JP2007037367A - Manufacturing method of laminated stator core - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a laminated stator core superior in roundness of an inner shape of a stator core piece and having no deterioration of iron loss due to joining and lamination integration of the stator core pieces without reducing productivity. <P>SOLUTION: The manufacturing method is used for manufacturing a laminated stator core by laminating a prescribed number of the stator core pieces. The method is composed so as to execute the following steps, that is, a step for forming a belt-like core piece having a linearly extending yoke, and a plurality of salient poles protruding from the yoke by pressing a metal plate; a step for forming a caulking part to the belt-like core piece; a step for dividing the yoke for each of a prescribed number of the salient poles, and for freely rotatably connecting the yoke parts adjacent to each other to the salient pole side by push-back; a step for separating the belt-like core piece after winding it by one turn, and for forming the stator core piece by joining the yoke at the terminal end of the separated belt-like core piece with the yoke at its tip; and a step for integrating the stator core pieces with each other by caulking and joining them while laminating a prescribed number of the stator core pieces. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention presses a metal plate to form a strip-shaped core piece, winds the strip-shaped core piece and joins the tip and end of the strip-shaped core piece to form an annular stator core piece, The present invention relates to a method for manufacturing a laminated stator core in which a predetermined number of the stator core pieces are laminated to produce a laminated stator core.

  Large-sized laminated iron cores incorporated in drive motors that generate high output are used. When producing such large-sized laminated iron cores, for example, laminated stator cores, large-sized manufacturing apparatuses (molding apparatuses) ) Is required, resulting in high costs, and a problem in that the yield when cutting the core material is greatly reduced.

  As a technique for solving the inconveniences as described above, by punching and forming a strip-shaped core piece of a shape in which a laminated stator core is linearly developed from a metal plate, by winding the strip-shaped core pieces spirally and laminating each other, A method of manufacturing a laminated stator core is provided (see, for example, Patent Document 1).

  A laminated stator core A shown in FIG. 7 includes a yoke Y having a cylindrical shape and a predetermined number of salient poles T, T... Projecting radially inward from the yoke Y, and has a belt-like core as shown in FIG. A strip-shaped iron core piece S in which salient pole parts St, St... Are formed on the side edges corresponding to the inner circumference of the yoke part Sy extending linearly is wound and laminated following the outer circumference of the guide G, It is manufactured by pressurizing the wound strip-shaped iron core pieces S, S... From above and below to each other, or fixing them together by welding.

  In addition, as another technique, as shown in FIG. 9, instead of continuously winding the strip-shaped core piece in a spiral shape, the strip-shaped core piece is cut every time the strip-shaped core piece is wound. There is provided a method of manufacturing a laminated stator core by joining an end and an end to form an annular stator core piece and sequentially laminating the stator core pieces (see, for example, Patent Document 2). ).

  The laminated stator core A ′ shown in FIG. 9 has a cylindrical yoke Y ′ and a predetermined number of salient poles T ′, T ′... Projecting radially inward from the yoke Y ′ and the outer circumference of the yoke Y ′. A notch K formed at a predetermined interval on the side edge and a wedge W extending in the laminating direction of the laminated stator core A ′ and inserted into the notch K are provided.

  One stator core piece Sa forms a strip-shaped core piece S ′ as shown in FIG. 10, that is, salient pole parts St ′, St ′... On the side edge corresponding to the inner circumference of the yoke part Sy ′ extending linearly. The wound strip-shaped core piece S ′ is wound around the outer periphery of the guide G, the wound strip-shaped core piece S ′ is separated from the subsequent strip-shaped core piece S ′, and the tip and end of the separated strip-shaped core piece S ′ are separated. And are formed by joining together. In the laminated stator core A ′, the stator core pieces Sa, Sa... Are laminated, and the stator core pieces Sa, Sa... Are fixed to each other by inserting wedges W into the notches K continuous in the lamination direction. Manufactured by.

