JP2007252092A - Core material in armature core in dynamo-electric machine, and method of manufacturing same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent iron loss from being damaged by a work hardening section formed on a cut surface when forming a core material composing an armature core for composing an armature core by progressive press work. <P>SOLUTION: A shaving process for removing the work hardening section is incorporated into the process of the progressive press work for punching each of first and second core materials 10, 11 sequentially. In a sheet material 16, the outside diameter side of a part corresponding to the outer-periphery edge of teeth 10e, 11e is punched circularly for forming a plurality of first outer-periphery edge punched holes H while a non-punched section N1 exists in-between, and a part corresponding to the outer-periphery edge of the teeth 10e, 11e is shaved via the first outer-periphery edge punched holes H. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention belongs to the technical field of a core material of an armature core in a rotating electrical machine such as an electric motor constituting an actuator and a manufacturing method thereof.

  Generally, among armature cores that constitute rotating electric machines such as this type of electric motor, there are ones in which a plurality of core materials are integrally fitted around an armature shaft, and in each of these core materials, A plurality of teeth are formed on the outer periphery of the through hole through which the motor shaft passes. When such a core material is formed (manufactured), a so-called progressive press in which a long thin plate material is intermittently transferred to a progressive mold apparatus to form the core material through a plurality of punching processes. A processing method has been proposed.

As an example of such progressive feeding, slot punching is performed by punching a slot-like portion formed between adjacent teeth in a long thin sheet material, and then the equivalent of a through hole into which the armature shaft is integrally fitted. It has been proposed that the core material is extracted from the thin plate material by punching the portion so as to be in a half-punched state and then punching the portion corresponding to the outer peripheral edge of each tooth.
JP-A-6-165447

  And the said conventional thing is the procedure of extracting a core material from a thin plate material by punching out the outer peripheral portion of a tooth at a time after punching a slot equivalent part beforehand from a thin plate material, and the outer peripheral portion of a tooth. Is in a cut-off state as it is punched (cut and broken). By the way, in general, it is known that when a metal material is subjected to processing such as cutting, work hardening occurs at the cutting site. For this reason, the core material formed by the conventional procedure is punched out. Work hardening has occurred at the site. When an armature core is formed using such a core material, when forming a magnetic path between each tooth and a permanent magnet, work hardening of the outer peripheral edge of the tooth has a significant effect on the magnetic path formation. In addition, problems such as an increase in iron loss and a decrease in motor performance due to loss of magnetic characteristics occur. In order to avoid this, it is considered that the work-hardened part formed on the outer peripheral edge of the tooth can be removed (removed) by scraping it off by shaving or the like. If the core material is subjected to removal processing such as shaving processing, the removal processing will be performed on each core material cut from the thin plate material, so the work is complicated. In addition, there are problems that work takes a long time and troublesome work is required, and this is a problem to be solved by the present invention.

The present invention was created in view of the above-described circumstances in order to solve these problems, and the invention of claim 1 provides a plurality of circumferential directions on the outer periphery of the through hole through which the armature shaft passes. The core material of the armature core in which the teeth are disposed, and when the core material is formed by punching a thin plate material, the work hardening portion formed on each outer peripheral edge portion of the teeth is removed by the removing means Is a core material of an armature core in a rotating electrical machine characterized by
The invention according to claim 2 is the core material of the armature core in the rotating electric machine, wherein the removing means is a shaving process.
In the invention of claim 3, in forming the core material of the armature core in which a plurality of teeth in the circumferential direction are arranged on the outer periphery of the through-hole through which the armature shaft passes, by punching the thin plate material, After punching out an outer peripheral edge part, it is the manufacturing method of the core material of the armature core in a rotary electric machine which removed the work hardening part formed in each teeth outer peripheral part by the removal means.
According to a fourth aspect of the present invention, there is provided a method for manufacturing a core material of an armature core in a rotating electrical machine, wherein the removing means is a shaving process.
In the invention of claim 5, the shaving process is incorporated into a progressive press process for sequentially punching each part of the core material, and the outer diameter side of the part corresponding to the outer peripheral edge of the tooth is punched into an arc shape in a thin plate material. The punched portion is formed with a non-punched portion between the punched portions adjacent to each other in the circumferential direction, and after shaving the portion corresponding to the outer periphery of the teeth through the punched portion, the non-punched portion is punched, It is a manufacturing method of the core material of the armature core in the rotary electric machine of Claim 4 comprised so that a core material may be extracted from a thin-plate material.
The invention according to claim 6 is the core material of the armature core in the rotating electrical machine according to any one of claims 5 to 6, wherein the non-punched portion is formed on the outer diameter side of the portion corresponding to the teeth adjacent in the circumferential direction. It is a manufacturing method.
According to the seventh aspect of the present invention, each tooth is formed with a recessed groove portion that is recessed on the inner diameter side in the circumferential direction intermediate portion of the outer peripheral edge portion, and the non-punched portion is the outer diameter of the portion corresponding to the recessed groove portion. It is a manufacturing method of the core material of the armature core in the rotary electric machine as described in any one of Claim 5 currently formed in the side.

