JP2008011615A - Method of manufacturing laminated core, and that laminated core - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a laminated core where laminated cores are fastened with one another by a strong caulking force, and its manufacturing method. <P>SOLUTION: This manufacturing method for a laminated core has a process of blanking the lowest core piece, where an upward caulking projection 10Bt projected to its topside as a caulking part and a through are formed, a process of blanking core pieces up to the second highest sheet where upward caulking projections 10At projected to its topside as caulking parts and through holes are formed, a process of blanking the highest core piece, where a downward caulking projection projected to its downside as a caulking part and a through 10C are formed, and a process of caulking and laminating a plurality of core pieces integrally from the lowest core piece to the highest core piece by caulking and coupling the upward caulking projections and the fellow downward caulking projections to each other. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

    The present invention relates to a method for manufacturing a laminated core in which iron core pieces are formed by punching from a metal plate, and the laminated iron core pieces are caulked and bonded, and a laminated iron core produced by the manufacturing method.

    For example, a laminated core constituting a motor core (rotor / stator), which is a main part of an electric motor, is punched into a predetermined shape from a metal plate (outlined) in order to increase the output and efficiency of the electric motor. The laminated iron core pieces are laminated, and the laminated iron core pieces are caulked and integrated with each other.

  In addition, the laminated iron core does not cause a gap between the laminated iron core pieces so that the iron core pieces are not opened or separated during the manufacturing process or during the assembly of the electric motor. The caulking connection must be made with a strong fastening force.

  Here, the caulking connection between the core pieces in the conventional laminated iron core is performed by using the caulking portion formed by the half punching protrusion, the V-shaped protrusion, the half punching protrusion, or the like on the other core piece. Although the core pieces that are generally laminated are firmly caulked and bonded to each other on the back side recess of the part, for reasons of the manufacturing process, the caulking strength in the lowermost layer and the lower layer is reduced, so that There is a problem that a gap is generated in a part of the iron core, or in a case where the iron core piece is peeled off in a remarkable case.

In order to solve the problems as described above, a technique for improving the caulking strength between core pieces in a laminated core is provided (for example, see Patent Document 1).
The laminated iron core A shown in FIG. 10 and FIG. 11 is formed by laminating a predetermined number of iron core pieces B formed with a plurality of caulking protrusions Bc and through holes Bo projecting on one side, and caulking and joining them together. It is manufactured by.

  Further, the laminated core A is formed by separately forming a block B1 and a block B2 obtained by laminating a predetermined number of core pieces B, B... And superimposing the caulking protrusions Bc, and the caulking protrusion Bc of the block B1 is formed by the block B2. In addition to being inserted into the through hole Bo, the caulking projection Bc of the block B2 is made into the through hole Bo of the block B1, and the block B1 and the block B2 are pressed against each other to be caulked and joined.

In the laminated iron core A having the above-described configuration, the upward caulking protrusions Bc exist in the lowermost layer and the lower layer, and the superposed caulking protrusions Bc extend over the plurality of iron core pieces B. The improvement of the caulking strength between B is recognized.
JP 2000-37051 A

    By the way, in the conventional laminated iron core A shown in FIG. 10 and FIG. 11, the block B1 and the block B2 formed by caulking and laminating a predetermined number of iron core pieces B, B. After that, the block B1 and the block B2 taken out from the press mold apparatus must be crimped together in a dedicated assembly apparatus, and the manufacturing process is complicated, resulting in inconvenience that the productivity is inferior.

  In the laminated core A having the above-described configuration, since the block B1 and the block B2 are joined to each other with the block B1 and the block B2, the block B1 and the block B2 have a through hole Bo through which the caulking protrusion Bc is not inserted. The caulking strength is not necessarily sufficient, especially in laminated cores using thin core pieces (for example, around 0.2 mm) and large (large-diameter) laminated cores. There was an inconvenience.

  An object of the present invention is to provide a laminated core in which laminated cores are fastened with high caulking strength and the cores do not open or peel off with good productivity in view of the above-described actual situation. It is providing the manufacturing method of an iron core, and the laminated iron core manufactured according to this manufacturing method.

