JP2007295668A - Method of manufacturing core with no caulking trace - Google Patents

Method of manufacturing core with no caulking trace Download PDF

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Publication number
JP2007295668A
JP2007295668A JP2006118322A JP2006118322A JP2007295668A JP 2007295668 A JP2007295668 A JP 2007295668A JP 2006118322 A JP2006118322 A JP 2006118322A JP 2006118322 A JP2006118322 A JP 2006118322A JP 2007295668 A JP2007295668 A JP 2007295668A
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Prior art keywords
core
product
scrap
caulking
yoke
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Katsunori Imaji
克則 今地
Takaomi Shunan
隆男弥 秀南
Shinichi Sakamoto
真一 坂本
Kazuaki Irie
一明 入江
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Yaskawa Electric Corp
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Yaskawa Electric Corp
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Priority to JP2006118322A priority Critical patent/JP2007295668A/en
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/14—Stator cores with salient poles
    • H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
    • H02K1/148—Sectional cores
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/02—Details of the magnetic circuit characterised by the magnetic material
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/04—Details of the magnetic circuit characterised by the material used for insulating the magnetic circuit or parts thereof
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/08—Salient poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/022—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with salient poles or claw-shaped poles

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a core with no caulking trace which can reduce iron loss of a finished product. <P>SOLUTION: In the method of manufacturing a laminate core formed by punching multiple cores as products from a steel plate, and laminating the multiple cores; a caulking portion 12K is previously provided on a scrapped portion 12 adjacent to each product, the scrapped portion is punched from the steel plate, the product 11 is integrated with the scrapped portion 12, combined parts are integrated and formed into a block using the caulking portions 12K of the many pieces and taken out of a mold, each product 11 is fixed by main bonding or welding, and finally, each scrapped portion 12 is detached from the product 11 to obtain each product 11. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

本発明は、金型のコア積層方法に関するもので、特にカシメ跡のないコアの製造方法に関する。   The present invention relates to a method for laminating a core of a mold, and particularly relates to a method for producing a core without caulking marks.

従来より、打ち抜いたコアを金型内で積層し、ブロック化する方法として、
（１）コアの表面にＶカシメや丸カシメ等のカシメ突起を形成し、そのカシメを用いて積層する締結方法がある（第１の締結方法）。
（２）また、コア自体に予め接着剤を塗布して積層したり、型内に接着剤を塗布した打ち抜きでは、型内で高周波加熱や溶接といった大掛かりな設備で積層、ブロック化し、取り出す締結方法がある（第２の締結方法）。
図６は、従来技術１である丸カシメ方式による積層方法を説明する図で、（ａ）は内コア、（ｂ）は外コアをそれぞれ示す平面図である。
図６（ａ）において、６０は一体型内コアである。一体型内コア６０はポールシュー６１側を半径方向の中心側にし、ヨーク側端面６３を半径方向外側にして成るティース６２を多数個放射状に一体配設して成るものである。これを、放射状に形成された丸カシメ６０Ｋを用いて、多数個積層して一体化している。
一方、図６（ｂ）において、環状ヨーク外コア６５には丸カシメ６５Ｋが周方向に間隔を隔てて複数個形成されている。この丸カシメ６５Ｋを用いて環状ヨーク外コア６５を多数個積層して一体化している。
そこで、図６（ａ）の積層コア６０のティース６２に巻線をした後、図６（ｂ）のヨーク６５を焼きばめして一体にし、固定子を形成している。 Conventionally, as a method of stacking punched cores in a mold and making them into blocks,
(1) There is a fastening method in which caulking protrusions such as V caulking and round caulking are formed on the surface of the core, and lamination is performed using the caulking (first fastening method).
(2) In addition, when a core is coated with an adhesive in advance and laminated, or when punching is performed with an adhesive applied to a mold, a fastening method in which a large-scale facility such as high-frequency heating or welding is stacked, blocked, and removed. (Second fastening method).
6A and 6B are diagrams for explaining a stacking method by a round caulking method, which is the prior art 1, wherein FIG. 6A is a plan view showing an inner core and FIG. 6B is an outer core.
In FIG. 6A, reference numeral 60 denotes an integral inner core. The integral inner core 60 is formed by radially arranging a large number of teeth 62 each having a pole shoe 61 side in the radial center and a yoke side end surface 63 radially outward. A large number of them are stacked and integrated using a circular caulking 60K formed radially.
On the other hand, in FIG. 6B, a plurality of round caulking 65K are formed in the annular yoke outer core 65 at intervals in the circumferential direction. A plurality of annular yoke outer cores 65 are laminated and integrated using this round caulking 65K.
Therefore, after winding the teeth 62 of the laminated core 60 in FIG. 6A, the yoke 65 in FIG. 6B is shrink-fitted and integrated to form a stator.