According to the first and third aspects of the invention, the work hardened portion formed on the outer peripheral edge portion of the teeth is removed, and an armature core having excellent magnetic properties can be formed by reducing iron loss, and motor efficiency A good electric motor can be provided.
By setting it as invention of Claim 2, 4, a work hardening part can be removed easily and accurately.
According to the inventions of the fifth, sixth and seventh aspects, the shaving process can be performed easily and inexpensively, and an electric motor having excellent performance can be provided, but the cost can be reduced. .

Next, a first embodiment of the present invention will be described with reference to the drawings.
In the figure, reference numeral 1 denotes an electric motor (rotary electric machine) serving as a drive source for electrical components mounted on a vehicle, and an inner periphery of a yoke (motor housing) 2 formed in a bottomed cylindrical shape constituting the electric motor 1. A permanent magnet 3 is fixed on the surface so that two pairs of N and S poles can be formed in the circumferential direction, thereby forming a four-pole electric motor 1 in which the same poles are opposed to each other in the radial direction. . Reference numeral 4 denotes an armature, and an armature core 7 formed by laminating a plurality of core members 6 that are ring-shaped plate members is integrally fitted on an armature shaft 5 constituting the armature 4, and A commutator (commutator) 8 is fitted and fixed at the tip of the armature core 7. The armature shaft 5 is supported at the base end via a bearing 2b provided on the cylinder bottom 2a of the yoke 2, while the tip end is provided on a cover 2c provided on the opening end of the yoke 2. Thus, the interior of the yoke 2 is rotatably provided. Further, a holder stay 9 is supported in a sandwiched manner between the cover 2c and the yoke 2, and brush holders 9a are formed on the holder stay 9 at four locations in the circumferential direction. The brushes 9b are respectively mounted in the brush holders 9a so that they can be protruded and retracted, and the protruding tip (inner diameter side tip) of the brush 9b abuts (contacts) with the commutator 8 in an elastic manner, so that an external power source can be Although it is configured to be supplied to the commutator 8 through 9b, these basic configurations are the same as conventional ones.

Now, the core material 6 constituting the armature core 7 includes a first core material 10 in which a through hole 10a integrally fitted to the armature shaft 5 is formed, and an armature having a larger diameter than the first core material 10. Two types are used, the second core material 11 having a through hole 11a that is loosely fitted to the shaft 5, and the armature core 7 is formed by laminating a plurality of first core materials 10 at both ends in the axial direction. The plurality of second core materials 11 are laminated. By configuring the armature core 7 using the first and second core materials 10 and 11 as described above, a gap is formed between the inner diameter portion of the second core material 10 and the armature shaft 5, thereby the commutator. 8 and the base end side bearing 2b can be arranged close to each other, and the armature shaft 5 can be made compact in size.
Reference numerals 12 and 13 denote a pair of insulators provided on the distal end side and the proximal end side in the axial direction of the armature core 7.

