JP2010093997A - Method of manufacturing stacked core and mold apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a stacked core and a mold apparatus which improve the productivity of the stacked core by preventing damage to a punch and by eliminating the interruption of production due to the replacement of the punch. <P>SOLUTION: In the method of manufacturing a stacked core 10 and a mold apparatus, a predetermined number of divided stacked cores 11, which are formed by stacking divided core pieces 16 and which are provided with stacked teeth 13 for each divided stacked yoke 12, are formed by coupling in an annular shape finally. Furthermore, intervals between adjacent stacked pole teeth 15 formed at the inside tips of the stacked teeth 13 are very small. In a slot punching process of the divided core pieces 16, intervals 33 between adjacent pole teeth 20 are formed by blanking with a punch having a tip end 34 wider than the width dimension of each interval 33. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

The present invention relates to a method of manufacturing a laminated core and a mold apparatus, and more particularly to a method of manufacturing a laminated core and a mold apparatus having a small gap between pole teeth formed at a tooth tip (radially inside).

In the manufacture of a laminated core composed of a plurality of divided laminated cores, as described in Patent Document 1, cutting and pushback are performed with a press die, and each divided core piece is the same as an annular integrated core. In this way, a method of punching and forming is known, and since the laminated iron core is punched and discharged from the mold, it can be wound easily because the diameter between the teeth can be expanded.

JP 2005-318863 A

However, in recent years, particularly in the stator using the punching method, in order to improve the magnetic characteristics of the motor, there is a tendency to set a narrow gap between the teeth tip portions (pole teeth). As a result, the width of the punch punched out here becomes smaller, and when the punched width of the gap is equal to or less than the plate thickness, the punch strength is insufficient and the punch frequently breaks.

In particular, at the punch tip, the stress distribution per unit area becomes the largest and exceeds the compressive strength limit of the punch, so that the damaged portions are concentrated on the punch tip.
When the punch is broken in this way, the production must be interrupted every time in order to replace the punch, resulting in a problem that the productivity of the laminated core is significantly reduced.
Further, a non-divided laminated core in which annular core pieces are laminated is also required to have a small gap at the tip of the teeth, and a common problem occurs in the production of such a laminated core.

The present invention has been made in view of the above problems, and prevents the breakage of the punches that form gaps between the tips of the teeth, and improves the productivity of the laminated core by eliminating the interruption of production due to punch replacement. An object of the present invention is to provide a method for manufacturing a laminated core and a mold apparatus.

The method for manufacturing a laminated core according to the first aspect of the present invention is formed by laminating divided iron core pieces, and finally forming a predetermined number of divided laminated iron cores having laminated teeth portions for each divided laminated yoke portion. A method of manufacturing a stator laminated core formed by connecting to
In a yoke portion forming region in which the divided core pieces arranged annularly on a thin plate material are connected to each other, the connecting portions of the adjacent divided core pieces are sheared and bent, and one side of the separated connecting portions is bent. Cutting and bending process;
A pushback step of forming the same portion as the thin plate material by pushing back the bent portion in the thin plate material;
A slot punching step for forming a predetermined number of teeth pieces by punching and forming a predetermined number of slots in the thin plate material and simultaneously forming a gap by punching between adjacent pole teeth;
An internal punching step of punching and forming the tooth tip of the teeth piece;
An outer punching lamination step of punching out the outer shape of the divided core pieces to separate and form the individual divided core pieces, and laminating the divided core pieces on the lower divided core pieces previously formed by punching. And
In the slotting step, the gap between the pole teeth is formed by punching with a punch having a tip portion wider than the width dimension of the gap.

Here, in this method of manufacturing a laminated core, when the divided core pieces are caulked and laminated, a caulking portion forming step is provided before the outer shape laminating step.
The maximum width of the tip of the punch is preferably in the range of 1.1 to 2 times the minimum gap between the pole teeth.
And it is preferable that the rotor is punched inside the divided core piece that is annular in the previous step of the inner shape punching step, and the tip of the punch reaches the inner circle from which the rotor is removed. Of course, the present invention also applies to the case where the rotor is punched inside the split core piece that is annular in the previous step of the inner punching step, and the tip of the punch does not reach the inner circle where the rotor is punched. Is done.