図７は、従来技術２であるＶカシメ方式による積層方法（特許文献１参照）を説明する平面図である。図において、７０は分割型コア用ティースで、ティース７２の先端にポールシュー７１を、ポールシュー７１の反対側にヨーク７３をそれぞれ形成し、３箇所にＶカシメ７０Ｋを設けている。分割型コア用ティース７０を多数個Ｖカシメ７０Ｋを用いて積層したものを、それぞれヨーク７３を係合させて３６０度に亘って配設することで固定子を形成している。
特開２００４−３１２９３３号公報 FIG. 7 is a plan view for explaining a stacking method (see Patent Document 1) by the V-caulking method, which is the prior art 2. FIG. In the figure, reference numeral 70 denotes a split-type core tooth. A pole shoe 71 is formed at the tip of the tooth 72, a yoke 73 is formed on the opposite side of the pole shoe 71, and V caulking 70K is provided at three locations. A stator is formed by stacking a large number of split core teeth 70 using V caulking 70K, with the yokes 73 engaged and arranged over 360 degrees.
JP 2004-312933 A

ところが、前記第１の締結方法では、コア製品部にＶカシメや丸カシメを設けてブロック化していたので、Ｖカシメや丸カシメ部によって、製品の鉄損を大きくする不具合があった。
また、前記第２の締結方法では、金型内でコアをブロック化する場合、金型内に積層コアを固着するための加熱装置や溶接装置を必要とするため、金型が複雑な構造となるし、金型内に加熱装置を組み込む場合、金型の温度上昇により、鉄心打ち抜き精度がばらつく問題があった。
本発明はこれらの課題を解決するためになされたもので、積層コアを固着するための加熱装置や溶接装置を金型内に必要としないようにしたので、金型が複雑な構造とならず、また金型内に加熱装置を組み込む場合の鉄心打ち抜き精度がばらつく問題もなくなり、コア製品部にＶカシメや丸カシメを設けることがないため、製品の鉄損を小さくできるカシメなしコアの製造方法を提供することを目的としている。 However, in the first fastening method, V caulking or round caulking is provided in the core product portion to form a block, so there is a problem that the iron loss of the product is increased by the V caulking or round caulking portion.
Further, in the second fastening method, when the core is blocked in the mold, a heating device and a welding device for fixing the laminated core in the mold are required, so that the mold has a complicated structure. However, when the heating device is incorporated in the mold, there is a problem that the punching accuracy of the iron core varies due to the temperature rise of the mold.
The present invention has been made to solve these problems, and since a heating device and a welding device for fixing the laminated core are not required in the mold, the mold does not have a complicated structure. In addition, since there is no problem that the iron core punching accuracy varies when the heating device is incorporated in the mold, and there is no provision of V caulking or round caulking in the core product part, the manufacturing method of the caulking-free core that can reduce the iron loss of the product The purpose is to provide.

これらの課題を解決するために、本発明では、廃物であるスクラップ部を利用してこれにＶカシメや丸カシメを設け、これを製品とフラットプッシュバックによって一体でブロック化し、抜き落としを行なうようにするものである。スクラップ部と製品間は、切欠きと弾性をもつ構造のスリットにより保持される。金型より、取り出されたブロックを加熱硬化や溶接を行なった後、スクラップ部を取り外すようにしている。   In order to solve these problems, in the present invention, a scrap portion which is a waste is used, and a V caulking or a round caulking is provided on the scrap portion, and the product and the flat pushback are integrated into a block to be removed. It is to make. The scrap part and the product are held by a slit having a notch and elasticity. After the block taken out from the mold is heat-cured and welded, the scrap portion is removed.