    In order to achieve the above object, a manufacturing method of a laminated core according to the invention of claim 1 is characterized in that a core piece formed with a crimped portion by press working is externally removed from a metal plate, and a plurality of laminated core pieces are interposed via the crimped portion. A method of manufacturing a laminated iron core that is integrally coupled to each other, the step of extruding at least the lowest core piece formed with an upward caulking projection and a through hole protruding upward as a caulking portion; Removing the outer shape of at least one uppermost iron core piece formed with upward caulking protrusions protruding upward as upper portions and downward caulking protrusions protruding downward, and following this step as caulking portions downward A projecting downward caulking projection and a step of extracting the outermost at least uppermost iron core piece formed with a through hole, and when caulking the upward caulking projections together To, by caulking the down caulking projections to each other, it is characterized by caulking integrally laminated multiple core sheets from the bottom of the core pieces to core pieces of the highest level.

  The laminated iron core according to the invention of claim 2 is a laminated iron core formed by extruding an outer shape of an iron core piece having a crimped portion formed by press working from a metal plate and integrally bonding the laminated iron core pieces to each other via the crimped portion. And an upward caulking projection protruding upward as a caulking portion and at least the lowest iron core piece forming a through hole, an upward caulking projection protruding toward the upper surface as a caulking portion, and a downward projection protruding toward the lower surface as a caulking portion An iron core piece from at least one lowermost sheet forming the caulking protrusion to at least one lowermost sheet, a downward caulking protrusion protruding to the lower surface side as a caulking part, and at least the uppermost iron core piece forming a through hole; A plurality of core pieces from the lowermost core piece to the uppermost core piece by the caulking connection between the upward caulking protrusions and the caulking connection between the downward caulking protrusions. Characterized in that it is caulked integrally laminated.

    According to the manufacturing method of the laminated core according to the invention of claim 1, the cores from the lowest core piece to the uppermost core piece are formed by caulking the upward caulking projections and caulking the downward caulking projections. Since the pieces are integrally caulked and laminated, the laminated iron core pieces are fastened with high caulking strength, so that a laminated iron core in which the iron core pieces are unlikely to open and peel can be obtained.

  Further, according to the method for manufacturing a laminated core according to the present invention, a laminated core formed by caulking and bonding all the core pieces from the start of lamination to the end of lamination with both upward and downward caulking protrusions, It will be manufactured consistently by a series of press work, and it becomes possible to manufacture a laminated core that can suppress the opening and peeling of the core piece as much as possible with extremely good productivity.

  According to the laminated core relating to the invention of claim 2, the core pieces from the lowest core piece to the uppermost core piece are integrated by the caulking connection between the upward caulking protrusions and the caulking connection between the downward caulking protrusions. Since caulking is performed, the laminated iron core pieces are fastened with high caulking strength, and the iron core pieces are unlikely to open or peel off, and thus excellent performance and excellent shape accuracy can be obtained.

Hereinafter, the present invention will be described in detail with reference to the drawings illustrating embodiments.
1 to 3 show an example of a laminated iron core according to the present invention. This laminated iron core 1 is a rotor (rotor) of an electric motor, and has a hub 1H having a shaft hole 1O in the center, and the hub. Magnetic poles 1T, 1T... Projecting radially from 1H are provided.

  The laminated iron core 1 is formed by laminating a predetermined number of iron core pieces 10, and the laminated iron core pieces 10 are upwardly and downwardly caulked portions 10 </ b> A formed on individual hubs 1 </ b> H and magnetic poles 1 </ b> T, 1 </ b> T. They are fastened (crimped together) to each other via the caulking portion 10B.

  Each of the individual core pieces 10, 10... Constituting the laminated core 1 has a predetermined planar shape, and the downward caulking portion 10 </ b> A and the upward caulking portion 10 </ b> B are provided at predetermined locations in the individual iron core pieces 10. Yes.

  Of the iron core pieces 10 constituting the laminated iron core 1, each of the iron core pieces 10 (m) positioned between the uppermost iron core piece 10 (t) and the lowermost iron core piece (b) has a downward caulking portion 10A. And an upward caulking portion 10B.

  The downward caulking portion 10A has a protrusion 10At protruding from the lower surface 10l of the iron core piece 10 and a back-side concave portion 10Ar depressed in the upper surface 10u of the iron core piece 10, and the upward caulking portion 10B is an upper surface of the iron core piece 10. A protrusion 10Bt protruding from 10u and a back-side recess 10Br recessed into the lower surface 10l of the iron core piece 10 are provided.

  Further, among the core pieces 10 constituting the laminated core 1, the downwardly crimped portion 10A is formed in the uppermost core piece 10 (t) at a position corresponding to the downward crimped portion 10A of the iron core piece 10 (m) described above. In addition, a through hole 10C is formed at a position corresponding to the upward caulking portion 10B of the iron core piece 10 (m) described above.

