JP2003189514A - Electric apparatus having laminated core, laminated core press die and laminated core assembly facility - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To simplify a manufacturing process of an electric apparatus having a laminated core in order to reduce the cost thereof and improve the performance thereof. <P>SOLUTION: This electric apparatus has a laminated core comprising a plurality of laminated metal thin sheets. The metal thin plates comprise a plurality of material sheets which are laminated one by one or every plurality of sheets. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electric device having a laminated core, a laminated core press die for an electric device, and a laminated core assembling equipment, and particularly to a metal such as a motor, a linear motor, a transformer, a silicon steel plate or the like. The present invention relates to a structure of a product having a laminated core, a manufacturing method thereof, and a manufacturing apparatus thereof.

[0002]

2. Description of the Related Art The core of magnetic products such as a motor stator core is designed to prevent eddy currents generated inside the core.
It is common to use a thin iron plate having a thickness of 0.5 mm, 0.35 mm, or the like, and a plurality of laminated insulating coatings. The mainstream of this lamination is to perform crimping or laser welding in the mold. However, there are many types of this silicon steel sheet, one with a large iron loss, one with a small iron loss, and a sheet thickness of 0.15 mm to 1.0 mm, and the material is selected with a balance between price and required performance.

As a prior art relating to a structure in which the material of the stator core of a motor is selectively used, there is Japanese Patent Laid-Open No. 2000-3418.
There is a structure in which the materials of the yoke portion and the teeth portion of the divided core are changed in Japanese Patent Publication No. 89. The stator structure of this publication divides the yoke portion and the teeth portion of the stator core into
The structure has convex and concave portions having a dovetail shape, and has a structure in which the dovetail shapes are combined.

[0004]

In the above prior art, the material cannot be changed in the laminated core such as the motor core unless the core is divided. Many types of silicon steel sheets are prepared according to their iron loss values, but the prices vary greatly depending on the market demand. Therefore, the main materials of the high grade material and the low grade material are inexpensive, and the middle grade is expensive. Therefore, the materials used to achieve the required performance are often over-specified by using high-grade materials without using intermediate materials.

Therefore, it is conceivable to mix a plurality of high-grade materials and low-grade materials to obtain just good performance and price, but there is no method other than using the above-mentioned method, that is, gold is conventionally used. Since they cannot be laminated in the mold at the same time, a two-step process of obtaining the stator core by reassembling the yoke and teeth separately punched out of the mold is required. In this case, the number of steps is increased, so that it is meaningless to balance the material cost with the performance.

One object of the present invention is to provide an electric device such as a motor having a core laminated by changing the laminated material of the motor core in the stacking direction and reducing the material cost.

Another object is to apply magnetic products such as motors, linear motors, solenoids and transformers.
It is to realize a structure in which another material is sandwiched between the laminated cores as a core holding member and magnetic insulation.

Still another object is to obtain an electric device such as a motor core, a linear motor, a transformer or the like having a high heat dissipation property by sandwiching a high heat conductive material.

[0009]

One of the features of the present invention is:
In an electric device having a laminated core formed by laminating a plurality of thin metal plates, an electric device having a laminated core characterized by including a core having a structure in which a plurality of materials are laminated one by one or in a plurality of sheets. In the equipment.

The present invention also provides a laminated core press die for electric equipment, which is constructed by laminating a plurality of thin metal plates.
It is characterized in that it has a shape corresponding to laminating a plurality of materials one by one or a plurality of materials.

Further, according to the present invention, in a laminated core assembly facility for assembling a laminated core constituted by laminating a plurality of thin metal plates, a plurality of cores punched by a press die are made of a plurality of materials, one by one. Further, it is characterized by having a supply unit for supplying a plurality of sheets to an assembling facility by a core supply means such as a part feeder, and a caulking laminating unit for performing caulking lamination of the supplied cores one by one or every plural sheets. .

Further, the present invention is, in an electric device, having a laminated core formed by laminating a plurality of thin metal plates, and between a core punched and laminated by a press die and a core other than the press die. It is characterized in that it has a core formed by sandwiching and sandwiching a metal member or a resin member formed by the forming means.

Further, according to the present invention, in an apparatus for manufacturing an electric device having a laminated core formed by laminating a plurality of metal thin plates, a core other than the press die is punched and laminated between the cores. The core is manufactured by sandwiching and sandwiching a metal member or a resin member formed by the forming means.