具体的には、請求項１記載の発明は、カシメなしコアの製造方法に係り、鋼板から製品部としてのコアを多数個打ち抜き、該多数のコアを積層して成る積層コアの製造方法において、前記製品部に隣接するスクラップ部に予めカシメ部を設け、前記スクラップ部を前記鋼板から打ち抜いた後に前記スクラップ部をプッシュバックにより前記製品部と一体化し、当該一体化したものを多数個前記カシメ部を用いて積層ブロック化して、金型から取り出し、前記製品部を本接着又は溶接で固めて、最後に前記スクラップ部を前記製品部から取り外して製品を得ることを特徴としている。
請求項２記載の発明は、請求項１記載のカシメなしコアの製造方法において、前記製品部が、ポールシュー側を半径方向中心側にかつヨーク側を半径方向外側にして成るティースを多数個放射状に一体配設した一体型内コアであり、前記スクラップ部が、前記一体型内コアのポールシュー側に隣接して成る環状捨て抜き部であることを特徴としている。
請求項３記載の発明は、請求項１記載のカシメなしコアの製造方法において、前記製品部が、一体型内コアを内側に内接収容するための環状ヨーク外コアであり、前記スクラップ部が、前記環状ヨーク外コアの外周に隣接して成る捨て抜き外周部であることを特徴としている。
請求項４記載の発明は、請求項２又は３記載のカシメなしコアの製造方法において、前記スクラップ部の一部が半径方向に切り欠かれていることを特徴としている。
請求項５記載の発明は、請求項１記載のカシメなしコアの製造方法において、前記製品部が、先端にポールシューをかつ前記ポールシューの反対側にヨークを形成し、隣接のティースのヨークと係合するための係合部をそれぞれ前記ヨークの両端に形成しさらに切り欠きを前記ヨークの外周中央部に形成して成る分割型コア用ティースであり、前記スクラップ部が、前記切り欠きに嵌合可能な突起を備え前記ヨークの外周にプッシュバックされるスクラップ固着部であることを特徴としている。
請求項６記載の発明は、請求項５記載のカシメなしコアの製造方法において、前記突起にスリットを半径方向に形成したことを特徴としている。 Specifically, the invention according to claim 1 relates to a manufacturing method of a core without crimping, in a manufacturing method of a laminated core formed by punching a large number of cores as product parts from a steel plate and laminating the multiple cores. The scrap part adjacent to the product part is preliminarily provided with a caulking part, and after the scrap part is punched out from the steel plate, the scrap part is integrated with the product part by pushback, and a plurality of the caulking parts are integrated. Is formed into a laminated block, taken out from the mold, the product part is solidified by main bonding or welding, and finally the scrap part is removed from the product part to obtain a product.
According to a second aspect of the present invention, in the method for manufacturing a crimpless core according to the first aspect, the product portion has a plurality of teeth in which the pole shoe side is a radial center side and the yoke side is a radial outer side. And the scrap portion is an annular dumping portion formed adjacent to the pole shoe side of the integral inner core.
According to a third aspect of the present invention, in the method for manufacturing a caulkingless core according to the first aspect, the product portion is an annular yoke outer core for internally accommodating the integrated inner core, and the scrap portion is The outer peripheral portion of the annular yoke is adjacent to the outer periphery of the annular yoke, and is a discarded outer peripheral portion.
According to a fourth aspect of the present invention, in the method for manufacturing a crimpless core according to the second or third aspect, a part of the scrap portion is cut out in a radial direction.
According to a fifth aspect of the present invention, in the method for manufacturing a crimpless core according to the first aspect, the product portion includes a pole shoe at a tip and a yoke on the opposite side of the pole shoe, and a yoke of an adjacent tooth. A split-type core tooth in which engaging portions for engaging are formed at both ends of the yoke and a notch is formed in the central portion of the outer periphery of the yoke, and the scrap portion is fitted into the notch. It is a scrap adhering portion provided with a matable protrusion and pushed back to the outer periphery of the yoke.
According to a sixth aspect of the present invention, in the method for manufacturing a crimpless core according to the fifth aspect, a slit is formed in the projection in the radial direction.

これにより、積層コアを固着するための加熱装置や溶接装置を金型内に必要としないので、金型が複雑な構造とならず、また金型内に加熱装置を組み込む場合の鉄心打ち抜き精度がばらつく問題もなくなり、コア製品部にＶカシメや丸カシメを設けることがないため、一体型コアおよび分割型コアのいずれにおいても製品の鉄損を小さくできるカシメなしコアの製造方法が得られるようになる。   This eliminates the need for a heating device or welding device for fixing the laminated core in the mold, so that the mold does not have a complicated structure, and the core punching accuracy when the heating device is incorporated in the mold is high. There is no problem of variation, and there is no need to provide V caulking or round caulking in the core product part, so that a manufacturing method of a caulking-free core that can reduce the iron loss of the product in both the integral core and the split core is obtained. Become.

以下に本発明について図面に基づいて詳細に説明する。   Hereinafter, the present invention will be described in detail with reference to the drawings.