  The first and second core members 10 and 11 are arranged on the outer periphery of the ring-shaped main body portions 10b and 11b having the same diameter, at equal intervals in the circumferential direction from the outer peripheral edges of the main body portions 10b and 11b. T-shaped teeth 10e, 11e formed of leg pieces 10c, 11c protruding in the direction and claw pieces 10d, 11d protruding from the protruding tips of the leg pieces 10c, 11c to both sides in the circumferential direction are provided in the circumferential direction. Ten are arranged. Accordingly, when the armature core 7 is formed by laminating the first and second core materials 10 and 11, the armature core 7 is provided with a long recess in the axial direction between the adjacent teeth 10e and 11e on the outer periphery of the armature core 7. The dovetail-shaped coil slots 10f and 11f are set to be formed in the circumferential direction. The coil slots 10f and 11f are wound with a winding 14a, and a plurality of coils 14 are formed on the outer periphery of the armature core 7. The ends of the windings 14a forming these coils 14 are connected to the commutator 8. By being electrically connected to the coil 14, external power is supplied to the coils 14 via the brush 9b and the commutator 8, and the coils 14 are set to be excited based on the supply of the external power. Yes.

Further, the first core material 10 is formed with an inner diameter side main body portion 10g in which a through hole 10a into which the armature shaft 5 is fitted is formed on the inner diameter side of the main body portion 10b. Between the outer diameter side main body portion (hereinafter referred to as the outer diameter side main body portion) 10b, ten bridge pieces 10h in the circumferential direction are provided so as to be positioned on the same radiation as the leg pieces 10c of the teeth 10e. The inner diameter side main body portion 10g and the outer diameter side main body portion 10b are integrally connected. The inner slot 10i formed between the bridge pieces 10h adjacent to each other in the circumferential direction becomes a long gap in the axial direction when the armature core 7 is configured, and the winding wound around the coil slots 10f and 11f. 14a is configured to function as a space for fusing the commutator 8 and as a space for releasing heat generated when the electric motor 1 is driven.
Further, in the circumferential direction intermediate portion of the claw pieces 10d, 11d constituting the teeth 10e, 11e, concave grooves 10j, 11j are formed in a state of being cut out on the inner diameter side, thereby driving the electric motor 1. The cogging generated in the armature 4 is reduced.
Further, on the inner diameter side of each of the first core material outer diameter side main body portion 10b and the second core material main body portion 11b, the first core material outer diameter side main body portion 11b is positioned on the same radiation as the leg pieces 10c, 11c of the teeth 10e, 11e. By pushing and forming the plate surfaces of the first and second core members 10 and 11 to one surface side, ten caulking projections 10k and 11k are formed in the circumferential direction.

  The first and second core materials 10 and 11 are subjected to a plurality of punching processes by performing so-called progressive press processing for intermittently transferring the long thin plate material 15 to the progressive die apparatus. It is set to be formed. Further, in the present invention, after the outer peripheral edge portions of the claw portions 10d and 11d constituting the teeth 10e and 11e of the first and second core materials 10 and 11 are punched and processed in the progressive pressing, the claw portions 10d. , A shaving process is incorporated as a removing means for removing the outer peripheral portion of the 11d, thereby removing the work hardening portion formed on the outer peripheral edge of each of the claw portions 10d, 11d (the teeth 10e, 11e) Thus, the core material is configured to be excellent in magnetic characteristics and improve the motor performance. In addition, the shaving process is performed before the step of extracting the first and second core materials 10 and 11 from the thin plate material 15, that is, the first and second core materials 10 and 11 corresponding to the thin plate material 15. Since the steps are performed at the stage where the parts are integrated, it is not necessary to shaving the first and second core materials 10 and 11 separately, but a series of steps for forming the first and second core materials 10 and 11. The shaving process can be performed in the above, and the shaving process can be performed easily and easily.