According to the manufacturing method of the laminated stator core as in Patent Document 1 and Patent Document 2, a large manufacturing apparatus (mold apparatus) is not required, and the yield when the core material is cut is improved. It is possible to avoid an increase in manufacturing costs.
JP-A-11-299136 JP-A-63-80741

However, the method disclosed in Patent Document 1 has the following problems.
That is, when winding a linear strip-shaped core piece around the guide G, it is necessary to forcibly bend the strip-shaped core piece, but it is difficult to wind a rigid strip-shaped core piece spirally with an even curvature. It is difficult to form the inner shape of the laminated stator core in a perfect circle. If the inner shape of the laminated stator core does not become a perfect circle, the shape of each layer will vary, and if the variation in shape is large, the salient pole part may shift itself between the laminated layers. In the laminated stator core, the deviation of the salient pole part is undesirable because it causes the motor characteristics to deteriorate.

  On the other hand, as in the method shown in Patent Document 2, making the inner shape of one stator core piece a perfect circle is compared to making each layer a perfect circle by spirally winding the belt-like core pieces. It is easy. However, in the method disclosed in Patent Document 2, an electrical conduction path is formed between the stacks by the joining portions of the strip-shaped core pieces and the wedges that fix the stator core pieces to each other. May increase accordingly. Iron loss is also undesirable because it causes the motor characteristics to deteriorate.

  Furthermore, in the method shown in Patent Document 2, it is necessary to transport the stator core pieces formed in an annular shape from the press work place to the welding work place, and join the cut portions of the stator core pieces by electric welding or the like. In addition, it is necessary to transport the welded stator core pieces from the welding work place to the stacking work place, and to stack the stator core pieces and insert wedges into the stacked stator core. As described above, in order to perform a plurality of processes in separate workplaces, a transfer operation between the respective workplaces is required, which causes a reduction in productivity.

  The present invention has been made in view of such a situation, and is a laminated fixing in which the inner core roundness of the stator core piece is excellent, and there is no deterioration of iron loss due to joining or lamination integration of the stator core piece. An object of the present invention is to provide a method for producing a core iron without reducing productivity.

  In order to achieve the above object, a manufacturing method of a laminated stator core according to the invention of claim 1 is a method of pressing a metal plate to form a strip-shaped core piece, winding the strip-shaped core piece one time, and the strip-shaped core piece. In the method of manufacturing a laminated stator core, the annular stator core piece is formed by joining the tip and the end of the core to form an annular stator core piece, and a predetermined number of the stator core pieces are laminated. A step of forming a strip-shaped core piece having a yoke portion that is processed and extending linearly and a plurality of salient pole pieces projecting from the yoke portion; a step of forming a crimped portion on the strip-shaped core portion; and the yoke A portion is divided into a predetermined number of salient pole pieces, and a step of further connecting the adjacent yokes to the salient pole piece side by a pushback is separated, and the band-shaped core piece is separated and separated. Of the end of the strip-shaped iron core piece Forming a stator core piece by joining a flange portion and a yoke portion at the tip, and stacking a predetermined number of the stator core pieces and caulking and integrating the stator core pieces together It is characterized by having.

  The method of manufacturing a laminated stator core according to the invention of claim 2 is the method of manufacturing a laminated stator core according to the invention of claim 1, wherein the caulking portion is a first caulking that follows the circumferential direction of the strip-shaped core piece. And a second crimping portion that follows the direction perpendicular to the circumference of the strip-shaped core piece.

  According to the method of manufacturing a laminated stator core according to the first aspect of the invention, the yoke part is divided into a predetermined number of salient pole parts, and then pushed back to freely rotate adjacent yoke parts toward the salient pole part. Since the annular stator core piece is formed by using the strip-shaped core pieces connected to each other, it is extremely easy to bend the strip-shaped core pieces to the salient pole part side. That is, it is possible to easily form a stator core piece whose inner shape is a perfect circle, and as a result, it becomes easy to form a laminated stator core whose inner shape is a perfect circle. Therefore, there is no problem that the salient pole part is shifted between the stacked stator cores, and the motor characteristics can be improved.

  Further, the yoke part at the end of the preceding strip-shaped iron core piece is separated from the yoke part at the tip of the following strip-shaped iron core piece, and the yoke part at the end of the preceding ribbon-shaped core piece and the tip of the preceding strip-shaped iron core piece Since the annular stator core piece is formed by joining the yoke portion, conventional welding is not required. Furthermore, since the stator core pieces are fixed by caulking, a conventional wedge is not required. Thus, by reducing the electrical continuity in the laminated stator core, the deterioration of the iron loss characteristic can be suppressed, and the motor characteristic can be improved.

