rigidity. When the product is disposed here, the rigidity of the material (the strip-shaped electrical steel sheet 4) after cutting the product is reduced, and twisting and distortion of the material (the strip-shaped electrical steel sheet 4) are promoted.

In embodiment 4, the guide pins 502 are disposed in the central portion of the second region 42 perpendicular to the rolling direction, and the plate-shaped stator core elements 11 are punched out from the region other than the guide pins 502 in the central portion, whereby the accuracy of the subsequent rotor core can be ensured while maintaining the material rigidity and improving the positioning accuracy and the material twist and distortion.

In the large diameter motor, a large number of large diameter core portions are arranged in a ring shape in parallel to form a stator (see fig. 1), and therefore, the influence of the deflection of the laminated core portions is larger than that of the small diameter motor. The laminated core portion is formed by overlapping thin plates, and the laminated core portions are joined to each other by a method of application such as caulking in order to improve the dimensional accuracy of the laminated core portion. Thus, the core will deflect in one direction under the influence of the riveting. This is referred to as caulking deflection (see fig. 11).

In the present embodiment, the core material taking direction is made symmetrical about the rolling direction as the center axis, and therefore, the symmetrical core portions are opposite in the direction of core skew, and the influence of caulking skew can be eliminated as a whole of the stator. Further, the thickness deviation is averaged over the entire stator (see the alternate long and short dash line separated by the arrow in fig. 10 (c)), and the influence of the thickness deviation can be reduced. In contrast, for example, when the number of extracted materials in fig. 9 is used, the stator core is configured such that the number of divided cores configuring the stator is a multiple of 4, the most advantageous effect can be obtained. The same effect can be obtained even if the rolling mill is located at a position symmetrical with respect to the central axis at right angles to the rolling direction. Further, as illustrated in fig. 10 (b), the cross section in the direction perpendicular to the rolling direction of the strip-shaped electrical steel sheet 4 has a larger thickness toward the center in the direction perpendicular to the rolling direction of the strip-shaped electrical steel sheet 4.

Embodiment 5

Hereinafter, embodiment 5 will be described with reference to fig. 12 and 13.

As shown in fig. 12, when the tooth width is set to be not more than the core back width × 2 when the motor radial direction at the center of the tooth is matched with the rolling direction, the magnetic path can be optimized.

Because the width of the pole teeth is less than or equal to the width of the core back multiplied by 2, the magnetic flux density of the pole teeth is high, and magnetic saturation is easy to generate. By matching the motor radial direction at the center of the pole teeth with the rolling direction, the magnetic characteristics of the direction of the magnetic flux density of the pole teeth are improved (the magnetic permeability is improved), whereby the torque of the motor can be improved.

The reason why magnetic saturation is likely to occur due to high magnetic flux density of the pole teeth when the pole teeth width is equal to or less than the core back width × 2 will be described below. The magnetic flux of the pole teeth is divided into two branches in the core back. As illustrated in fig. 13, the magnetic flux passing through the pole teeth is bifurcated in the back-core portion in the left-right direction. When the relationship of the pole tooth width ﹦ core back width × 2 is satisfied, if the magnetic flux density of the pole tooth reaches 2T (tesla), the magnetic flux is about 2T even if the magnetic flux is divided into two in the core back. Therefore, when the pole tooth width is equal to or less than the core back width × 2, the magnetic flux density of the pole tooth is high, and magnetic saturation is likely to occur.

Embodiment 6

Hereinafter, embodiment 6 will be described with reference to fig. 14.

As shown in fig. 14, when the tooth width > core back width × 2 is set when the motor circumferential direction of the center of the tooth is matched with the rolling direction, the magnetic path can be optimized.

Since the pole tooth width > core back width × 2, the magnetic flux density of the core back is high, and magnetic saturation is likely to occur. By matching the motor circumferential direction at the center of the pole teeth with the rolling direction, the magnetic characteristics in the direction of the magnetic flux density in the core back are improved (the magnetic permeability is improved), whereby the torque of the motor can be improved.

Embodiment 7

Hereinafter, embodiment 7 will be described with reference to fig. 15.

In embodiment 1, the case where the plate-shaped stator core elements 11 are punched out of the strip-shaped electromagnetic steel plates 4 in the first punching step to the fourth punching step is exemplified, but the objects T to be punched out of the plate-shaped stator core elements may be_P-1、T_P-2As illustrated in fig. 15, the plate-shaped stator core element 11 is punched out of the strip-shaped magnetic steel plate 4 by the first punching step and the second punching step.

Fig. 17 illustrates a relationship between the rolling direction A4M of the strip-shaped magnetic steel sheet 4 and the extending direction of the teeth 11T (radial direction of the rotating electrical machine) when the stator core element lamination blocks 11LB of

embodiments

1, 2, 4, 5, and 7 are incorporated into the rotating electrical machine, and a relationship between the rolling direction A4M of the strip-shaped magnetic steel sheet 4 and the extending direction of the teeth 11T (radial direction of the rotating electrical machine) when the stator core element lamination blocks 11LB of embodiments 3 and 6 are incorporated into the rotating electrical machine.

