JP2006353001A - Laminated iron core and its manufacturing method and apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a laminated iron core capable of effectively preventing generation of defective products while employing a laminate bonding method along with a rotating lamination process, and to provide its manufacturing method and apparatus. <P>SOLUTION: In a rotating lamination process, an iron core sheet 2 is laminated on a top surface of an iron core sheet group 3 with a torque being given by a rotating die, and there may be some remaining torque (rotational inertia) at lamination. However, in this system, when the iron core sheet 2 sits on the top surface of the iron core sheet group 3, a caulking protrusion portion K2 formed on a bottom surface of the iron core sheet 2 fits into a caulking recess portion K3 (or a metering hole K1) formed on the top surface of the another iron core sheet 2 which lies on the top of the iron core sheet group 3, thus preventing an overrun from a normal position of the iron core sheet 2. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a laminated iron core used for a stator or a rotor of a rotating electrical machine, a manufacturing method thereof, and a manufacturing apparatus thereof.

  A laminated iron core for a rotating electrical machine is generally manufactured by a progressive die apparatus using a hoop material (thin strip plate) of an electromagnetic steel sheet as a raw material. In the progressive die device, punch holes such as pilot holes, slots, and inner diameter teeth are sequentially punched into the hoop material to continuously form the core thin plates, and a predetermined number of core thin plates after outer punching are stacked. A laminated iron core is manufactured by fixing them. There are also the laminating caulking methods in which corrugation for caulking is formed on each iron thin plate and crimped and bonded together during lamination, and the laminating welding method in which the core thin plates are joined by laser welding etc. after lamination. However, since it is difficult to cause deterioration of the magnetic characteristics of the bonding site, an adhesive is applied to the surface of the hoop material in the progressive die apparatus, and the core sheet is laminated and bonded simultaneously with the outer punching ( Patent Documents 1 and 2) are widely adopted, and a lamination bonding method (see Patent Document 3) in which the adhesive strength is increased by heating using a thermosetting adhesive as an adhesive is also known. In addition, a lamination bonding method has been proposed in which a thermosetting insulating film is formed in advance on the surface of the hoop material, and heating and pressurization are performed in the outer punching lamination process, thereby omitting the adhesive application process ( (See Patent Documents 4 to 6).

Since the hoop material, which is a material of the iron core thin plate, is manufactured by rolling, the hoop material is slightly in the direction perpendicular to the rolling feed direction (that is, the width direction) due to the parallelism of the rolling rolls and the non-uniformity of the outer diameter. Plate thickness deviation occurs. Therefore, when the core thin plates after the outer shape punching are laminated as they are, both end faces of the completed laminated core are not parallel, and there is a concern that the performance of the rotating electrical machine in which the laminated core is incorporated may be deteriorated. Therefore, the die in the stacking process is structured to be rotatable, and when a predetermined number (one or a plurality) of core sheets are punched, the die is rotated by a predetermined angle (for example, 45 ° to 180 °), and the iron core is rotated. There has been proposed a technique for solving a problem caused by a thickness deviation by stacking (so-called rolling) while changing the rotation position of a thin plate (see Patent Document 7).
JP 2001-25218 A JP 2001-321850 A JP 2003-33711 A JP 2001-185432 A JP 2001-185433 A JP 2001-291827 A JP-A-5-42332

  When the roll-up method of Patent Document 7 is adopted in the lamination bonding method of Patent Documents 1 to 6, the following problems have occurred. In recent years, in the manufacture of laminated iron cores, there is a tendency to increase the operating speed of the progressive die apparatus in order to meet demands such as an increase in demand and a reduction in product costs. In this case, in the laminating process, a large inertial force in the rotating direction acts on the core thin plate group (iron core laminating portion) that has been drawn into the die portion so as to rotate and stack the iron core thin plates in a very short time. . As a result, there is a possibility that the iron core thin plate group pulled out and held in the die portion slightly overruns the inner surface holding the die portion.

  The core sheet that is stacked by punching the outer shape onto the core sheet group in the overrun die part is shifted in the rotational direction by the amount of overrun at this time, and when it is pulled out, it is punched A stator of a rotating electrical machine is manufactured in a state where the slot portion and the inner diameter teeth are displaced in the die portion by contacting the iron core thin plate that has been pushed in and the adhesive portion starts to harden. And cannot be used as a rotor. Such a laminated core can be reused by stripping off the adhesive, but it is actually discarded as a defective product due to problems in manufacturing efficiency. It was forced to decrease and increase manufacturing costs.