  In addition, each process such as the formation of the strip-shaped core pieces, the formation of the stator core pieces, and the lamination of the stator core pieces can be performed in the press device, so the strip-shaped core pieces and the stator core pieces are transported for each process. There is no need, and productivity can be improved.

  According to the method for manufacturing a laminated stator core according to the second aspect of the invention, the stator core pieces are joined together by caulking portions that follow the circumferential direction and caulking portions that follow the circumferential direction. The laminated stator core pieces having excellent shape accuracy can be manufactured, which can be firmly fixed without being shifted in the circumferential direction and the orthogonal direction.

Embodiments of the present invention will be described below with reference to the drawings.
1 to 4 show an embodiment of a method for manufacturing a laminated stator core according to the present invention, and a laminated stator core 1 manufactured based on the present invention has a stator core piece 20 having an annular shape. It is comprised by laminating | stacking a predetermined number.

  As shown in FIG. 1, the laminated stator core 1 is formed by laminating a predetermined number of annular stator core pieces 20 having a predetermined number of yoke portions 11 and salient pole portions 12, and punching and pushing a metal plate as will be described later. By backing up, the strip-shaped core piece 10 is formed by dividing the yoke section 11 for each predetermined number of salient pole sections 12 and rotatably connecting the adjacent yoke sections 11 to the salient pole section 12 side. 10 is wound for every predetermined number of yokes to form an annular stator core piece 20, and the stator core pieces 20 are laminated and caulked together.

Below, the manufacturing procedure of the lamination | stacking stator core 1 concerning this invention is demonstrated in detail by exemplifying the manufacturing procedure of the lamination | stacking stator core 1 mentioned above.
The production of the laminated stator core 1 is roughly divided into a step of forming the strip-shaped core piece 10 from the strip-shaped metal plate W, a step of forming the stator core piece 20 by making the strip-shaped core piece 10 annular, and a stator core. A step of forming a laminated stator core 1 by laminating a predetermined number of pieces 20, and each step is sequentially performed in a processing region of a press device.

  First, an example of the process of forming the strip-shaped core piece 10 from the strip-shaped metal plate W will be described.

  First, the metal plate W is passed through a pressing device (not shown). 2, the metal material between the salient pole parts 12 is punched from the metal plate W, and the yoke parts 11 are formed between the salient pole parts 12 so as to form the yoke parts 11 between the yoke parts 11. Punching metal material. In punching out the metal material between the yoke parts 11, the gap between the adjacent yoke parts 11 is tapered from the inner circumference equivalent edge side to the outer circumference equivalent edge side, while the adjacent yoke parts 11 are connected to the outer circumference equivalent side edge. Connect with.

  Next, as shown in step P3 of FIG. 2, a crimping portion 13 that follows the circumferential direction of the strip-shaped core piece 10 and a crimping portion 14 that follows the circumferential orthogonal direction are formed in each yoke portion 11. The yoke portion 11 included in the lowermost laminated stator core piece 1 has hole-shaped caulking portions 13 and 14 penetrating the yoke surface 11, and the laminated stator core piece 1 included in a layer other than the lowermost layer. In the yoke portion 11, protruding caulking portions 13 and 14 protruding to the back surface side are formed. Note that the number of crimping portions formed in the yoke portion 11 is not limited to two, but may be one or three or more. Further, a caulking portion may be formed in the salient pole portion 12.

  Next, as shown in Step P4 and Step P5 in FIG. 2, the outer peripheral equivalent side edge of the yoke portion 11 is punched to separate the upper portion (the outer peripheral equivalent side edge side) of the yoke portion 11 from the metal plate W, and the salient pole portion 12 The leading end portion is punched to cut off the salient pole portion 12 from the metal plate W, so that the metal plate W and the strip-shaped core piece 10 are separated.