図１は、本発明の実施例１に係るカシメなしコアの製造方法を説明する平面図で、（ａ）は一体型内コア部近傍図、（ｂ）は環状ヨーク外コア部近傍図をそれぞれ示している。
図１（ａ）において、１０は一体型内コアプッシュバック部、１１は製品部である一体型内コア、１２はスクラップ部である環状コア、ＰＢ（点線部）はプッシュバック部位、１１Ｐは内コアのポールシュー、１１Ｔはティース，１１Ｙはヨーク側端面、１２Ｋはスクラップ部１２に設けられた丸カシメである。
製品部は一体型内コア１１であり、これはポールシュー１１Ｐ側を半径方向の中心側にしてかつヨーク側端面１１Ｙを半径方向の外側にして成るティース１１Ｔを多数個（図では９個）放射状に一体配設した一体型内コアである。スクラップ部１２は環状コアであり、これには丸カシメ１２Ｋが環状コア１２の全周に亘って複数箇所（図では４箇所）設けられており、この環状コア１２の外周が一体型内コア１１のポールシュー１１Ｐ側にプッシュバックされている。
ここで、プッシュバックとは、打ち抜いた製品をスクラップの中に押し戻すことである。この場合、打ち抜かれた製品はダイの中に入るので、ダイの中の製品を排出する必要があり、そのためノックアウト機構で、打ち抜いた製品をダイから排出し、スクラップの中に押し戻すこととなる。この打ち抜いた製品をダイから排出し、スクラップの中に製品を再度押し戻す方法をプッシュバック法という。その後、スクラップから製品を取り外して回収する。
製品部１１とスクラップ部１２とをプッシュバックで一体化したもの１０を多数個そのカシメ部１２Ｋを用いて積層ブロック化して、金型から取り出す。
その後、製品部１１を本接着又は溶接で固め、最後にカシメ１２Ｋのあるスクラップ部１２を製品部１１から取り外すことにより、カシメ部１２Ｋのない製品１１が得られることとなる。
このように、本発明によれば、コアの製品部１１にＶカシメや丸カシメを設けることがないため、固定子の一体型内コアの鉄損を小さくすることができる。
また、後工程で接着や溶接を行った後、スクラップ部１２を製品部１１から分離し易くするため、切欠き１２Ｓをスクラップ部１２に設けている。 1A and 1B are plan views for explaining a manufacturing method of a caulking-free core according to Embodiment 1 of the present invention, wherein FIG. 1A is a view showing the vicinity of an integral inner core portion, and FIG. Show.
In FIG. 1A, 10 is an integrated inner core pushback portion, 11 is an integrated inner core that is a product portion, 12 is an annular core that is a scrap portion, PB (dotted line portion) is a pushback portion, and 11P is an inner portion. A core pole shoe, 11T is a tooth, 11Y is a yoke side end surface, and 12K is a round caulking provided in the scrap portion 12.
The product part is an integrated inner core 11 which has a large number (9 in the figure) of teeth 11T having the pole shoe 11P side in the radial center and the yoke side end surface 11Y in the radial direction. It is an integral type inner core that is integrally disposed on the inside. The scrap portion 12 is an annular core, and a round caulking 12K is provided at a plurality of locations (four locations in the figure) over the entire circumference of the annular core 12, and the outer periphery of the annular core 12 is the integrated inner core 11. Is pushed back to the pole shoe 11P side.
Here, the push back is to push the punched product back into the scrap. In this case, since the punched product enters the die, it is necessary to discharge the product in the die. For this reason, the punched product is discharged from the die and pushed back into the scrap by the knockout mechanism. The method of discharging the punched product from the die and pushing the product back into the scrap is called a pushback method. Thereafter, the product is removed from the scrap and collected.
A large number of product parts 11 and scrap parts 12 integrated by pushback 10 are laminated into blocks using the crimping parts 12K, and are taken out from the mold.
Thereafter, the product part 11 is solidified by main bonding or welding, and finally the scrap part 12 with the crimp 12K is removed from the product part 11 to obtain the product 11 without the crimp part 12K.
Thus, according to the present invention, V caulking or round caulking is not provided in the product part 11 of the core, so that the iron loss of the integral inner core of the stator can be reduced.
In addition, a notch 12S is provided in the scrap portion 12 in order to facilitate separation of the scrap portion 12 from the product portion 11 after bonding and welding in a subsequent process.

以上は本発明を固定子の一体型内コアの製造に適用する例で説明したが、同じことは、固定子の環状ヨーク外コア部についても適用することができる。
図１（ｂ）において、１５は環状ヨーク外コアプッシュバック部、１６は環状ヨーク外コア部、１７はスクラップ部、ＰＢ（点線部）はプッシュバック部位、１７Ｋはスクラップ部１７に設けられたＶカシメ、１７Ｓはスリットである。
ここでの製品部は環状ヨーク外コア部１６であり、これは珪素鋼板から打ち抜かれた後、スクラップ部１７にプッシュバックされている。
製品部１６とスクラップ部１７とをプッシュバックで一体化したもの１５を多数個そのカシメ部１７Ｋを用いて積層ブロック化して、金型から取り出す。
その後、製品部１６を本接着又は溶接で固め、最後にカシメ１７Ｋのあるスクラップ部１７を製品部１６から取り外すことにより、カシメ部１７Ｋのない製品１６が得られることとなる。
このように、本発明によれば、コアの製品部１６にＶカシメや丸カシメを設けることがないため、固定子の環状ヨーク外コア部の鉄損を小さくすることができる。 The above is an example in which the present invention is applied to the manufacture of an integral inner core of a stator, but the same can be applied to an annular yoke outer core portion of a stator.
In FIG. 1B, 15 is an annular yoke outer core pushback portion, 16 is an annular yoke outer core portion, 17 is a scrap portion, PB (dotted line portion) is a pushback portion, and 17K is a V provided in the scrap portion 17. Caulking 17S is a slit.
The product part here is an annular yoke outer core part 16 which is punched out of a silicon steel plate and then pushed back to the scrap part 17.
A large number of product parts 16 and scrap parts 17 integrated by pushback 15 are formed into laminated blocks using the caulking parts 17K and taken out from the mold.
Thereafter, the product part 16 is solidified by main bonding or welding, and finally the scrap part 17 with the caulking 17K is removed from the product part 16, whereby the product 16 without the caulking part 17K is obtained.
As described above, according to the present invention, V caulking or round caulking is not provided in the product portion 16 of the core, so that the iron loss of the annular yoke outer core portion of the stator can be reduced.