In a modified view, the following characteristic matters exist in the above embodiments 1 to 7.

Feature item 1:

a method for manufacturing a laminated core in which electromagnetic steel plates punched out of thin plates are laminated, wherein a rotor core and a stator core are punched out of the same thin plate, and guide pins are formed inside a rotor, whereby even a material after a cut stator having low rigidity is fed and positioned at equal intervals without twisting, the accuracy of the subsequent rotor core can be ensured, cogging torque and torque pulses can be suppressed, and vibration and noise reduction effects can be obtained thereby.

Feature item 2:

a method of manufacturing a laminated core according to feature 1 is characterized in that since the guide pins on the inner side of the rotor are thinner than the guide pins on the outer side, the guide pins can be easily arranged on the inner side by making the guide pins thin.

Feature item 3:

a method of manufacturing a laminated core according to feature 1 is characterized in that four guide pins are arranged at substantially four corners inside a rotor, and therefore, by uniformly arranging the guide pins at the four corners in punching of a product, positioning accuracy can be improved, and twisting and distortion of a material can be suppressed.

Feature item 4:

a method of manufacturing a laminated core, characterized in that, in the method of manufacturing a laminated core according to feature 1, the guide pins on the inner side of the rotor and the guide pins on the outer side are arranged at positions shifted in the material conveying direction, and therefore, since the guide pins are shifted from each other, the positioning accuracy can be improved, and the twisting and distortion of the material can be suppressed.

Feature item 5:

a method of manufacturing a laminated core according to feature 4 is characterized in that guide pins arranged in a material conveying direction are arranged at substantially equal intervals in the material conveying direction, and therefore, twisting and distortion of the material can be suppressed by uniform arrangement.

Feature item 6:

a method of manufacturing a laminated core according to feature 1 is characterized in that since the guide pins are arranged substantially symmetrically with respect to the center of the material conveying direction, the material can be prevented from being twisted or distorted by the symmetrical arrangement.

Feature item 7:

a method of manufacturing a laminated core, characterized in that a stator core is cut out in a plurality of steps, in addition to the method of manufacturing a laminated core according to the feature 1,

therefore, by cutting the stator core a plurality of times, the cutting resistance can be reduced, the distortion of the material can be reduced, and the accuracy of the rotor core thereafter can be ensured.

Feature item 8:

a method of manufacturing a laminated core, characterized in that, in the method of manufacturing a laminated core according to feature 1, guide pins are disposed without cutting the stator core from a position that is a center orthogonal to a material conveying direction,

therefore, in general, in order to ensure the accuracy of the stator core, the cutting is generally symmetrical with respect to a central axis orthogonal to the material conveying direction in most cases. In addition, (to improve accuracy by obtaining load balance) the guide pins are also symmetrically arranged in the same manner. Therefore, the center portion does not contribute much to the rigidity. Since the rigidity of the material after cutting the product is reduced and twisting and distortion of the material are promoted when the product is placed here, the material rigidity can be maintained and the positioning accuracy can be improved and the twisting and distortion of the material can be reduced by placing the guide pin without cutting the product from the center portion.

Feature item 9:

a manufacturing apparatus for a laminated core manufactured by laminating electromagnetic steel sheets punched out of thin plates and punching a rotor core and a stator core from the same thin plate, characterized in that a guide pin is formed inside a rotor,

therefore, even if the material after cutting the stator is low in rigidity, the material is supplied and positioned at equal intervals without being twisted, and the accuracy of the rotor core after cutting can be ensured, thereby suppressing cogging torque and torque pulses and obtaining vibration and noise reduction effects.

Feature item 10:

a manufacturing apparatus for a laminated core according to the feature 9 is characterized in that the guide pins on the inner side of the rotor are thinner than the guide pins on the outer side, and therefore the guide pins can be easily arranged on the inner side by making the guide pins thin.

Feature item 11:

a manufacturing apparatus for a laminated core according to the feature 9 is characterized in that four guide pins are arranged at substantially four corners inside a rotor, and therefore, by uniformly arranging the guide pins at the four corners in punching of a product, positioning accuracy can be improved, and twisting and distortion of a material can be suppressed.

Feature item 12:

a laminated core manufacturing apparatus according to the feature 9 is characterized in that the guide pins on the inner side of the rotor and the guide pins on the outer side are arranged at positions shifted in the material conveying direction, and the guide pins are shifted from each other, so that the positioning accuracy can be improved, and the twisting and distortion of the material can be suppressed.

Feature item 13:

a laminated core manufacturing apparatus according to the characteristic feature 12 is characterized in that the guide pins arranged in the material conveying direction are arranged at substantially equal intervals in the material conveying direction, and therefore, the twist and distortion of the material can be suppressed by the uniform arrangement.