  Next, as shown in Step P6 of FIG. 2, the connected yoke portions 11 are divided by, for example, slitting and further connected by pushback, and the connecting portions 15 and 16 are joined to the joint portions between the adjacent yoke portions 11. Form. The connecting portion 15 of the yoke portion 11 is connected to the connecting portion 16 of the adjacent yoke portion 11, so that the adjacent yoke portions 11 are rotatably connected to the salient pole portion 12 side. Incidentally, in the process P7 of FIG. 2, the chips of the metal plate W are wound up and removed.

  In addition, the order of the process P1 to the process P6 in FIG. 2 described above can be appropriately changed, and a plurality of processes can be performed simultaneously.

  Next, an example of the process of forming the stator core piece 20 from the strip-shaped core piece 10 will be described.

  First, the strip-shaped core pieces 10 are sequentially transported from the pressing device to a stator core piece machining area (not shown). As shown in FIG. 3, the yoke portion 11 located at the tip of the strip-shaped core piece 10 is locked to the outer periphery of the winding guide G, and a predetermined number of yoke portions 11 are disposed on the outer periphery of the winding guide G that rotates as indicated by the arrow F. The belt-shaped core piece 10 made of is wound once.

  At this time, as shown in FIG. 4, on the yoke portion 11 (At) located at the tip of the preceding strip-shaped core piece 10 (A), the yoke portion 11 located at the tip of the following strip-shaped core piece 10 (B). (Bt) is guided, and the yoke portion 11 (Be) positioned at the end of the preceding strip-shaped core piece 10 (A) is pushed downward by the core piece separator / connector S, so that the connected parts are separated and transferred. .

  That is, the lifting / lowering portion S1 of the core piece separator / connector S is lowered, and the connecting portion 16 (Ae) of the yoke portion 11 (Ae) located at the end of the preceding strip-shaped core piece 10 (A) (the place where it is pushed back). Is separated from the connecting portion 15 (Bt) of the yoke portion 11 (Bt) positioned at the tip of the subsequent strip-shaped core piece 10 (B), and the yoke portion positioned at the tip of the preceding strip-shaped core piece 10 (A) It joins to 11 (At) connection part 15 (At). In this way, one stator core piece 20 is formed.

  The strip-shaped core pieces 10 are separated in advance for each predetermined number of yoke portions 11, and each of the separated strip-shaped core pieces 10 is wound once to join the tip yoke portion 11 and the terminal yoke portion 11 together. One stator core piece 20 may be formed.

  Next, the formation of the laminated stator core 1 as shown in FIG. 1 is performed by repeating the operation of winding the strip-shaped core piece 10 once, laminating a predetermined number of stator core pieces 20 and caulking them together. The

  According to the manufacturing method of the laminated stator core 1 according to the present embodiment, the yoke portion 11 is divided for each predetermined number of salient pole portions 12 and then pushed back to bring the adjacent yoke portions 11 into the salient pole portion 12 side. Since the annular stator core piece 20 is formed using the strip-shaped core pieces 10 that are rotatably connected to each other, it is extremely easy to bend the strip-shaped core pieces 10 to the salient pole part 12 side. That is, it is possible to easily form the stator core piece 20 whose inner shape is a perfect circle, and as a result, it is easy to form the laminated stator core 1 whose inner shape is a perfect circle. Therefore, there is no problem that the salient pole part 12 is shifted between the stacked stator cores 1 and the motor characteristics can be improved.

  In addition, the leading yoke portion 11 (Ae) at the end of the connected strip-shaped core piece 10 (A) is separated from the yoke portion 11 (Bt) at the tip of the following strip-shaped core piece 10 (B) and preceded. An annular stator core piece 20 is formed by joining the yoke portion 11 (Ae) at the end of the strip-shaped core piece 10 (A) and the yoke portion 11 (As) at the tip of the preceding strip-shaped core piece 10 (A). This eliminates the need for conventional welding. Further, since the stator core pieces 20 are fixed to each other by caulking, a conventional wedge is not necessary. Thus, by reducing the electrical continuity in the laminated stator core 1, the deterioration of the iron loss characteristic can be suppressed, and the motor characteristic can be improved.

  Moreover, since each process, such as formation of the strip-shaped core piece 10, formation of the stator core piece 20, and lamination of the stator core pieces 20, can be performed in the press apparatus, the strip-shaped core piece 10 and the stator core are provided for each process. It is not necessary to transport the piece 20, and productivity can be improved.