そこで、この後、図１（ａ）の積層コア１０のティース１１Ｔに巻線をした後、図１（ｂ）のヨーク１６を焼きばめして一体にすることで、固定子を形成している。
また、後工程で接着や溶接を行った後、スクラップ部１７を製品部１６から分離し易くするため、切欠き１７Ｓをスクラップ部１７に設けている。 Therefore, after this, after winding the teeth 11T of the laminated core 10 of FIG. 1A, the yoke 16 of FIG. 1B is shrink-fitted and integrated to form a stator. .
In addition, a notch 17 </ b> S is provided in the scrap portion 17 in order to facilitate separation of the scrap portion 17 from the product portion 16 after bonding and welding in a subsequent process.

図２は、積層されたコア（図１（ｂ）のＸ−Ｘの切断線）の縦断面で、スクラップ部１７と製品ヨーク部１６が、プッシュバック（ＰＢ線）された円弧上で一体となり、この状態で金型より搬出される。スクラップ部１７はＶカシメ１７Ｋで締結されているのが判る。   FIG. 2 is a longitudinal section of the laminated core (XX cutting line in FIG. 1B), and the scrap portion 17 and the product yoke portion 16 are integrated on the arc that is pushed back (PB line). In this state, it is unloaded from the mold. It can be seen that the scrap portion 17 is fastened with V caulking 17K.

図３は、本発明の実施例２に係るカシメなしコアの製造方法を説明する平面図である。図において、３０は分割型コアプッシュバック部、３１は製品部としての分割型コア、３１ａは係合凹部、３１ｂは係合凸部、３１Ｋは切り欠き部、３１Ｐはポールシュー、３１Ｔはティース，３１Ｙはヨーク、３５はスクラップ部、３５ａは係合凸部、３５ｂは係合凸部３５ａの中央に形成されたスリット、３５Ｖはスクラップ部３５に設けられたＶカシメ、ＰＢ（点線部）はプッシュバック部位である。分割型コア３１は、中央部がティース３１Ｔで、先端にポールシュー３１Ｐを、ポールシュー３１ｐの反対側にヨーク３１Ｙをそれぞれ形成し、ヨーク３１Ｙの両端に係合凹部（図で右端）３１ａと係合凸部（図で左端）３１ｂを形成されている。これを多数個積層し、ティース３１Ｔに巻線を施した後、この係合凹部３１ａに別の分割型コア３１の積層体の係合凸部３１ｂを係合させ、これを繰り返すことにより、最終的に環状のコア（すなわち、固定子）が出来上がる。
実施例２では分割型コア３１のヨーク３１Ｙの外周中央部に切り欠き３１Ｋを形成している点が特徴で、この切り欠き３１Ｋにフラットプッシュバックにより、実施例２に係るスクラップ部３５の分割型コア３１の係合凸部３５ａを挿嵌することで、分割型コア３１と一体となりブロック化して、金型から取り出す。
スリット３５ｂは、後工程で接着や溶接固定された後、スクラップ部３５が容易に取り外せる形状としている。
その後、製品部３１を本接着又は溶接で固め、最後にスクラップ部３５を製品部３１から取り外すことにより、カシメ部３５Ｖのない製品３１が得られることとなる。
このように、本発明によれば、コアの製品部３１にＶカシメや丸カシメを設けることがないため、固定子の環状ヨーク外コア部の鉄損を小さくすることができる。
図４は、実施例２により積層されたコアの縦断面で、スクラップ部３５と製品部３１が、プッシュバックされて両者一体となりブロック化され、この状態で金型より搬出される。スクラップ部３５はＶカシメ３５Ｋで締結されている。 FIG. 3 is a plan view for explaining a manufacturing method of a crimpless core according to the second embodiment of the present invention. In the figure, 30 is a split-type core pushback part, 31 is a split-type core as a product part, 31a is an engaging concave part, 31b is an engaging convex part, 31K is a notch part, 31P is a pole shoe, 31T is a tooth, 31Y is a yoke, 35 is a scrap part, 35a is an engaging convex part, 35b is a slit formed at the center of the engaging convex part 35a, 35V is a V caulking provided in the scrap part 35, and PB (dotted line part) is a push It is the back part. The split core 31 has a tooth 31T at the center, a pole shoe 31P at the tip, a yoke 31Y on the opposite side of the pole shoe 31p, and an engagement recess (right end in the figure) 31a at both ends of the yoke 31Y. A joint convex portion (left end in the figure) 31b is formed. After laminating a large number of them and winding the teeth 31T, the engagement protrusions 31b of another laminate of the split cores 31 are engaged with the engagement recesses 31a, and this is repeated, so that the final An annular core (ie, stator) is completed.
The second embodiment is characterized in that a notch 31K is formed in the central portion of the outer periphery of the yoke 31Y of the split-type core 31. The flat-type pushback is used for the notch 31K, so that the split type of the scrap portion 35 according to the second embodiment is used. By inserting and fitting the engaging convex portion 35a of the core 31, it is integrated with the split core 31 to form a block and is taken out from the mold.
The slit 35b has a shape that allows the scrap portion 35 to be easily removed after being bonded or welded and fixed in a subsequent process.
Thereafter, the product part 31 is solidified by main bonding or welding, and finally, the scrap part 35 is removed from the product part 31 to obtain the product 31 without the crimping part 35V.
As described above, according to the present invention, V caulking or round caulking is not provided in the product portion 31 of the core, so that the iron loss of the annular yoke outer core portion of the stator can be reduced.
FIG. 4 is a longitudinal cross-sectional view of cores laminated according to the second embodiment. The scrap part 35 and the product part 31 are pushed back to be integrated into a block, and are transported from the mold in this state. The scrap part 35 is fastened by V caulking 35K.