Below, the manufacturing process of the 1st, 2nd core materials 10 and 11 is demonstrated based on drawing of FIGS.
Step A shown in FIG. 4 (A) is a step of punching a shaft punching hole H corresponding to the through-hole 11a of the second core material 11 with respect to the long thin plate material 15, and the first core material. When 10 is formed, it becomes a dormant state in which nothing is done.
Subsequently, the step B shown in FIG. 4B is a step of punching the outer peripheral edge portions of the teeth 10e and 11e, and is a step performed in the process of forming both the first and second core members 10 and 11. . In this step B, in the thin plate member 15, an arc-shaped first outer peripheral punching hole (corresponding to the punched portion) H1 is formed on the outer diameter side of the teeth 10e, 11e corresponding to the outer peripheral portion of the core members 10, 11. In this configuration, ten punches are punched in the circumferential direction. At this time, each of the first outer peripheral punching holes H1 does not punch out the outer diameter side portions of the corresponding portions of the recessed grooves 10j and 11j formed in the teeth 10e and 11e. The portion N is formed by punching out the outer diameter side of the portion corresponding to the outer peripheral edge located between the portions corresponding to the recessed grooves 10j and 11j between the adjacent teeth 10e and 11e. As a result, in the state where the first outer peripheral punching hole H1 is formed, the thin plate member 15 includes the first and second core members 10 and 11 corresponding to the first outer peripheral punching hole H1 and the first outer periphery. The outer portion (main body portion) of the peripheral punch hole H1 is connected (integrated) by the first non-punched portion N1 located on the outer diameter side of the portion corresponding to the recessed groove portions 10j and 11j.
In this case, the outer diameter side of the portions corresponding to the outer peripheral edge portions of the claw portions 10d and 11d excluding the portions corresponding to the recessed groove portions 10j and 11j formed in the claw portions 10d and 11d (the teeth 10e and 11e) is cut. Is the work hardening part.
In addition, as shown in FIG. 7A, the inner peripheral edge of the first outer peripheral punching hole H1 is slightly smaller than the portion corresponding to the outer peripheral edge of each tooth 10e, 11e (the outer diameter of the teeth 10e, 11e). The outer circumferential diameter of the first outer peripheral punching hole H1 is set so as to be on the outer diameter side, and the first outer peripheral punching is performed by inserting a shaving tool 16 used in shaving processing to be described later. The inner peripheral edge of the hole H1 is set to a size that can be shaved.

  The C process shown in FIG. 4C corresponds to the shaving process of the present invention, and is a process performed in the process of forming both the first and second core materials 10 and 11. In step C, the shaving tool 16 is inserted through the first outer peripheral punching hole H1, and the inner peripheral edge (the teeth 10e, 11e corresponding to the outer peripheral edge) of the first outer peripheral punching hole H1 is shaved. By doing so, the arcuate second outer peripheral punching hole H2 is formed in a state where the first outer peripheral punching hole H1 is expanded toward the inner diameter side (becomes wide in the radial direction). As a result, the work-hardened portion formed on the outer diameter side of each tooth 10e, 11e corresponding to the outer peripheral edge is removed (removed), and the inner peripheral edge of the second outer peripheral punching hole H2, that is, the teeth 10e, 11e. The portion corresponding to the outer peripheral edge is set to have a predetermined outer diameter. At this time, the first non-punched portion N1 formed in the step A becomes the second non-punched portion N2 that is widened to the inner diameter side by the second outer peripheral punching hole H1 (becomes wide in the radial direction). Due to the second non-punched portion N2, the thin plate material 15 is positioned on the inner side of the second outer peripheral punching hole H2, and the portion corresponding to the first and second core members 10, 11 and the outer side of the second outer peripheral punching hole H2. The part (main body part) is connected (integrated) by the second non-punched portion N2.

As described above, after the portions corresponding to the outer peripheral edge portions of the teeth 10e and 11e in the step C are in a state of being shaved, in the subsequent step D shown in FIG. In order to form a portion corresponding to the heat radiation slot 10i of the core material 10, the heat radiation slot punch hole H3 is punched to form ten bridge pieces 10h corresponding portions in the circumferential direction. And when forming the 2nd core material 11, it will be in a dormant state where nothing is done.
Next, the E process shown in FIG. 4 (E) is performed when both the first and second core materials 10 and 11 are formed, and is formed between adjacent teeth 10e and 11e. Slot punch holes H4 corresponding to ten coil slots 10f and 11f in the circumferential direction are formed. As a result, the second outer peripheral punching hole H2 and the slot punching hole H4 are in communication with each other at portions corresponding to both ends in the circumferential direction of the adjacent slots 10e and 11e, and the thin plate member 15 is the main body portion serving as the outer peripheral portion. And the first and second core members 10 and 11 are connected (integrated) only by the second non-punched portion N2 formed at 10 places in the circumferential direction of the first and second core members 10 and 11. ).