  Further, since the stator core pieces 20 are caulked and joined by the caulking portion 13 that follows the circumferential direction and the caulking portion 14 that follows the circumferential orthogonal direction, the stator core pieces 20 are firmly fixed without being shifted in the circumferential direction and the orthogonal direction. The laminated stator core piece 1 that can be fixed and has excellent shape accuracy can be manufactured.

  By the way, as shown in FIG. 2, according to the said Example, the strip | belt-shaped iron core piece 10 is formed from the strip | belt-shaped metal plate W, and this stator core piece is formed by making this strip | belt-shaped iron core piece 10 cyclic | annular. For this reason, it is possible to improve the yield at the time of plate cutting, but in order to further improve the yield, as shown in FIG. 5, two strip-shaped core pieces 10 and 10 are formed from a strip-shaped metal plate. do it.

  That is, the two strip-shaped core pieces 10 and 10 are turned upside down on the metal plate, and the salient pole portions 12 of one strip-shaped core piece 10 and the salient pole portions 12 of the other strip-shaped core piece 10 are alternately arranged. Plan the boards so that they line up.

  Since the metal plate can be effectively used by stripping the strip-shaped core pieces 10 and 10 in the arrangement as shown in FIG. 5, the yield when stripping the strip-shaped core pieces 10 and 10 from the metal plate W is obtained. As a result, the manufacturing cost can be avoided.

  In the above-described embodiment, when the strip-shaped core piece 10 is formed, the yoke part 11 is divided for each salient pole part 12, but the yoke part may be divided for a plurality of salient pole parts. For example, the yoke portion 11 ′ may be divided into two salient pole piece portions 12 ′ as in a strip-shaped core piece 10 ′ shown in FIG.

(A) And (b) is the whole top view and whole side view which show one Example of the lamination | stacking stator core manufactured by applying the method in connection with this invention. The conceptual diagram which shows the process sequence which forms a strip | belt-shaped iron core piece. The conceptual diagram which shows the formation method of a stator core piece. (A) And (b) is a conceptual diagram which shows isolation | separation and joining of a yoke part. The figure which shows another Example which strips a strip-shaped iron core piece from a metal plate. The figure which shows another Example of a strip | belt-shaped iron core piece. (A) And (b) is the whole top view and whole side view which show one Example of the laminated stator core manufactured by applying a prior art. The conceptual diagram which shows the formation method of the stator core piece shown in FIG. (A) And (b) is the whole top view and whole side view which show one Example of the lamination | stacking stator core manufactured by applying another prior art. The conceptual diagram which shows the formation method of the stator core piece shown in FIG.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Laminated stator core, 10 ... Strip | belt-shaped core piece, 11 ... Yoke part, 12 ... Salient pole part, 13, 14 ... Crimp part, 20 ... Stator core piece.

Claims (2)

A metal plate is pressed to form a strip-shaped core piece, the strip-shaped core piece is wound once and the tip and end of the strip-shaped core piece are joined to form an annular stator core piece, and the stator core In the manufacturing method of the laminated stator core for producing a laminated stator core by laminating a predetermined number of pieces,
A step of pressing a metal plate to form a strip-shaped core piece having a yoke portion extending linearly and a plurality of salient pole pieces protruding from the yoke portion;
Forming a crimped portion on the strip-shaped core piece;
Dividing the yoke part into a predetermined number of salient pole parts, and further connecting adjacent yoke parts to the salient pole part side by pushback; and
A step of separating the strip-shaped core piece by winding, forming a stator core piece by joining the yoke portion at the end and the yoke portion at the tip of the separated strip-shaped core piece;
A step of laminating a predetermined number of the stator core pieces, and caulking and integrating the stator core pieces together;
The manufacturing method of the laminated stator core characterized by having.   The said crimping part has a 1st crimping part which follows the circumference direction of the said strip-shaped iron core piece, and a 2nd crimping part which follows the circumference orthogonal direction of the said strip-shaped iron core piece, It is characterized by the above-mentioned. Manufacturing method of laminated stator core.

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