Still another feature of the present invention is a method of laminating a plurality of materials one by one in a die for punching and laminating a motor core, or laminating and removing another material for each of a plurality of materials, and a method for removing the material. Another method is to supply another material between the laminated cores and laminate them to obtain an integral core.

One method of solving means is a method in which two kinds of materials to be supplied to the press are preliminarily superposed and supplied to the press to obtain a laminated material of different materials. This method can be realized by setting a feeder for feeding two types of materials in layers and sending them into the press, and a clearance for punching an iron plate having the same thickness as the punching clearance of the die.

As another means for solving the problems, two materials to be supplied to the press are preliminarily superposed and supplied to the press, and punching is performed at the same time.
The stacking step is performed by independently providing a feeder for feeding each material so that a plurality of sheets are fed, and when one material is fed a certain number of times, the feeding of the material is stopped and the other material is fed. By this operation, different materials can be laminated for each of the plurality of sheets in the caulking laminating section which is the final step.

Further, a method of supplying another material between the laminated cores to perform lamination is performed by using a parts feeder or the like for supplying the core of another member such as aluminum or a resin molded product to the lamination part which is the final step of the die. A supply mechanism is provided, and each time a plurality of sheets are punched, another member is inserted into the laminating section by using an actuator such as a solenoid, and is laminated in the caulking laminating section simultaneously with the laminating core by a die.

As the laminating method, it is possible to use the above-mentioned method by laser welding other than the caulking laminating method.

The above and other features of the invention are further described below.

[0020]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described with reference to the drawings.

FIG. 1 shows a basic stator core structure of a motor, which is an embodiment of the present invention. Figure 1 (a)
1B is a perspective view of the stator core structure, FIG. 1B is a side view of the stator core structure, and a dotted line is an imaginary line showing a void inside the core. The laminated core 2 is formed by laminating a plurality of silicon steel sheets, and has a structure in which different materials are used for each sheet. For example, the core material of the low iron loss material core 2a is a high grade material having an iron loss value of 2.1 (W / kg) of 35A.
No. 210 is used, and the core material of the high iron loss material core 2b is a low grade material and has a core loss value of 6.0 (W / kg) of 35A600.
It is possible to combine such as using. The coil 1 is wound around the laminated core 2.

2 and 11 show the steps for obtaining this core. FIG. 2 is a side view of equipment for performing the pressing process. The two materials to be supplied to the press are preliminarily superposed and supplied to the press to obtain a stack of different materials for each sheet. In this equipment, low iron loss material 3
a, a roll feeder (feeding device) 6 for stacking two kinds of materials consisting of the high iron loss material 3b and feeding them into the press, a slack amount sensor 7, a press upper die 4 and a press lower die 5.
Set the clearance for punching an iron plate having the same thickness as the die punching clearance. In the example above, 0.3
Since two 5 mm iron plates are stacked and punched, the same die clearance as when punching a 0.7 mm core is taken.

FIG. 11 is a flowchart showing the process. When the process starts (START111), the process 112
The low iron loss material 3a and the high iron loss material 3b are set in the equipment. In step 113, the material is conveyed through the slack amount sensor 7 into a press die (having a press upper die 4 and a press lower die 5) by a roll feeder (feeding device) 6 in a stacked state. In step 114, the press die is stroked a predetermined number of times to perform caulking and laminating in the laminating groove of the lower press die 5. In step 115, the laminated body in the laminated groove is cut off without crimping punches to perform product separation processing. After repeating steps 113 to 115 a predetermined number of times, in step 116, the product 29 is taken out from the lower press die 5.

FIG. 3 shows another embodiment of the present invention. Although the motor cores are laminated as in FIG. 1, a plurality of sheets (three sheets in FIG. 3) are laminated as one block, and the blocks are further laminated.