図５は、実施例２の抜き型レイアウトの１例で、（Ａ）は打ち抜く迄の平面図、（Ｂ）は取り外しの説明をする平面図である。
図（Ａ）において、加工ステーション（イ）〜（ホ）を経て、珪素鋼板Ｗから固定子鉄心の構成部品であるコア３１を製造する。
まず、加工ステーション（イ）でパイロット穴Ｐから所定の間隔をおいて、スリット３５ｂをあける。
次に、加工ステーション（ロ）でパイロット穴Ｐから上記間隔をおいてスリット３５ｂを含んだスクラップ部３５を打ち抜き、その後プッシュバックする。
また、スクラップ部３５の中央線を挟んで下方の左右対称の位置にポールシュー形成穴Ｓ１、Ｓ２を開ける。
加工ステーション（ハ）はアイドル工程である。
加工ステーション（ニ）では、Ｖカシメ３５Ｖを形成する。
加工ステーション（ホ）では、製品ヨーク部３１をブランキング（打ち抜き）する。
以上の工程を経て、製品ヨーク部３１とプッシュバックで一体化されたスクラップ部３５とから成る一体物Ｓ１が得られる。
同様にして、順次製造される一体物Ｓ２，Ｓ３，・・・を所定数積層して、ブロック化して、金型から取り出す。その後、製品ヨーク部３１を本接着又は溶接で固める（図Ｂの（Ｉ）参照）。最後に、スクラップ部（図ＢのＩａ）を取り外して製品（図ＢのＩｂ）とする。
このように、Ｖカシメを形成したスクラップ部３５が最終的に取り外されて、製品コア部３１にはＶカシメがないので、固定子の鉄損を小さくすることができる。
なお、図５では、判り易くするために、珪素鋼板から一体物Ｓ１を１個打ち抜く例で説明したが、実際は加工ステーション（イ）と（ロ）の中間において、加工ステーション（イ）と同じ打ち抜き動作を図で上下１８０度逆転して行わせ、同じく、加工ステーション（ロ）と（ハ）の中間においても、加工ステーション（ロ）と同じ打ち抜き動作を図で上下１８０度逆転して行わせ、以下、同様なことを行わせることで、珪素鋼板を無駄なく利用することができ、省資源となる。 FIGS. 5A and 5B show an example of the punching die layout of the second embodiment. FIG. 5A is a plan view until punching, and FIG. 5B is a plan view for explaining removal.
In FIG. (A), the core 31 which is a component part of a stator core is manufactured from the silicon steel plate W through the processing stations (a) to (e).
First, the slit 35b is opened at a predetermined interval from the pilot hole P at the processing station (a).
Next, the scrap portion 35 including the slit 35b is punched out from the pilot hole P at the processing station (b), and then pushed back.
Further, pole shoe formation holes S1 and S2 are opened at symmetrical positions below the center line of the scrap portion 35.
The processing station (c) is an idle process.
In the processing station (d), V caulking 35V is formed.
At the processing station (e), the product yoke portion 31 is blanked (punched).
Through the above steps, an integrated object S1 including the product yoke portion 31 and the scrap portion 35 integrated by pushback is obtained.
Similarly, a predetermined number of integrally manufactured products S2, S3,... Are stacked, formed into blocks, and taken out from the mold. Thereafter, the product yoke portion 31 is hardened by main bonding or welding (see (I) in FIG. B). Finally, the scrap part (Ia in FIG. B) is removed to obtain a product (Ib in FIG. B).
Thus, since the scrap part 35 in which the V caulking is formed is finally removed and the product core part 31 has no V caulking, the iron loss of the stator can be reduced.
In FIG. 5, for the sake of easy understanding, an example in which one piece S1 is punched from a silicon steel plate has been described. However, in practice, the punching is the same as that of the processing station (A) between the processing stations (A) and (B). The operation is reversed 180 degrees up and down in the figure, and similarly, the same punching operation as the processing station (b) is reversed 180 degrees up and down in the figure between the machining stations (b) and (c). Hereinafter, by performing the same thing, the silicon steel sheet can be used without waste, thereby saving resources.