Feature item 14:

a manufacturing apparatus for a laminated core according to any one of the above-mentioned items 9 to 13, wherein the guide pins are arranged substantially symmetrically with respect to the center of the material conveying direction, whereby twisting and distortion of the material can be suppressed by the symmetrical arrangement.

Feature item 15:

a laminated core manufacturing apparatus according to the feature 9, wherein the stator core is cut out in a plurality of steps,

Feature item 16:

a laminated core manufacturing apparatus according to the feature 9, wherein the guide pins are disposed without cutting the stator core from a position which is a center orthogonal to the material conveying direction,

In the drawings, the same reference numerals denote the same or corresponding parts.

In addition, although the present application describes various exemplary embodiments and examples, various features, modes, and functions described in one or more embodiments are not limited to the application to specific embodiments, and can be applied to the embodiments alone or in various combinations.

Therefore, countless modifications not illustrated are assumed to be within the technical scope disclosed in the present application. For example, the case where at least one component is modified, added, or omitted is included, and the case where at least one component is extracted and combined with the components of other embodiments is also included.

Claims

1. A method of manufacturing a laminated core for a rotating electrical machine, the rotating electrical machine comprising:

a stator core configured by annularly connecting stator core element lamination blocks in a circumferential direction, the stator core element lamination blocks configured by laminating plate-shaped stator core elements formed in a T shape by a pole tooth portion and a core back portion in an axial direction; and

a rotor core that is configured by laminating annular plate-shaped rotor core elements in an axial direction and that is surrounded by the stator core,

the method for manufacturing a laminated core for a rotating electrical machine is characterized in that,

prior to a step of punching out the plate-like rotor core element from a strip-like magnetic steel plate formed by rolling, a plate-like stator core element is punched out in a region of a second region of the strip-like magnetic steel plate on the inner side of a first region where the plate-like rotor core element is punched out by a punching mechanism, and a plurality of guide pins are arranged in the first region and the second region, respectively, before the plate-like stator core element is punched out from the strip-like magnetic steel plate by the punching mechanism.

2. The method of manufacturing a laminated core for a rotating electrical machine according to claim 1,

the diameter of each of the plurality of guide pins of the second region is smaller than the diameter of each of the plurality of guide pins of the first region.

3. The method of manufacturing a laminated core for a rotating electrical machine according to claim 1,

the plurality of guide pins of the second region are arranged at four corners of the second region.

4. The method of manufacturing a laminated core for a rotating electrical machine according to claim 1,

the guide pins of the second region and the guide pins of the first region are arranged at positions shifted in a direction in which the strip-shaped electrical steel sheet is fed to a manufacturing apparatus.

5. The method of manufacturing a laminated core for a rotating electrical machine according to claim 1,

the distance between the guide pins in the second region and the guide pins in the first region in the feeding direction in which the strip-shaped magnetic steel sheet is fed to a manufacturing apparatus is set to be the same as the distance between the guide pins in the second region in the feeding direction.

6. The method of manufacturing a laminated core for a rotating electrical machine according to claim 1,

the guide pins are arranged symmetrically with respect to a central axis of the plate-shaped rotor core element parallel to the rolling direction.

7. The method of manufacturing a laminated core for a rotating electrical machine according to claim 1,

the plate-shaped stator core component is blanked out of the strip-shaped electromagnetic steel plate by a plurality of blanking processes performed by the punching mechanism.

8. The method of manufacturing a laminated core for a rotating electrical machine according to claim 1,

the guide pin is disposed in a central portion of the second region that is orthogonal to the rolling direction, and the plate-shaped stator core element is punched out from a region other than the guide pin in the central portion.

9. A laminated core manufacturing apparatus for a rotating electrical machine, the rotating electrical machine comprising:

the laminated core manufacturing apparatus for a rotating electrical machine is characterized by comprising a punching mechanism,

the punching mechanism punches the plate-shaped stator core element in a region of a second region of the strip-shaped electromagnetic steel sheet that is more inside than a first region where the plate-shaped rotor core element is punched, prior to a step of punching the plate-shaped rotor core element from the strip-shaped electromagnetic steel sheet formed by rolling,

before the plate-shaped stator core member is punched out of the strip-shaped electromagnetic steel plate by the punching process by the punching mechanism, a plurality of guide pins are arranged in the first region and the second region, respectively.

10. The laminated core manufacturing apparatus of a rotating electrical machine according to claim 9,

11. The laminated core manufacturing apparatus of a rotating electrical machine according to claim 9,

12. The laminated core manufacturing apparatus of a rotating electrical machine according to claim 9,

13. The laminated core manufacturing apparatus of a rotating electrical machine according to claim 9,

14. The laminated core manufacturing apparatus of a rotating electrical machine according to claim 9,

15. The laminated core manufacturing apparatus of a rotating electrical machine according to claim 9,

16. The laminated core manufacturing apparatus of a rotating electrical machine according to claim 9,