4F, in the case of forming the first core material 10, the shaft punching hole H5 corresponding to the through hole 10a is punched and the portion corresponding to the caulking protrusion 10k is extruded and formed. To do. When the second core material 11 is formed, a portion corresponding to the caulking projection 11k is extruded and formed.
And it transfers to G process shown in FIG.4 (G) from this state, but this G process is set so that neither 1st nor 2nd core material 10 and 11 may be made into a dormant state. ing. In the rest state, it is set as idling, such as ensuring the balance of the progressive die apparatus.
After passing through the pause step, in the H step shown in FIG. 4 (H), the first and second core members 10 and 11 are formed by punching the concave groove punching holes H6 in the corresponding portions of the concave groove portions 10j and 11j. And is set to be extracted from the thin plate material 15.

  Incidentally, the armature core 7 forms the first core material 10 through the B process, the C process, the D process, the E process, the F process, the G process, and the H process, and the A process, B process, C process, E The second core material 11 is formed through the process, the F process, the G process, and the H process, and the extracted core materials 10 and 11 are sequentially guided into the die for forming the armature core and fixed by caulking. It is set to form by an in-mold automatic lamination method. For this reason, in the progressive press working, after forming the appropriate number of second core materials 11 set in advance, the appropriate number of first core materials 10 are formed, and further the appropriate number of second core materials 11 are formed. These operations are performed, and these are sequentially integrated in the die using the caulking projections 10k and 11k.

In the present embodiment configured as described, the core material 6 constituting the armature core 7 uses two types of first and second core materials 10 and 11, but in this case, the first, The second core materials 10 and 11 are formed by punching the thin plate material 15 by performing progressive press processing, respectively, but the outer peripheral edge portions of the teeth 10e and 11e having a large influence on the magnetic characteristics as the armature core 7 Since the shaving process as a removing means is applied to the cut surface punched out by the progressive press process, the work hardened portion formed on the cut surface is removed, thereby reducing the iron loss. Thus, the armature core 7 having excellent magnetic characteristics can be formed, and the electric motor 1 with high motor efficiency can be provided.
Here, FIG. 8 shows the armature 4 configured using the first and second core members 10 and 11 subjected to the shaving process, and the armature in which the outer peripheral edge portion of the teeth is cut off without being subjected to the shaving process. And the first, second, and third electric motors that are shaved and incorporated into different first, second, and third stators, and the first, second, and third electric motors that are not in the shaving state. The results of measuring the amount of magnetic flux in the teeth of each armature are shown. According to FIG. 8, it is confirmed that the amount of magnetic flux is greater in the teeth subjected to the shaving process than in the teeth not subjected to the shaving process even when incorporated in any stator, and the usefulness of the shaving process is demonstrated. Is done.

  In addition, since this method uses a shaving process as the removing means, the work hardened part can be removed easily and accurately, and workability is improved.

  Further, in this, the step of shaving the outer peripheral edge portions of the teeth 10e, 11e of the first and second core materials 10, 11 is after the first and second core materials 10, 11 are extracted from the thin plate material 15. Instead, since it is made to be connected to the thin plate material 15 via the second non-punched portion N2, the process of the flow work for performing the progressive press work on the first and second core materials 10, 11 Thus, the shaving process can be performed easily and inexpensively, and the electric motor 1 having excellent performance can be provided, which can contribute to the cost reduction.