FIGS. 4, 5 and 12 show the equipment and method for obtaining this motor core. FIG. 4 is a side view of the press process equipment, and has a structure in which two types of materials are stacked and fed as in FIG. FIG. 5 is a drawing of the press process equipment viewed from above. In this structure, a part different from that of FIG. 2 is that each material feeding device is independent. The feeding device 6a for the low iron loss material 3a and the feeding device 6b for the high iron loss material 3b can be separately operated. As shown in FIG. 5, this feeder has a structure for feeding only the respective materials so as to sandwich the shifted positions of the respective materials. The operation of this configuration will be described with reference to FIGS. Now, the feeding device 6b is stopped and the feeding device 6a is operated. As a result, the material 3a is sent and punched into the shape of the motor core to be laminated in the final step. This drawing shows that the materials are pilot holes, central holes, slots, caulking dowels, and then withdrawing and stacking. Now, in this drawing, the leading end of the material 3b is shown to be stopped at the slot punched portion, but when punching the material 3a, the already punched portion is blanked. After punching the specified number of materials 3a, the feeding device 6a returns the material 3a for two steps and stops, and the feeding device 6a
b is operated. As a result, punching of the material 3b is restarted, and this also punches a prescribed number. By repeating this operation, a plurality of cores made of different materials as shown in FIG. 3 can be obtained. The process will be described in more detail with reference to FIG. When the process is started (START 121), in step 122, the low iron loss material 3a and the high iron loss material 3b are set in the equipment. In step 123, the material is fed through the slack amount sensor 7 to the roll feeder (feed device) 6a,
6b, and set in a press die (having a press upper die 4 and a press lower die 5) in an overlapping state. At step 124,
The roll feeder 6a conveys the low iron loss material 3a into a press die (having a press upper die 4 and a press lower die 5). In step 125, the press die is stroked a predetermined number of times, and the low iron loss material 3a is caulked and laminated in the lamination groove of the lower press die 5. Next, in step 126, the roll feeder 6
The high iron loss material 3b is conveyed into the press die by b. Process 1
At 27, the press die is stroked a predetermined number of times, and the high iron loss material 3b is caulked and laminated in the laminating groove of the lower press die 5. In step 128, the laminated body in the laminated groove is cut off without crimping punch to perform product cutting processing. After repeating Steps 124 to 128 a predetermined number of times, in Step 129, the product 29 is taken out from the lower press die 5, and the step ends (EN
D130).

Yet another embodiment is shown. Figure 6 (a)
1A and 1B show a motor core as in FIGS. This structure is a structure in which a block 2c made of metal, resin, or the like that is not stacked is sandwiched between a plurality of stacked cores 2a. This block is manufactured by cutting, die-casting, resin molding, plastic working, etc. in parts other than pressing of the laminated core. Further, FIG. 6B shows the structure of an E-shaped core used in a transformer or a linear motor. Similar to FIG. 6A, this structure also has a structure in which blocks 2c of unlaminated metal, resin, etc. are sandwiched between the laminated cores 2.

The equipment and method for obtaining the laminated core of FIG. 6 in the laminated mold will be described with reference to FIGS. 7, 8 and 13. FIG. 7 is a drawing of the punching laminated die of the E-shaped core as seen from above the die, and FIG. 8 is a drawing as seen from the side of the die. Figure 13
It is a flowchart which shows a process. In the die, as in the motor core punching shown in FIG. 5, the core shape is gradually punched at each punching station. Since the material 3 is one type, the feeding device 6 is one set. 3 in the example shown here
A structure in which the block 2c is sandwiched between the laminated cores is shown. The block 2c is made of aluminum and is a component molded by aluminum die casting. This component has the same shape as the laminated core, and the caulking dowel is in the same position as the laminated product.

First, ordinary punching and laminating is performed using this mold. The material 3 fed into the press die by the feeding device 6 is punched by the vertical movement of the upper die 4 and the lower die 5. Then, the core 2a cut off from the material at the caulking portion in the final step is held by the lateral pressure of the caulking groove,
The core 2a punched out before is caulked. After the operation of the press is repeated three times, the cutting punch (punching punch) 11 attached to the upper die is pushed out by the solenoid cylinder 12, and the scrap core 2d is punched in the process in which nothing is done in the normal stroke. At the same time, the cut-off crimping laminated punch 14 which is a punch for cut-off crimping attached to the upper die is also connected to the solenoid cylinder 13
From the die surface to the aluminum die cast block 2c
Extruded by the thickness of, and push down the laminated core to a position deeper than the normal crimping position. In the next stroke, both the cut-off punch (punching punch) 11 and the cut-off crimping laminated punch 14 for cut-off crimping return to the normal position. Also, during the stroke, the aluminum die cast block 2c
Is transferred to the caulking groove by the block transfer means 9 for transferring the aluminum die cast part 2 to the caulking groove. At this time, since the empty portion punched by the preceding stroke is sent to the caulking groove portion, it can be transferred without interfering with the core 2a and the material. Aluminum die cast block 2 transferred by the next stroke of the mold
The c is caulked in the caulking groove by a normal caulking operation. Further, after this, by performing the normal pressing operation three times, the three low iron loss material cores 2a are placed on the aluminum block.
Are laminated. By repeating the above operation, 3
The laminated cores and the aluminum blocks can be alternately laminated.