  Further, among the iron core pieces 10 constituting the laminated iron core 1, in the lowest iron core piece 10 (b), the upward caulking portion 10 B is formed at a position corresponding to the above-described upward caulking portion 10 B of the iron core piece 10 (m). In addition, a through hole 10C is formed at a position corresponding to the downward caulking portion 10A of the iron core piece 10 (m) described above.

  All the core pieces 10, 10... Constituting the laminated core 1 are caulked and laminated with the lower surface 101 of the upper core piece 10 and the upper surface 10u of the lower core piece 10 in close contact with each other without any gap.

  Here, the iron core pieces 10 (m), 10 (m)... From the uppermost at least one lowermost sheet to the lowermost at the uppermost one are lower than the protrusion 10At of the downward caulking portion 10A of the upper iron core piece 10. Is pressed into the back side recess 10Ar of the downward caulking portion 10A of the core piece 10, and the protrusion 10Bt of the upward caulking portion 10B of the lower core piece 10 is in the back side recess 10Br of the upward caulking portion 10B of the upper core piece 10. By press-fitting, they are crimped together.

  Further, in the lowermost core piece 10 (b) constituting the laminated core 1, the protrusion 10At of the downward caulking portion 10A of the upper iron core piece 10 is press-fitted into the through hole 10C, and the protrusion 10Bt of the upward caulking portion 10B is By press-fitting into the back side concave portion 10Br of the upward caulking portion 10B in the upper iron core piece 10, the caulking connection is integrally made with each other.

  Further, the uppermost core piece 10 (t) constituting the laminated core 1 has the protrusion 10Bt of the upward caulking portion 10B in the lower iron core piece 10 press-fitted into the through hole 10C, and the protrusion 10At of the downward caulking portion 10A is By press-fitting into the back side concave portion 10Ar of the downward caulking portion 10A in the lower iron core piece 10, they are caulked and joined together.

  That is, the laminated core 1 having the above-described configuration includes the lowermost iron core piece 10 (b), the intermediate iron core pieces 10 (m), 10 (m), and the uppermost iron core piece 10 (t). They are fastened to each other via a downward caulking portion 10A and an upward caulking portion 10B, whereby the entire laminated iron core 1 is integrated.

  On the other hand, the laminated core 1 having the above-described configuration is obtained by individually punching and forming core pieces 10 of a predetermined shape from a strip-shaped steel plate (metal plate) in a tandem press line constructed by arranging a plurality of press mold apparatuses side by side. .. Are manufactured by laminating a predetermined number of core pieces 10, 10, and fastening the core pieces 10 together with a downward caulking portion 10 </ b> A and an upward caulking portion 10 </ b> B.

  Further, the tandem press line includes processing stations S1 to S7 for sequentially performing intended processing on the strip-shaped steel plate (metal plate) W that is intermittently conveyed as shown in FIG. .

Below, the process of manufacturing the laminated iron core 1 in the said tandem press line is demonstrated in detail.
First, pilot holes p, p... Are punched and formed at a predetermined pitch at the edge of the strip steel plate W at the processing station S1, and the shaft hole 10o is punched and formed in the strip steel plate W at the processing station S2.

  Next, openings s1, s1,... Between the magnetic poles are punched and formed in the strip steel plate W at the processing station S3, and slots s2, s2,.

Next, in the processing station S5, downward crimping portions 10A, 10A...
As shown in FIG. 6, the processing station (press die device) S5 includes a punch 5p that penetrates a stripper plate 5s located above the die 5d, and moves the punch p downward as indicated by an arrow D. A downward crimping portion 10 </ b> A is formed at a predetermined position of the strip steel plate W.

  That is, by punching the strip-shaped steel plate W downward from above with the punch 5p, the protrusion 10At is formed to protrude from the lower surface of the strip-shaped steel plate W (core piece 10), and the back side recess 10Ar is formed in the strip-shaped steel plate W (iron core). It will be formed in the upper surface of the piece 10).

Next, upward crimping portions 10B, 10B,... Are formed at predetermined positions on the strip steel plate W at the processing station S6.
As shown in FIG. 7, the processing station (press die device) S6 includes a punch 6p that penetrates a stripper plate 6s positioned below the die 6d, and moves the punch p upward as indicated by an arrow U. An upward caulking portion 10B is formed at a predetermined position of the strip steel plate W.

  That is, by punching the strip steel plate W upward from below with the punch 6p, the protrusion 10Bt is formed to protrude from the upper surface of the strip steel plate W (iron core piece 10), and the back side recess 10Br is formed in the strip steel plate W (iron core). It will be formed in the lower surface of the piece 10).