A mold apparatus according to a second invention comprises a stator formed by annularly connecting a predetermined number of divided laminated cores each having a divided laminated yoke part and a laminated tooth part, which are composed of laminated divided core pieces. A mold apparatus for manufacturing a laminated iron core,
A cutting and bending station for carrying out a cutting process of shearing and separating one side of the separated connecting portion, and connecting and separating the connecting portions of the divided core pieces arranged annularly in a thin plate material;
A pushback station for performing a pushback step of forming the same material as the thin plate material by pushing back the bent portion of the thin plate material;
A slotting station that performs a slotting step for forming a predetermined number of teeth pieces by punching and forming a predetermined number of slots in the thin plate material and simultaneously forming a gap by punching between adjacent pole teeth;
An internal punching station for performing an internal punching step of punching and forming the tooth tip of the tooth piece;
Forming the outer shape of the divided core pieces by punching the outer shape to separate and form the individual divided core pieces and laminating the divided core pieces on the lower divided core pieces previously punched and formed A laminating station,
In the slotting station, the gap between the pole teeth is formed by punching with a punch having a tip portion wider than the width dimension of the gap.

In the mold apparatus according to the second invention, the maximum width of the tip of the punch may be in a range of 1.1 to 2 times the minimum gap between the pole teeth.

A method for manufacturing a laminated core according to a third aspect of the invention is a method for manufacturing a stator laminated core in which a predetermined number of annular core pieces each having a plurality of teeth pieces are laminated inside an annular yoke piece,
A slot punching step of punching and forming a predetermined number of slots corresponding to the number of the tooth pieces in the thin plate material, and simultaneously forming a gap by punching between adjacent pole teeth, ,
An internal punching step of punching and forming the tooth tip of the teeth piece;
The outer shape of the annular core piece is punched to separate and form the annular core piece, and the outer punching lamination step of laminating and joining the annular core piece to the lower annular core piece previously formed by punching, and
In the slotting step, the gap between the pole teeth is formed by punching with a punch having a tip portion wider than the width dimension of the gap.

A mold apparatus according to a fourth aspect of the present invention is a mold apparatus for manufacturing a stator laminated core in which a predetermined number of annular core pieces each having a plurality of teeth pieces are laminated inside an annular yoke piece. There,
A slotting station for punching and forming a predetermined number of slots corresponding to the number of the tooth pieces in the thin plate material, and simultaneously forming a gap by punching between adjacent pole teeth; ,
An internal punching station for punching and forming the tooth tip of the tooth piece,
An outer shape laminating station for punching out the outer shape of the annular core piece and separating and forming the annular core piece, and laminating and bonding the annular core piece to the lower annular core piece previously punched and formed;
In the slotting station, the gap between the pole teeth is formed by punching with a punch having a tip portion wider than the width dimension of the gap.

In the manufacturing method and mold apparatus of the laminated core according to the present invention, when forming a gap between the tip portions (pole teeth) of each tooth piece portion, the result is that the tip portion of the punch that punches out this gap is inflated, Compared with a conventional punch, the surface pressure applied to the tip of the punch can be reduced, and the strength of the punch can be improved to prevent breakage.
Further, even when the gap width (punching width) is equal to or less than the plate thickness, punching can be performed without damaging the punch.
Since breakage of the punch can be prevented, the production interruption conventionally required for punch replacement is eliminated, and the productivity of the laminated core is improved.

Next, embodiments of the present invention will be described with reference to the accompanying drawings for understanding of the present invention.
Here, FIG. 1 is a perspective view of a laminated core manufactured by the method of manufacturing a laminated core according to the first embodiment of the present invention, and FIG. 2 is a mold apparatus for carrying out the method of manufacturing the laminated core. FIG. 3A and FIG. 3B are detailed explanatory views of a cutting and bending process in the manufacturing method of the laminated core, and FIG. 4A is a slot removal station of the same die apparatus. FIG. 5B is an explanatory view of the slot removing station of the mold apparatus, and FIG. 5 is an explanatory view of the caulking portion forming station and the outer shape stacking station of the mold apparatus. FIG. 6 is a perspective view of a laminated core manufactured by the method of manufacturing a laminated core according to the second embodiment of the present invention, and FIG. 7A is a slotting station of a mold apparatus for producing the laminated core. FIG. 8B is an explanatory view of a slot removing station of the mold apparatus, and FIG. 8 is an explanatory view of a caulking portion forming station and an outer shape stacking station of the mold apparatus.