The process will be described in more detail with reference to FIG.
When the process is started (START 131), the material 3 is set in the equipment in the process 132. In step 133, the material 3 is set in a press die (having a press upper die 4 and a press lower die 5) by a roll feeder (feeding device) 6 in a stacked state. In step 134, the press die is stroked a predetermined number of times to caulk the low iron loss material core 2a into the lamination groove of the lower press die 5. Next, in step 135, the cutting punch (punching punch) 11 punches the scrap core 2d. In step 136, the roll feeder 6 conveys the material 3 by one pitch. In step 137, the aluminum die cast block 2c is transferred into the mold by using a transfer means such as the solenoid cylinder 10. In step 138, the laminating punch is driven by a solenoid (cylinder) to press the block into the caulking laminating groove. After repeating steps 134 to 138 a predetermined number of times, the product 29 is taken out from the lower press die 5 in step 139, and the step is ended (END140).

FIG. 9 shows an example of assembling equipment for assembling a laminated core 2 punched and laminated by a press and a component 2c manufactured by a manufacturing method other than the press die, for example, an aluminum die cast block. The core 2a punched and laminated by a press die is taken out from the die and supplied to a component aligning and feeding mechanism such as a bowl feeder 19. The bowl feeder 19 has a function of aligning and positioning the laminated cores 2 in a certain direction,
The laminated core 2 is supplied to the assembly hand 22 having the moving device 18. At another station, the aluminum die-cast block 2c, which is a component manufactured by aluminum die-casting, is supplied to a component alignment / supply mechanism such as the bowl feeder 19. This station has the function of aligning and positioning the aluminum die-cast block 2c in a fixed direction.
Is supplied to the assembly hand 22 having the moving device 18. The assembling hand 22 alternately takes out the components from the left and right component supply mechanisms and assembles them into the laminating groove 21 of the laminating jig 20. The laminated cores 2 and the aluminum die-cast blocks 2c assembled here are alternately laminated and taken out after assembling a prescribed quantity.

FIG. 10 illustrates the structure of a linear motor having a stator core in which the laminated core 2 and the aluminum die cast block 2c described above are alternately laminated. Figure 10
(A) shows the teeth shape of the stator core. This stator core is composed of a laminated core and has holes 2 for positioning pins.
3a. FIG. 10B shows the yoke portion of the stator core. In this part, aluminum die cast block 2
C and the laminated core 2 are alternately laminated, and the coil 1 is wound on the entire core as illustrated. Also in this yoke core portion, the hole 23 for the positioning pin 23c is formed.
b. FIG.10 (c) shows the shape which combined the yoke core part and the tea score part. The teeth portion and the yoke portion have a shape that is assembled by butting, and the positioning pin 23c is inserted to maintain the relative positional relationship between the yoke core and the teeth core.
This realizes a shape in which aluminum blocks having a laminated core magnetic insulating function are alternately assembled to obtain a linear motor stator.

According to the above, for example, it is possible to reduce the manufacturing cost of a motor by using an inexpensive core without deteriorating the performance as a motor. Further, since the high heat conductive material is sandwiched between the cores, the heat dissipation of the coil is improved, and since the thermal conductivity is also high, the motor having better temperature characteristics,
A linear motor is obtained. As a result, the motor and the linear motor can be further downsized, and since the core is formed in the mold, the number of steps is small, and the yield motor is improved, and the cost and material cost can be reduced.

[0033]

According to one aspect of the present invention, it is possible to provide an electric device that has a core laminated by changing the laminated material in the stacking direction and reduces the material cost.

According to another aspect of the present invention, in a magnetic application product, it is possible to realize a structure in which another material is sandwiched between the laminated cores as a core holding member and magnetic insulation.

Further, according to still another aspect of the present invention, by sandwiching a high thermal conductive material, it is possible to obtain an electric device having improved heat dissipation.