  The present invention has been made in view of such a background, and while adopting a laminating and bonding method using a combination of turning and stacking, enables the turning and stacking by high-speed rotation and effectively suppresses the occurrence of defective products. It is another object of the present invention to provide a laminated iron core, a method for producing the same, and a production apparatus that enable strong lamination and fixing.

  The laminated iron core according to the invention of claim 1 is a laminated iron core formed by laminating and bonding an iron core thin plate formed in a predetermined shape from a strip-shaped thin steel sheet, after sequentially rotating in accordance with the predetermined shape, A positioning fitting for restricting the rotation angle during the rotation is formed on the iron core thin plate constituting the laminated iron core.

  The laminated core according to the invention of claim 2 is characterized in that, in the laminated core of claim 1, the positioning fitting portion is formed as a half-bumped protrusion.

  The laminated iron core according to the invention of claim 3 is characterized in that the positioning fitting portion is formed as a cut and raised protrusion.

  According to a fourth aspect of the present invention, there is provided the laminated iron core according to any one of the first to third aspects, wherein the positioning fitting portion formed on the iron core thin plate has a magnetic equilibrium. In order to suppress the influence of the above, it is characterized in that it is formed at a substantially intermediate portion between adjacent magnetic poles.

  The laminated core according to the invention of claim 5 is the laminated core according to claim 4, wherein the positioning fitting formed on the iron core thin plate suppresses an increase in magnetic resistance. It is characterized in that it is formed in the vicinity of the outer peripheral surface.

  Moreover, the manufacturing method of the laminated iron core which concerns on invention of Claim 6 is a manufacturing method which concerns on the laminated iron core as described in any one of Claims 1-5, Comprising: The thin film of an adhesive agent on the surface previously A step of punching and forming an iron core thin plate having a predetermined shape from a strip-shaped thin steel plate having a layer, a step of forming the positioning fitting portion on the iron core thin plate, and a step of curing the adhesive. And

  Moreover, the manufacturing method of the laminated iron core which concerns on invention of Claim 7 is a manufacturing method which concerns on the laminated iron core as described in any one of Claims 1-5, Comprising: From a strip | belt-shaped thin steel plate, it is a predetermined shape. It includes a step of punching and forming the iron core thin plate, a step of forming a positioning fitting portion on the iron core thin plate, and a step of applying an adhesive to the surface of the iron core thin plate.

  The laminated core manufacturing apparatus according to the invention of claim 8 includes a plurality of punching means for punching and forming an iron core thin plate of a predetermined shape from a strip-shaped thin steel plate, and positioning for regulating a rotation angle at the time of rotational lamination. Processing means for forming the fitting portion on the iron core thin plate, rotary laminating means for laminating and bonding the iron core thin plate sequentially at an angle regulated by the positioning fitting portion, and adhesive after the start of the rotation lamination And an adhesive curing means for curing the adhesive.

  An apparatus for manufacturing a laminated core according to the invention of claim 9 is the apparatus for producing a laminated iron core according to claim 8, wherein an adhesive is applied to the surface of the iron core thin plate at an intermediate portion of the plurality of punching means. It is characterized by the fact that a means to do this is also provided.

  Since the positioning fitting part for preventing overrun is provided in the core thin plate used in the laminating and bonding method, overrun of the core thin plate is prevented at the time of rolling and stacking by high-speed rotation is possible. The occurrence of defective products is reduced and the product yield is improved. In addition, the coupling of the positioning fittings to prevent overruns contributes to an increase in the coupling force, and it is possible to reliably laminate and bond even at high operating speeds, contributing to the improvement of the productivity of the laminated core and consequently to the reduction of the product cost. It becomes possible to do.

  In addition, in the structure in which the positioning fitting part is also used as the caulking part, the iron core thin plate is firmly integrated by the caulking part in addition to the adhesive part in the lamination process. Can be omitted, and the complexity of the manufacturing apparatus can be avoided.

Hereinafter, an embodiment of a method of manufacturing a stator for an electric motor (stator) to which the present invention is applied will be described in detail with reference to the drawings.
1 is a view showing a strip layout according to the embodiment, FIG. 2 is a plan view of a thin iron core plate, FIG. 3 is a longitudinal sectional view of a hoop material at a portion where a positioning fitting portion is formed, and FIG. These are explanatory drawings which show the effect | action of embodiment.