First, a laminated core (stator laminated core) 10 manufactured by the method for manufacturing a laminated core according to the first embodiment of the present invention shown in FIG. 1 will be described. This laminated iron core 10 is formed by arranging a predetermined number (9 in this embodiment) of divided laminated iron cores 11 in an annular shape, and each divided laminated iron core 11 includes an arc-shaped divided laminated yoke portion 12, and the divided laminated yoke portion 12. And a laminated tooth portion 13 integrally connected to the inner center. The laminated tooth portion 13 has a laminated tooth shaft portion 14 and laminated pole teeth 15 formed on the inner end thereof.

Each divided laminated core 11 is formed by caulking and laminating a plurality (usually many) divided core pieces 16. Each of the divided core pieces 16 has a yoke piece portion 19 having connecting portions 17 and 18 formed on both sides, and a teeth piece portion 21 having a pole tooth 20 on the inner front side and inside the yoke piece portion 19. (See FIG. 2). The connecting portion 17 is formed with a convex portion, and the connecting portion 18 is formed with a concave portion that fits into the convex portion.

When this laminated iron core 10 is ejected from the mold apparatus after punching and lamination, each divided laminated iron core 11 once falls apart from the annular arrangement, but the laminated tooth shaft portion 14 is wound to provide a predetermined number of divided laminated iron cores. 11 is connected by the lamination | stacking connection parts 17a and 18a which have a recessed part and a convex part, and it arrange | positions again cyclically | annularly and is completed. Since the interval between the adjacent laminated pole teeth 15 is small, a more efficient motor can be provided.

Then, the manufacturing method of the laminated core which concerns on the 1st Embodiment of this invention, and its metal mold apparatus are demonstrated, referring FIGS.
As shown in FIGS. 2 to 5, the mold apparatus for performing the method of manufacturing the laminated core according to the first embodiment of the present invention has pilot holes 25 and 26 formed at predetermined pitches on both sides in advance, The yoke piece 19 is formed in such a manner that the divided core pieces 16 arranged in a ring shape as shown by a two-dot chain line in FIG. 2 are connected to the thin plate material 27 having a thickness of about 0.3 to 0.5 mm. In a region (that is, a yoke portion forming region), a cutting station S1 that performs a cutting process of shearing and separating the connecting portions 17 and 18 of adjacent divided core pieces 16 and bending the separated connecting portion 18 on one side. have

In FIG. 2, 27 a represents the rotor piece that has been removed, and 27 b represents the inner circle after the rotor piece 27 a has been punched. Moreover, 28a shows the cutting line of the site | part 30 (refer FIG. 3 which is an enlarged view of the arrow A of FIG. 2) by which shear separation was carried out.

Then, by pushing back the part 30 bent in the cutting and bending station S1 with a flat punch or stripper lower surface (not shown), the cut part 30 is flush with the thin plate material 27, that is, the front and back surfaces of the cut part 30 are It has a pushback station S2 for performing a pushback process for forming the thin plate material 27 so as to coincide with the front and back surfaces.

In the cutting and bending station S1, as shown in FIG. 3A, the circumferential length a of the portion 30 to be cut and processed is 2 to 2 of the circumferential length b of the concavities and convexities of the connecting portions 17 and 18. As shown in FIG. 3B, the connecting portions 17 and 18 can be separated at a sufficiently small bending angle (for example, 15 to 35 degrees). Further, the width of the portion 30 in the radial direction is longer than the width of the yoke piece 19 and protrudes about 2 to 5 times the thickness of the thin plate material 27 on both sides in the radial direction.

As shown in FIGS. 4A and 4B, this mold apparatus punches and forms a predetermined number of slots 32 in the thin plate material 27 and at the same time punches between adjacent pole teeth 20 to provide a gap 33. Thus, a slotting station S3 for performing a slotting process for forming a predetermined number of teeth pieces 21 is provided.