[Brief description of drawings]

FIG. 1 is a diagram showing a structure in which different kinds of materials are laminated one by one on a motor stator core of an embodiment of the present invention.

FIG. 2 is a diagram illustrating a manufacturing method for obtaining a core in which different kinds of materials are laminated one by one according to an embodiment of the present invention.

FIG. 3 is a diagram showing a structure in which a plurality of different materials are laminated on a motor stator core according to an embodiment of the present invention.

FIG. 4 is a diagram illustrating a pressing process for obtaining a core in which a plurality of different materials are laminated according to an embodiment of the present invention, as viewed from the side of the mold.

FIG. 5 is a diagram illustrating a pressing process for obtaining a core in which a plurality of different materials are laminated according to an embodiment of the present invention, as viewed from above the mold.

FIG. 6 is a diagram showing a structure in which a plurality of punched laminated cores and aluminum blocks are alternately laminated on the motor stator core of the embodiment of the present invention, and a plurality of punched laminated cores and aluminum are formed on the transformer and linear motor cores. It is a figure which shows the structure which laminated | stacked the block by turns.

FIG. 7 is a diagram illustrating a pressing process for obtaining a core in which a plurality of laminated cores and aluminum blocks are alternately laminated according to an embodiment of the present invention, as viewed from the top of the mold.

FIG. 8 is a diagram illustrating a pressing process for obtaining a core in which a plurality of laminated cores and aluminum blocks are alternately laminated according to an embodiment of the present invention as viewed from the side of the mold.

FIG. 9 is a diagram illustrating an assembly facility for obtaining a core in which a plurality of laminated cores and aluminum blocks are alternately laminated according to an embodiment of the present invention.

FIG. 10 is a diagram illustrating a structure of a linear motor using a core in which a plurality of laminated cores and aluminum blocks are alternately laminated according to an embodiment of the present invention.

FIG. 11 is a process flow diagram corresponding to FIG. 2;

FIG. 12 is a process flow diagram corresponding to FIGS. 4 and 5;

FIG. 13 is a process flow chart corresponding to FIGS. 7 and 8;

[Explanation of symbols]

1 ... Coil, 2 ... Laminated core, 2a ... Low iron loss material core, 2
b ... High iron loss material core, 2c ... Aluminum die cast block, 2d ... Scrap core, 3a ... Low iron loss material, 3b ...
High iron loss material, 4 ... press upper mold, 5 ... press lower mold, 6 ... roll feeder (feeding device), 7 ... sag amount sensor, 9
... Block transfer means, 10, 12, 13 ... Solenoid cylinders, 11 ... Cutting punches, 14 ... Cutting caulking laminated punches.

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Kim Hironaka             7-1-1, Omika-cho, Hitachi-shi, Ibaraki Prefecture             Inside the Hitachi Research Laboratory, Hitachi Ltd. F-term (reference) 5E062 AA06 AC13                 5H002 AA06 AA09 AB01                 5H615 AA01 BB01 PP01 PP06 SS03                       SS05 SS13 SS20 TT13 TT15

Claims (5)

[Claims] 1. An electric device having a laminated core formed by laminating a plurality of thin metal plates, comprising a core having a structure in which a plurality of materials are laminated one by one or a plurality of materials are laminated. An electric device having a laminated core. 2. A laminated core press die for an electric device, which is formed by laminating a plurality of thin metal plates, having a shape corresponding to laminating a plurality of materials one by one or a plurality of materials. Laminated core press mold for electrical equipment. 3. A laminated core assembling facility for assembling a laminated core constituted by laminating a plurality of thin metal plates, wherein each of a plurality of cores punched by a press die is made of a plurality of materials.
Further, it is characterized by having a supply unit for supplying a plurality of sheets to an assembling facility by a core supply means such as a part feeder, and a caulking laminating unit for performing caulking lamination of the supplied cores one by one or every plural sheets. Laminated core assembly equipment. 4. A metal member having a laminated core formed by laminating a plurality of metal thin plates, and a core formed by punching with a press die and formed between the cores by a forming means other than the press die. Or an electric device having a core in which resin members are sandwiched and laminated. 5. A manufacturing apparatus for an electric device having a laminated core constituted by laminating a plurality of thin metal plates, wherein a core is punched by a press die and the core is separated by a forming means other than the press die. An apparatus for manufacturing an electric device, which manufactures a core in which a molded metal member or a resin member is sandwiched and laminated.