≪Manufacturing process of laminated iron core≫
<First half punching process>
In the case of the present embodiment, the basic shape of the iron core thin plate 2 excluding the outer shape is formed on the hoop material 1 in the first half punching step shown on the left side of FIG. That is, while the hoop material 1 is intermittently fed in the progressive die apparatus, first, the pilot hole P is punched (1), the inner diameter lower hole d1 and the outer groove small hole h is punched (2), and the slot S. The punching process (3), the punching process (4) of the inner diameter d, and the punching process (5) of the inner diameter tooth T are sequentially performed. These punching processes are performed by punching of a progressive mold apparatus. However, since the configuration is known, the progressive mold apparatus is not illustrated in this embodiment. In addition, if the progressive die apparatus is provided with an adhesive application means on the one using the lamination caulking method, or a positioning fitting portion forming means is provided on the one using the lamination adhesion method, the equipment cost will be greatly increased. Can be prevented.

<Positioning fitting forming process for overrun prevention>
When the first half punching process is completed, a positioning fitting portion is formed in the yoke portion Y on the hoop material 1 by a punch (not shown). That is, while the hoop material 1 is intermittently fed in the progressive die apparatus, the punching process (6) of the measuring hole (positioning fitting part) K1 and the forming process of the caulking convex part (positioning fitting part) K2 (7 ) And are given sequentially. The measuring hole K1 is drilled in an iron core thin plate (measuring iron core thin plate) 2 used for controlling the laminated thickness of the laminated iron core, and penetrates the hoop material 1 as shown in FIG. On the other hand, the caulking convex portion K2 is formed on the iron core thin plate 2 other than for measurement, and is formed on the lower surface of the hoop material 1 by being half-punched by a punch as shown in FIG. Further, a caulking concave portion (positioning fitting portion) K3 is formed on the upper surface of the hoop material 1 at a portion where the caulking convex portion K2 is formed. Note that each of the measuring hole K1, the caulking convex portion K2, and the caulking concave portion K3 has a cylindrical wall surface, and the caulking convex portion K2 is fitted into the measuring hole K1 and the caulking concave portion K3 with a slight gap. The dimensions are set.

<Adhesive application process>
When the positioning and fitting portion forming step is completed, the adhesive E is supplied and applied to the hoop material 1 in a spot shape on the magnetic pole portion J portion between the slot portions S as shown in FIG. (8). Note that the adhesive E is not applied to the iron core thin plate 2 punched immediately before the iron core thin plate 2 for measurement.

<Outline punching process>
When the adhesive application process is completed, the outer shape D is punched into a rotary die (not shown) by the outer punch, and the iron core thin plate 2 is completed. In the outer shape punching step, a plurality (eight in this embodiment) of outer grooves M are formed in the outer shape D.

<Rotational lamination process>
The core sheet 2 obtained by the outer shape punching process is rotated by a predetermined angle (for example, 90 °) one by one (or a plurality of sheets) together with the rotary die, and then the core sheet 2 is already laminated. Laminated. Thereby, the iron core thin plate 2 is mutually fitted by fitting the caulking convex portion K2 into the caulking concave portion K3 formed on the upper surface of the iron core thin plate 2 positioned at the uppermost portion of the iron core thin plate group 3 (or the measuring hole K1). At the same time, the adhesive E applied to the magnetic pole part J is spread between the iron core thin plates 2, and the iron core thin plates 2 are bonded to the iron core thin plate group 3. Then, when the iron core thin plate 2 in which the measurement hole K1 is formed is punched and laminated, the iron core thin plate group 3 previously laminated is separated, and a laminated iron core 4 composed of a predetermined number of iron core thin plates 2 (see FIG. 4) is formed.

≪Overrun prevention≫
In the rotating lamination process, the iron core thin plate 2 is seated on the upper surface of the core thin plate group 3 by being given a rotational force by a rotating die, but as described above, the remaining rotational force (rotational inertia) remains at the time of seating. There is. This tendency is particularly remarkable when the operating speed of the progressive die apparatus is set high. However, in the case of this embodiment, when the iron core thin plate 2 is seated on the upper surface of the iron core thin plate group 3, the caulking convex portion K2 formed on the lower surface of the iron core thin plate 2 is the uppermost part of the iron core thin plate group 3, as shown in FIG. It fits into the caulking concave portion K3 (or the measurement hole K1) formed on the upper surface of the iron core thin plate 2 located in the position, and overrun from the normal position of the iron core thin plate 2 is prevented. As a result, in the completed laminated core 4, the bonding strength between the iron core thin plates 2 in the laminated core 4 becomes very high due to the combined use of bonding and caulking, and at the same time, there is no deviation of the slot portion S and the inner diameter teeth T and the like. The occurrence frequency of non-defective products decreases.