Of course, the present invention is not limited to the above-described embodiment, and may be the second embodiment shown in FIG.
This is the same as the first embodiment, and the first and second core materials 10 and 11 are formed in the same manner as in the first embodiment. , The non-punched portion N is formed on the outer diameter side of the portion corresponding to the space between the teeth 10e and 11e adjacent to each other in the circumferential direction. It is formed on the outer diameter side of a corresponding portion, and is configured to insert a shaving tool 16 through the first outer peripheral punching hole H7 and shaving it to form a second outer peripheral punching hole H8. In this case, after the through holes 10a and 11a, the inner slots 10i and the recessed grooves 10j and 11j of the first and second core materials 10 and 11 are formed by punching, as a final step, between the adjacent teeth 10e and 11e. By forming a slot punching hole H9 for forming the slots 10f and 11f and extracting the first and second core members 10 and 11 from the thin plate member 15, the shaving process is performed in a progressive press process. In this way, the shaving process can be carried out easily and in a state where the cost can be reduced. With this configuration, it is possible to incorporate shaving into the progressive press process even when manufacturing a core material in which no groove is formed in the outer peripheral edge of the tooth.
Further, as a removing means for removing the work-hardened portion formed on the outer peripheral edge portion of the punched core material, a technique by cutting can be used.

It is side surface sectional drawing of an electric motor. 2A and 2B are front views of the first and second core materials, respectively. It is a front view of the principal part of an electric motor. 4 (A), 4 (B), and 4 (C) are front views for explaining manufacturing procedures of the first and second core materials, respectively. FIGS. 5D and 5E are front views for explaining the manufacturing procedure of the first and second core materials, respectively. 6 (F), 6 (G), and 6 (H) are front views for explaining manufacturing procedures of the first and second core materials, respectively. FIGS. 7A and 7B are enlarged front views of main parts for explaining the manufacturing procedures of the first and second core materials, respectively. It is a graph which shows the magnetic flux amount in each of the electric motor each formed using the tooth | gear which carried out the shaving process, and the tooth | gear of the non-shaving process. FIGS. 9A and 9B are enlarged front views of main parts for explaining the manufacturing procedures of the first and second core materials in the second embodiment, respectively.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Electric motor 4 Armature 5 Armature shaft 6 Core material 7 Armature core 10 First core material 10a Through hole 10e Teeth 10f Coil slot 10h Bridge piece 10i Inner slot 11 Second core material H Shaft punching hole H1 First outer peripheral punching hole H2 Second outer peripheral punching hole N2 Second non-punching part

Claims (7)

  A core material of an armature core in which a plurality of teeth in the circumferential direction are arranged on the outer periphery of a through-hole through which an armature shaft passes, and when forming the core material by punching a thin plate material, A core material of an armature core in a rotating electrical machine, wherein the formed work-hardened portion is removed by a removing means.   The core member of the armature core in the rotating electric machine, wherein the removing means is a shaving process.   After punching the outer peripheral edge of each tooth of the core material when forming the core material of the armature core with a plurality of circumferential teeth disposed on the outer periphery of the through hole through which the armature shaft passes, by punching the thin plate material The manufacturing method of the core material of the armature core in the rotary electric machine, wherein the work hardening portion formed on the outer peripheral edge portion of each tooth is removed by the removing means.   The removing means is a shaving process, and a manufacturing method of a core material of an armature core in a rotating electric machine.   The shaving process is incorporated into the progressive press process that punches out each part of the core material in sequence, and the punched part is punched into the thin plate material by punching the outer diameter side of the part corresponding to the outer periphery of the teeth in an arc shape. A non-punched portion is formed between the punched portions adjacent to each other, a portion corresponding to the outer peripheral edge of the teeth is shaved through the punched portion, and then the non-punched portion is punched to extract the core material from the thin plate material. The manufacturing method of the core material of the armature core in the rotary electric machine of Claim 4 comprised as follows.   The method for manufacturing a core material of an armature core in a rotating electrical machine according to any one of claims 5 to 7, wherein the non-punched portion is formed on an outer diameter side of a portion corresponding to a portion between adjacent teeth in the circumferential direction.   Each tooth is formed with a recessed groove portion that is recessed on the inner diameter side at a circumferentially intermediate portion of the outer peripheral edge portion, and the non-punched portion is formed on the outer diameter side of the portion corresponding to the recessed groove portion. The manufacturing method of the core material of the armature core in the rotary electric machine as described in any one of claim | item 5.

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