  After forming the downward crimping portion 10A at the processing station S5 and then forming the upward crimping portion 10B at the processing station S6, the core piece 10 is formed by punching (excluding the outer shape) from the strip steel plate W at the processing station S7. Are stacked, and the core pieces 10 are fastened to each other by the downward caulking portion 10A and the upward caulking portion 10B.

  As shown in FIG. 8, the processing station S7 includes an outer punch 7p penetrating the stripper plate 7s, a die 7d provided on the base 7b, and a table 7t accommodated in the die 7d. By lowering the outer shape punch 7p as shown by the arrow G, the core piece 10 is punched from the strip steel plate W (outer shape is removed).

  Furthermore, after punching and forming the core piece 10 at the processing station S7, the outer punching punch 7p is lowered, so that the upper core piece 10 punched and formed by the outer punching punch 7p is punched and formed first. The lower core piece 10 placed on the table 7t is pressed and fastened to each other via the downward caulking portion 10A and the upward caulking portion 10B.

  That is, the protrusion 10At of the downward caulking portion 10A of the upper iron core piece 10 is press-fitted into the back side recess 10Ar of the downward caulking portion 10A of the lower iron core piece 10, so that the upper iron core piece 10 and the lower iron core piece 10 Is fastened through the downward caulking portion 10C.

  Further, the protrusion 10Bt of the upward caulking portion 10B of the lower iron core piece 10 is press-fitted into the back side concave portion 10Br of the upper caulking portion 10B of the upper iron core piece 10, so that the upper iron core piece 10 and the lower iron core piece 10 are Is fastened through the upward caulking portion 10B.

  Here, in a series of steps when manufacturing one laminated iron core 1, the lowermost iron core piece 10 (b) is formed with upward caulking projections 10B and through holes 10C at the processing stations S5 and S6. In the processing station S7, the strip-shaped steel plate W is formed by punching (outside shape extraction).

  Further, in a series of steps when manufacturing one laminated iron core 1, the core pieces 10 (m) from at least the lowermost one to the lowermost at the uppermost one are processed at the processing stations S5 and S6. A downward caulking projection 10A and an upward caulking projection 10B are formed, and are punched from the strip-shaped steel sheet W (outside shape is removed) at the processing station S7.

  Furthermore, in a series of steps when manufacturing one laminated iron core 1, the uppermost iron core piece 10 (t) is formed with a downward caulking projection 10A and a through hole 10C at the processing stations S5 and S6. In the station S7, the belt-shaped steel plate W is punched (extracted from the outer shape).

  In the processing station S7, as described above, the core piece 10 is formed by punching from the strip-shaped steel sheet W, and a predetermined number of core pieces 10, 10... Are stacked, and the core pieces 10 are fastened and integrated with each other. The production of the laminated core 1 will be completed.

  According to the manufacturing method of the laminated core 1 described above, all the parts from the lowermost core piece 10 (b) to the uppermost core piece 10 (t) in both the downward caulking portion 10A and the upward caulking portion 10B. Since the core pieces 10, 10... Are integrally laminated by caulking, the laminated core pieces 10 are fastened with high caulking strength, and the laminated core 1 in which the iron core pieces 10 are unlikely to open and peel is produced. .

  Furthermore, according to the manufacturing method of the laminated core 1 described above, all the core pieces 10, 10... From the start of lamination to the end of lamination are caulked and laminated with both the downward caulking portion 10A and the upward caulking portion 10B. The laminated core 1 is manufactured with good productivity by a series of pressing processes in a tandem press line, that is, without requiring a complicated operation such as assembling separately formed laminated core blocks. .

  Further, in the laminated iron core 1 having the above-described configuration, as described above, the laminated iron core pieces 10 are fastened with high caulking strength by the downward caulking portion 10A and the upward caulking portion 10B. Even in the case of a laminated core using a core piece of about (mm) or a large (large diameter) laminated core, it is possible to prevent the opening (gap) or peeling of the core piece, and the laminated core 1 has excellent performance and superiority. The acquired shape accuracy.

  Here, in the above-described embodiment, the protrusion 10At of the downward caulking portion 10A and the protrusion 10Bt of the upward caulking portion 10B are both concave-shaped sections protruding in a rectangular shape. For example, FIG. Like the core piece 20 shown, the protrusion 20At of the downward caulking portion 20A and the protrusion 20Bt of the upward caulking portion 20B can both be V-shaped.