In this case, the punch for punching and forming the slot 32 has a width c of about 0.1 to 0.5 mm which is smaller than the plate thickness, and the inner front end 34 is an inner hole of the divided core piece 16. 36 is formed inwardly in the radial direction, and the width of the excess portion is gradually widened. In this embodiment, the maximum width d of the punch protruding radially inward from the gap 33 is about 1.1 to 2 times the width c of the punch corresponding to the width of the gap 33 which is the minimum width. It should be noted that it is sufficient that the allowance of the inner tip 34 of the punch to protrude radially inward (from the inner hole 36) has a width of 1 to 4 times the minimum width of the punch.

In FIG. 4B, the inner tip 35 of the punch according to the conventional example is shown at the same time, but the width of the inner tip 35 is substantially equal to the width c of the gap 33. If the width of the front end of the punch is increased toward the front side like the inner front end 34, the surface pressure applied to the front end of the punch can be reduced, and the strength of the punch is improved to prevent breakage. be able to. At the same time, wear at the time of punch punching is reduced, and the life of the punch is greatly extended.

In this embodiment, the inner tip 34 of the punch does not protrude inward beyond the inner circle 27b formed when the rotor piece 27a is punched out. It can also be formed beyond the circle 27b. In this case, no load is applied to the tip of the punch, and the press operation is performed with a lighter load. Note that if all the slots 32 are removed at the same time, a large amount of power is required.

As shown in FIG. 4, this mold apparatus is an inner shape for carrying out an inner shape punching process for punching and forming an inner hole 36 that becomes a tooth tip of the tooth piece portion 21 (that is, a radially inner portion of the pole tooth 20). As shown in FIG. 5, the punching station S <b> 4 and a caulking portion forming station S <b> 5 for forming a plurality of caulking portions 37 on each divided core piece 16 are provided. In addition, if the position of the crimping part forming station S5 is upstream of the next outer shape stacking station S6, the installation position is arbitrary.

For the caulking portion 37, a well-known caulking structure such as half-cut caulking or V-shaped caulking can be applied. As is well known, the caulking portion of the lowermost divided core piece 16 is a caulking through hole.
Note that when the divided iron core pieces 16 are connected by means other than caulking (for example, welding, pins), the caulking portion forming station can be omitted.

The mold apparatus performs outline drawing in a state where the divided core pieces 16 subjected to the above press processing are arranged in an annular shape, separates the individual divided core pieces 16 from the thin plate material 27, and removes the divided core pieces 16 first. The outer punching and laminating station S6 for carrying out the outer punching and laminating step of laminating and bonding to the lower divided core pieces 16 formed by punching. In the outer shape stacking station S6, the divided core pieces 16 can be rolled and skewed. In addition, since transposition and skew are well-known, description is abbreviate | omitted.

Since the laminated core 10 manufactured by the method for manufacturing a laminated core using the mold apparatus described above is separated from the divided laminated cores 11 after being discharged from the mold apparatus, winding is extremely easy. Become. In assembly, it can be easily formed in an annular shape by connecting the concave and convex portions of the laminated connecting portions 17a and 18a of each divided laminated iron core 11.

Next, a laminated core (stator laminated core) 40 manufactured by the method for manufacturing a laminated core according to the second embodiment of the present invention will be described with reference to FIG. The laminated iron core 40 has an outer annular laminated yoke portion 41 and a plurality of laminated teeth portions 42 provided on the inner side. The laminated tooth portion 42 has a laminated tooth shaft portion 43 and laminated pole teeth 44 formed on the inner end thereof.

The laminated core 40 is formed by caulking and laminating a plurality (usually a large number) of annular core pieces 45 having the same shape. Each of the annular core pieces 45 has a plurality of teeth pieces 47 having pole teeth 46 at the inner front part inside the annular yoke piece 45a. And the space | interval of the adjacent pole tooth | gear 46 is very small, for example, is 0.2 mm (further 0.15-0.3 mm) and is smaller than plate | board thickness, Therefore An efficient motor can be provided. Reference numeral 48 denotes a caulking portion.