以上のように、本発明によれば、積層コアを固着するための加熱装置や溶接装置を金型内に必要としないので、金型が複雑な構造とならず、また金型内に加熱装置を組み込む場合の鉄心打ち抜き精度がばらつく問題もなくなる。
また、スクラップ部にＶカシメや丸カシメを設け、コア製品部にはＶカシメや丸カシメを設けることがないため、一体型コアおよび分割型コアのいずれにおいても製品の鉄損を小さくできるようになる。 As described above, according to the present invention, since a heating device and a welding device for fixing the laminated core are not required in the mold, the mold does not have a complicated structure, and the heating device is provided in the mold. The problem that the punching accuracy of the iron core varies in the case of incorporating the iron is also eliminated.
In addition, since there is no V caulking or round caulking in the scrap part and no V caulking or round caulking in the core product part, the iron loss of the product can be reduced in both the integral core and the split core. Become.

本発明の実施例１に係るカシメなしコアの製造方法を説明する平面図で、（ａ）は一体型内コア部近傍、（ｂ）は環状ヨーク外コア部近傍をそれぞれ示している。BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1A is a plan view for explaining a caulkingless core manufacturing method according to Embodiment 1 of the present invention, where FIG. 1A shows the vicinity of an integral inner core portion, and FIG. 積層されたコア（図１（ｂ）のＸ−Ｘの切断線）の縦断面である。It is a longitudinal cross-section of the laminated | stacked core (XX cutting line of FIG.1 (b)). 本発明の実施例２に係るカシメなしコアの製造方法を説明する平面図である。It is a top view explaining the manufacturing method of the crimpless core which concerns on Example 2 of this invention. 実施例２により積層されたコアの縦断面である。4 is a longitudinal section of a core laminated according to Example 2. 実施例２の抜き型レイアウトの１例で、（Ａ）は打ち抜く迄の平面図、（Ｂ）は取り外しの説明をする平面図である。In the example of the punching die layout of Example 2, (A) is a plan view until punching, and (B) is a plan view for explaining removal. 従来技術１である丸カシメ方式による積層方法を説明する図で、（ａ）は内コア、（ｂ）は外コアをそれぞれ示す平面図である。It is a figure explaining the lamination | stacking method by the round crimping method which is the prior art 1, (a) is an inner core, (b) is a top view which shows an outer core, respectively. 従来技術２であるＶカシメ方式による積層方法を説明する平面図である。It is a top view explaining the lamination | stacking method by the V caulking system which is the prior art 2. FIG.