  Although description of specific embodiment is finished above, the aspect of the present invention is not limited to this embodiment. For example, in the above embodiment, the present invention is applied to a stator of an electric motor, but may be applied to a rotor (rotor) of an electric motor, or may be applied to a stator or a rotor of a generator. May be. Moreover, in the said embodiment, although the positioning fitting part shall have a cylindrical wall surface, it has a planar wall surface (For example, as shown to FIG. 5 (a), (b), it is rectangular in planar view). Or a cut and raised shape as shown in FIG.

  In addition, publicly known literature can be adopted. Further, instead of the above-described caulking coupling means, for example, when the outer groove M (see FIG. 2) is formed as an iron core thin plate, or when there is no influence on performance, one similar groove is formed on the outer shape ( Or, by forming a plurality of projections on the inner surface of the die portion to engage with these (these) grooves, the core thin plate group that is drawn and stacked in the die portion is integrated with the die portion in the rotational direction. By doing so, it is possible to prevent overrun due to inertia in the rotational direction of the die portion.

  Moreover, although the process of heating etc. is not provided for the solidification of the adhesive in the above embodiment, a heating process may be further performed after the adhesive is unloaded from the mold using a thermosetting material. Good. In the above embodiment, the adhesive is applied to the surface of the hoop material in the progressive die apparatus. However, by previously forming a thermosetting insulating film on the surface of the hoop material, the adhesive application step is performed. It may be omitted.

  In addition, the specific shape and number of positioning fittings to prevent overrun, the installation location, etc. are also formed at the intermediate location between adjacent magnetic poles in order to suppress the effect on magnetic equilibrium, or the magnetoresistance is increased. However, the present invention is not limited to the examples in the embodiment, and can be changed as appropriate without departing from the gist of the present invention.

It is a figure which shows the strip layout which concerns on embodiment. It is a top view of an iron core thin plate. It is a longitudinal cross-sectional view of the hoop material in the site | part in which the positioning fitting part was formed. It is explanatory drawing which shows the effect | action of embodiment. It is a principal part longitudinal cross-sectional view which shows the modification of a positioning fitting part. It is a principal part longitudinal cross-sectional view which shows the modification of a positioning fitting part.

Explanation of symbols

1 Hoop material 2 Iron core thin plate 3 Iron core thin plate group 4 Laminated core K1 Measuring hole (positioning fitting to prevent overrun)
K2 Caulking projection (positioning fitting to prevent overrun)
K3 Caulking recess (positioning fitting to prevent overrun)
E Adhesive

Claims (9)

  In the laminated iron core formed by laminating and bonding the iron core thin plate formed by extracting the belt-shaped thin steel plate into a predetermined shape in order corresponding to the predetermined shape, the iron core thin plate constituting the laminated iron core A laminated iron core comprising a positioning fitting portion for restricting a rotation angle during the rotation.   The laminated iron core according to claim 1, wherein the positioning fitting portion is formed as a half-cut projection.   The laminated core according to claim 1, wherein the positioning fitting portion is formed as a cut and raised protrusion.   The positioning fitting portion formed on the iron core thin plate is formed at a substantially intermediate portion between adjacent magnetic poles so as to suppress an influence on magnetic balance. The laminated iron core according to any one of 3 above.   The positioning fitting portion formed on the iron core thin plate is formed close to the outer peripheral surface of the iron core thin plate so as to suppress an increase in magnetic resistance. Laminated iron core.   A step of forming an iron core thin plate of a predetermined shape from a strip-shaped thin steel plate provided with a thin film layer of adhesive on the surface in advance, a step of forming the positioning fitting portion on the iron core thin plate, and curing the adhesive The manufacturing method which concerns on the laminated iron core as described in any one of Claims 1-5 characterized by including the process to make.   Including a step of punching and forming an iron core thin plate of a predetermined shape from a strip-shaped thin steel plate, a step of forming a positioning fitting portion on the iron core thin plate, and a step of applying an adhesive to the surface of the iron core thin plate. The manufacturing method which concerns on the laminated iron core as described in any one of Claims 1-5 characterized by the above-mentioned.   A plurality of punching means for punching and forming an iron core thin plate of a predetermined shape from a strip-shaped thin steel sheet, a processing means for forming a positioning fitting portion for regulating a rotation angle at the time of rotational lamination on the iron core thin plate, A laminate comprising: a rotary laminating means for laminating and bonding the iron core thin plates while sequentially rotating at an angle regulated by the positioning fitting portion; and an adhesive curing means for curing the adhesive after the start of the rotational lamination. Iron core manufacturing equipment.   9. The laminated iron core manufacturing apparatus according to claim 8, wherein means for applying an adhesive to the surface of the iron core thin plate is provided at an intermediate portion of the plurality of punching means.

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