The manufacturing method of this laminated iron core 40 is demonstrated referring FIG. 7 (A), (B), and FIG. In the mold apparatus for manufacturing the laminated core 40, a predetermined number of slots 49 corresponding to the number of the teeth pieces 47 are punched and formed in the rotor thin sheet material 27, and at the same time, the gap between adjacent pole teeth 46 is punched. 50, a slotting station S11 for carrying out a slotting process for forming a predetermined number of teeth pieces 47, and an internal punching process for punching and forming an inner hole 36 serving as a tooth tip of the teeth pieces 47 are carried out. The inner shape punching station S12, the caulking portion forming station S13 for performing the caulking portion forming step for forming the caulking portion 48 at a predetermined position, and the annular core piece 45 are separated and formed by punching the outer shape of the annular core piece 45. The outer shape stacking step is performed in which the annular core piece 45 is laminated and bonded to the lower annular core piece 45 previously punched and formed. And a contour punching laminating station S14.

In particular, as described above, in the slotting station S11 of this mold apparatus, as shown in FIG. 7B, a predetermined number of slots 49 are punched and formed in the thin plate material 27 and at the same time, adjacent pole teeth 46 are formed. A slot punching process for forming a predetermined number of teeth pieces 47 is performed by punching a gap to provide a gap 50.

In this case, the punch for punching and forming the slot 49 has a width c of about 0.1 to 0.5 mm, which is smaller than the plate thickness, and the inner front end portion 51 is an inner hole of the annular core piece 45. 36 is formed inwardly in the radial direction, and the width of the excess portion is gradually widened. In this embodiment, the maximum width d of the punch projecting radially inward from the gap 50 is about 1.1 to 2 times the width c of the punch corresponding to the width of the gap 50 which is the minimum width. It should be noted that it is sufficient that the allowance of the inner tip 51 of the punch to protrude radially inward (from the inner hole 36) is 1 to 4 times the minimum width of the punch.

The operations of the inner shape punching station S12, the caulking portion forming station S13, and the outer shape punching laminating station S14 are the same as those in the method for manufacturing the laminated iron core according to the first embodiment, and will be omitted. In this embodiment, it is a matter of course that the transposition or skew of the annular core piece may be formed.

In the embodiment described above, specific numbers are used to facilitate understanding of the present invention, but the present invention is not limited to these numbers.
Moreover, although this invention demonstrated what each division | segmentation laminated | stacked iron core 11 fell apart, it is applied also to the type of lamination | stacking iron core with which an adjacent division | segmentation laminated iron core is connected by the connection part which can move freely.

It is a perspective view of the laminated iron core manufactured by the manufacturing method of the laminated iron core which concerns on the 1st Embodiment of this invention. It is explanatory drawing of the bending station and pushback station of the metal mold | die apparatus for enforcing the manufacturing method of the same laminated iron core. (A), (B) is detailed explanatory drawing of the cutting and bending process in the manufacturing method of the laminated core. (A) is explanatory drawing of the slot extraction station of the same mold apparatus, and an internal shape extraction station, (B) is explanatory drawing of the slot extraction station of the same mold apparatus. It is explanatory drawing of the crimping part formation station and external shape lamination | stacking station of the metal mold | die apparatus. It is a perspective view of the laminated core manufactured by the manufacturing method of the laminated core which concerns on the 2nd Embodiment of this invention. (A) is explanatory drawing of the slot extraction station of the metal mold | die apparatus for manufacturing the laminated iron core, and an internal shape punching station, (B) is explanatory drawing of the slot extraction station of the metal mold | die apparatus. It is explanatory drawing of the crimping part formation station and external shape lamination | stacking station of the metal mold | die apparatus.

Explanation of symbols

10: laminated iron core, 11: divided laminated iron core, 12: divided laminated yoke portion, 13: laminated tooth portion, 14: laminated tooth shaft portion, 15: laminated tooth, 16: divided iron core pieces, 17, 18: connecting portion, 17a, 18a: Laminate connection part, 19: Yoke piece part, 20: Polar tooth, 21: Teeth piece part, 25, 26: Pilot hole, 27: Thin plate material, 27a: Rotor piece, 27b: Inner circle, 28a: Cut Bending line, 30: site, 32: slot, 33: gap, 34: inner tip, 35: inner tip, 36: inner hole, 37: caulking, 40: laminated iron core, 41: annular laminated yoke, 42 : Laminated tooth part, 43: Laminated tooth shaft part, 44: Laminated pole tooth, 45: Circular iron core piece, 45a: Yoke piece part, 46: Polar tooth part, 47: Teeth piece part, 48: Caulking part, 49: Slot, 50: Clearance, 51: Inner tip