  Further, like the core piece 30 shown in FIG. 9B, the protrusion 30At of the downward caulking portion 30A and the protrusion 30Bt of the upward caulking portion 30B are both trapezoidal, or the core piece shown in FIG. 40, the protrusion 40At of the downward caulking portion 40A and the protrusion 40Bt of the upward caulking portion 40B can both be cut up and used as protrusions.

  Moreover, in the Example mentioned above, although the example which manufactures the laminated core 1 with the tandem press line constructed | assembled by arranging several press die apparatuses side by side was comprised, it was constructed | assembled by one progressive die apparatus. It goes without saying that the laminated core 1 can be manufactured by a progressive press line.

  Furthermore, in the above-described embodiments, an example in which the present invention is applied to a rotor (rotor) in an electric motor has been shown, but of course, the present invention is also extremely effective for a stator (stator) in an electric motor. It goes without saying that it can be applied.

The external appearance perspective view which shows one Example of the laminated iron core manufactured according to the manufacturing method in connection with this invention. (a) And (b) is the whole top view and whole side view of the laminated iron core shown in FIG. III-III sectional view taken on the line in FIG. (a), (b), and (c) are a cross-sectional view conceptually showing the uppermost iron core piece constituting the laminated iron core of FIG. 1, a cross-sectional view conceptually showing an intermediate iron core piece, and the lowest A sectional view conceptually showing an iron core piece, The top view of the strip | belt-shaped steel plate which showed the manufacturing process in each station in the press line for manufacturing the laminated iron core shown in FIG. The principal part expanded sectional view which shows the manufacturing process of the laminated iron core in the processing station shown in FIG. The principal part expanded sectional view which shows the manufacturing process of the laminated iron core in the processing station shown in FIG. The principal part expanded sectional view which shows the manufacturing process of the laminated iron core in the processing station shown in FIG. (a), (b), and (c) are principal part sectional drawings of the core piece which shows the modification of a crimping part. (a) And (b) is the whole top view and whole side view which show the conventional laminated iron core. XI-XI sectional view taken on the line in FIG.

Explanation of symbols

1 ... laminated iron core,
10 ... Iron core piece,
10u ... upper surface,
10l ... bottom surface,
10A: downward caulking part (caulking part),
10At ... downward caulking projection,
10Ar ... back side recess,
10B ... upward caulking part (caulking part),
10 Bt ... upward caulking projection,
10Br ... back side recess,
10C ... through hole,
S1 ... Processing station,
S2 ... Processing station,
S3 ... Processing station,
S4 ... Processing station,
S5 ... Processing station,
S6 ... Processing station,
S7 ... Processing station,
W: Strip steel plate (metal plate).

Claims (2)

A method of manufacturing a laminated core in which an iron core piece having a crimped portion formed by pressing is externally extracted from a metal plate, and the plurality of laminated iron core pieces are integrally coupled to each other via the crimped portion,
Forming an upward caulking projection and a through-hole projecting to the upper surface side as a caulking portion, and extracting at least the lowest iron core piece;
Following the step of removing the outer shape of at least the lowermost iron core piece, up to at least one lowermost sheet formed with upward caulking protrusions protruding to the upper surface side as caulking parts and downward caulking protrusions protruding to the lower surface side as caulking parts The process of extracting the core piece of the outer shape,
Following the step of extracting the outermost core piece up to at least one uppermost layer, the step of extracting the outer shape of at least the uppermost iron core piece formed with a downward caulking projection and a through hole projecting to the lower surface side as a caulking portion, Including
A plurality of core pieces from the lowest iron core piece to the uppermost iron core piece are integrally caulked and laminated by caulking and bonding the upward caulking protrusions together and by caulking and bonding the downward caulking protrusions together. A method for producing a laminated iron core characterized by: An iron core piece having a crimped portion formed by pressing is externally extracted from a metal plate, and a plurality of laminated core pieces are integrally joined to each other via the crimped portion,
At least the lowest iron core piece that forms an upward caulking protrusion and a through hole that protrude to the upper surface side as a caulking part,
An iron core piece from the uppermost at least one lowermost to the lowermost at least one uppermost, forming an upward caulking protrusion protruding to the upper surface side as a caulking portion and a downward caulking protrusion protruding to the lower surface side as the caulking portion,
It has a downward caulking projection protruding to the lower surface side as a caulking part and an at least uppermost iron core piece formed with a through hole,
A plurality of core pieces from the lowest iron core piece to the uppermost iron core piece are integrally caulked and laminated by caulking connection between the upward caulking protrusions and caulking connection between the downward caulking protrusions. A laminated iron core characterized by

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