符号の説明Explanation of symbols

１０ 一体型内コアプッシュバック部
１１ 一体型内コア（製品部）
１１Ｐ 内コアのポールシュー
１１Ｔ ティース
１１Ｙ ヨーク
１２ 環状コア（スクラップ部）
１２Ｋ 丸カシメ
１２Ｓ 切欠き
１５ 環状ヨーク外コアプッシュバック部
１６ 環状ヨーク外コア（製品）部
１７ スクラップ部
１７Ｋ Ｖカシメ
１７Ｓ スリット
３０ 分割型コアプッシュバック部
３１ 分割型コア
３１ａ 係合凹部
３１ｂ 係合凸部
３１Ｋ 切り欠き部
３１Ｐ ポールシュー
３１Ｔ ティース
３１Ｙ ヨーク
３５ スクラップ部
３５ａ 係合凸部
３５ｂ スリット
３５Ｖ Ｖカシメ
ＰＢ プッシュバック部位 10 Integrated inner core pushback part 11 Integrated inner core (product part)
11P pole shoe of inner core 11T teeth 11Y yoke 12 annular core (scrap part)
12K Round caulking 12S Notch 15 Annular yoke outer core pushback part 16 Annular yoke outer core (product) part 17 Scrap part 17K V caulking 17S Slit 30 Divided core pushback part 31 Divided core 31a Engaging recess 31b Engaging protrusion Part 31K Notch part 31P Pole shoe 31T Teeth 31Y Yoke 35 Scrap part 35a Engaging convex part 35b Slit 35V V caulking PB Pushback part

Claims (6)

鋼板から製品部としてのコアを多数個打ち抜き、該多数のコアを積層して成る積層コアの製造方法において、前記製品部に隣接するスクラップ部に予めカシメ部を設け、前記スクラップ部を前記鋼板から打ち抜いた後に前記スクラップ部をプッシュバックにより前記製品部と前記スクラップ部とを一体化し、当該一体化したものを多数個前記カシメ部を用いて積層ブロック化して、金型から取り出し、前記製品部を本接着又は溶接で固めて、最後に前記スクラップ部を前記製品部から取り外して製品を得ることを特徴とするカシメなしコアの製造方法。   In a manufacturing method of a laminated core formed by punching a large number of cores as product parts from a steel plate and laminating the many cores, a caulking part is provided in advance in a scrap part adjacent to the product part, and the scrap part is removed from the steel plate. After punching, the scrap part is integrated with the product part and the scrap part by pushback, and a plurality of the integrated parts are formed into a laminated block using the caulking part, taken out from the mold, and the product part is removed. A caulking-free core manufacturing method, wherein the core is solidified by main bonding or welding, and finally the scrap portion is removed from the product portion to obtain a product. 前記製品部が、ポールシュー側を半径方向中心側にかつヨーク側を半径方向外側にして成るティースを多数個放射状に一体配設した一体型内コアであり、
前記スクラップ部が、前記一体型内コアのポールシュー側に隣接して成る環状捨て抜き部であることを特徴とする請求項１記載のカシメなしコアの製造方法。 The product part is an integral inner core in which a large number of teeth each having a pole shoe side as a radial center side and a yoke side as a radial outside are integrally arranged radially,
2. The method of manufacturing a crimpless core according to claim 1, wherein the scrap portion is an annular discard portion formed adjacent to the pole shoe side of the integral inner core. 前記製品部が、一体型内コアを内側に内接収容するための環状ヨーク外コアであり、
前記スクラップ部が、前記環状ヨーク外コアの外周に隣接して成る捨て抜き外周部であることを特徴とする請求項１記載のカシメなしコアの製造方法。 The product part is an annular yoke outer core for inscribed accommodation of the integral inner core inside;
The method for producing a crimpless core according to claim 1, wherein the scrap portion is a discarded outer peripheral portion formed adjacent to the outer periphery of the annular yoke outer core. 前記スクラップ部の一部が半径方向に切り欠かれていることを特徴とする請求項２又は３記載のカシメなしコアの製造方法。   The method for manufacturing a crimpless core according to claim 2 or 3, wherein a part of the scrap portion is cut out in a radial direction. 前記製品部が、先端にポールシューをかつ前記ポールシューの反対側にヨークを形成し、隣接のティースのヨークと係合するための係合部をそれぞれ前記ヨークの両端に形成しさらに切り欠きを前記ヨークの外周中央部に形成して成る分割型コア用ティースであり、
前記スクラップ部が、前記切り欠きに嵌合可能な突起を備え前記ヨークの外周にプッシュバックされるスクラップ固着部であることを特徴とする請求項１記載のカシメなしコアの製造方法。 The product part is formed with a pole shoe at the tip and a yoke on the opposite side of the pole shoe, and engaging parts for engaging with yokes of adjacent teeth are formed at both ends of the yoke, respectively, and further cutouts are formed. It is a tooth for a split type core formed at the outer peripheral center of the yoke,
The method of manufacturing a crimpless core according to claim 1, wherein the scrap portion is a scrap fixing portion that includes a protrusion that can be fitted into the notch and is pushed back to the outer periphery of the yoke. 前記突起にスリットを半径方向に形成したことを特徴とする請求項５記載のカシメなしコアの製造方法。   6. The method of manufacturing a crimpless core according to claim 5, wherein a slit is formed in the projection in a radial direction.
JP2006118322A 2006-04-21 2006-04-21 Method of manufacturing core with no caulking trace Pending JP2007295668A (en)

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