Claims (7)

A method of manufacturing a stator laminated core, which is formed by laminating divided iron core pieces and finally connecting a predetermined number of divided laminated iron cores having laminated tooth portions for each divided laminated yoke portion in an annular shape,
In a yoke portion forming region in which the divided core pieces arranged annularly on a thin plate material are connected to each other, the connecting portions of the adjacent divided core pieces are sheared and bent, and one side of the separated connecting portions is bent. Cutting and bending process;
A pushback step of forming the same portion as the thin plate material by pushing back the bent portion in the thin plate material;
A slot punching step for forming a predetermined number of teeth pieces by punching and forming a predetermined number of slots in the thin plate material and simultaneously forming a gap by punching between adjacent pole teeth;
An internal punching step of punching and forming the tooth tip of the teeth piece;
An outer punching lamination step of punching out the outer shape of the divided core pieces to separate and form the individual divided core pieces, and laminating the divided core pieces on the lower divided core pieces previously formed by punching. And
In the slotting step, the gap between the pole teeth is formed by punching with a punch having a tip portion wider than the width dimension of the gap. The method for manufacturing a laminated core according to claim 1, wherein the maximum width of the tip of the punch is in a range of 1.1 to 2 times the minimum gap between the pole teeth. . In the manufacturing method of the laminated core according to any one of claims 1 and 2, in the previous step of the inner shape punching step, rotor cutting is performed on the inner side of the annular divided core piece, and the tip of the punch is A method for manufacturing a laminated iron core, characterized in that the inner core reaches a rotor-extracted inner circle. A mold apparatus for manufacturing a stator laminated iron core formed by connecting a predetermined number of divided laminated iron cores which are composed of laminated divided iron core pieces and have divided laminated yoke parts and laminated tooth parts in an annular shape. There,
A cutting and bending station for carrying out a cutting process of shearing and separating one side of the separated connecting portion, and connecting and separating the connecting portions of the divided core pieces arranged annularly in a thin plate material;
A pushback station for performing a pushback step of forming the same material as the thin plate material by pushing back the bent portion of the thin plate material;
A slotting station that performs a slotting step for forming a predetermined number of teeth pieces by punching and forming a predetermined number of slots in the thin plate material and simultaneously forming a gap by punching between adjacent pole teeth;
An internal punching station for performing an internal punching step of punching and forming the tooth tip of the tooth piece;
Forming the outer shape of the divided core pieces by punching the outer shape to separate and form the individual divided core pieces and laminating the divided core pieces on the lower divided core pieces previously punched and formed A laminating station,
In the slotting station, the gap between the pole teeth is formed by punching with a punch having a tip portion wider than the width of the gap. 5. The mold apparatus according to claim 4, wherein the maximum width of the tip of the punch is in a range of 1.1 to 2 times the minimum gap between the pole teeth. A method for manufacturing a stator laminated core in which a predetermined number of annular core pieces each having a plurality of teeth pieces inside an annular yoke piece are laminated,
A slot punching step of punching and forming a predetermined number of slots corresponding to the number of the tooth pieces in the thin plate material, and simultaneously forming a gap by punching between adjacent pole teeth, ,
An internal punching step of punching and forming the tooth tip of the teeth piece;
The outer shape of the annular core piece is punched to separate and form the annular core piece, and the outer punching lamination step of laminating and joining the annular core piece to the lower annular core piece previously formed by punching, and
In the slotting step, the gap between the pole teeth is formed by punching with a punch having a tip portion wider than the width dimension of the gap. A mold apparatus for manufacturing a stator laminated core in which a predetermined number of annular core pieces each having a plurality of tooth pieces are laminated inside an annular yoke piece,
A slotting station for punching and forming a predetermined number of slots corresponding to the number of the tooth pieces in the thin plate material, and simultaneously forming a gap by punching between adjacent pole teeth; ,
An internal punching station for punching and forming the tooth tip of the tooth piece,
An outer shape laminating station for punching out the outer shape of the annular core piece and separating and forming the annular core piece, and laminating and bonding the annular core piece to the lower annular core piece previously punched and formed;
In the slotting station, the gap between the pole teeth is formed by punching with a punch having a tip portion wider than the width of the gap.

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