JP2013017281A - Manufacturing method of laminated iron core having skew - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a laminated iron core having skew, which is formed by laminating magnetic poles of a thin winding iron core formed by winding a belt-like iron core piece without a gap by gradually shifting them.SOLUTION: A belt-like iron core piece 12 obtained by coupling respective segment iron core pieces 10 via a coupling section 11 is bent by the coupling section 11 and is formed by winding. Step portions 13 and 14 are disposed at winding start and winding end of the belt-like iron core pice 12. The step portions 13 and 14 form a thin winding iron core 16 formed between magnetic pole sections 15 adjacent in a plan view. The thin winding iron cores 16 are laminated in a state where the magnetic pole sections 15 are gradually shifted and laminated iron core 17 having a skew in the magnetic pole sections 15 is manufactured. In the method for manufacturing the laminated iron core 17, one or both of the winding start and the winding end of the belt-like iron core piece 12 are cut by a minute angle region to form the thin winding iron core 16. In lamination of the thin winding iron cores 16 which are vertically adjacent, the step portion 14 at the winding end and the step portion 13 of the winding start of each thin winding iron core 16 are made to abut in a circumferential direction.

Description

The present invention is formed by bending a strip-shaped core piece, in which segment core pieces are connected via a connecting portion, and spirally winding the connecting piece, and having a plurality of magnetic pole portions in the circumferential direction. The present invention relates to a method for manufacturing a laminated iron core having a skew that is produced by laminating parts while gradually shifting the portions.

Conventionally, a laminated iron core in which a plurality of permanent magnets are attached along the circumferential direction has a sinusoidal magnetic flux distribution in the circumferential direction. Therefore, the permanent magnet is divided into permanent magnets by dividing the permanent magnet in the axial direction of the laminated iron core. Manufactured by attaching magnets to multiple magnet mounting holes provided along the circumferential direction of a thin iron core (block iron core), and laminating multiple thin iron cores with split permanent magnets while rotating them at a constant angular circumferential direction. (For example, refer to Patent Document 1).
On the other hand, for the purpose of improving the material yield at the time of manufacturing the laminated core, the laminated core is obtained by folding the band-shaped core pieces, in which the segment core pieces are connected via the connecting portions, and winding them in a spiral shape to be caulked and laminated. Is manufactured (for example, refer to Patent Document 2).
Therefore, as a method of manufacturing a laminated iron core having a sinusoidal magnetic flux distribution in the circumferential direction with a high material yield, as shown in FIG. 8 (A), segments are connected via a connecting portion 105 (see FIG. 9 (B)). A plurality of magnet insertion holes provided side by side in the circumferential direction of the thin wound core 101 by forming a thin wound core 101 by spirally winding a strip-shaped core piece 100 to which the core pieces 106 (see FIG. 9B) are connected. It is conceivable to divide and attach a split permanent magnet (not shown) to each 102 and to stack a plurality of thin wound cores 101 with the split permanent magnets attached thereto while rotating them by a certain angle in the circumferential direction.

WO2007 / 086312 Japanese Patent No. 4176121

In the thin wound core 101 shown in FIG. 8A, a step 103 is formed on the lower surface of the thin wound core 101 at the beginning of winding of the strip-shaped core piece 100, and the winding end of the strip-shaped core piece 100 is finished on the upper surface of the thin wound core 101. Accordingly, the stepped portion 104 is formed at the same angular position in the circumferential direction (in the same phase), for example. For this reason, as shown in FIG. 8 (B), when the winding end of the lower thin wound core 101 and the winding start position of the upper thin wound core 101 are aligned with each other, FIG. As shown, the step 104 on the upper surface of the lower thin wound core 101 and the step 103 on the lower surface of the upper thin wound core 101 can be brought into contact with each other. Without generating a gap with the wound core 101, it is possible to manufacture the laminated core 112 in which the winding start and the winding end have the same phase.
8A to 8C (the same applies to FIGS. 9A, 10, 11A, and 12A to 12C), the thin wound core 101 and the laminated core 112 are used. Are omitted, and the end shape of the step 103 at the beginning of winding and the end shape of the step 104 at the end of winding in the thin wound core 101 and laminated core 112 are also linear. Are omitted.

However, as shown in FIG. 9A, the upper thin wound core 101 is stacked while rotating the upper thin wound core 101 in the right direction with respect to the lower thin wound core 101 (the thin wound core 101 is stacked while being block skewed in the right direction. 9 (B), the stepped portions 104 and 103 on the upper and lower surfaces of the thin wound core 101 are in the same phase as shown in FIG. 9B. Therefore, as shown in FIG. The winding end side and the winding start side end of the upper thin wound core 101 overlap with each other to generate an interference area 107, which causes a problem that the thin wound core 101 cannot be stacked (FIG. 10). reference).

As shown in FIG. 11 (A), when the thin wound core 101 is stacked while being block skewed in the left direction, as shown in FIG. 11 (B), the step portions 104 on the upper and lower surfaces of the thin wound core 101, Since 103 is in phase, as shown in FIGS. 11C and 12A to 12C, the step 104 on the upper surface of the lower thin wound core 101 and the lower surface of the upper thin wound core 101 are formed. The stepped portion 103 is separated and a gap area 108 is generated. For this reason, there arises a problem that the magnetic performance of the laminated core formed while the thin wound core 101 is block skewed in the left direction is deteriorated. Since the gap area 108 is generated, a part of the magnet insertion hole 102 formed in the lower thin wound core 101 is opened in the gap area 108 due to the relationship between the skew angle and the width dimension of the magnet insertion hole 102. Appears as part 110. For this reason, there arises a problem that the resin injected into the magnet insertion hole 102 for sealing the divided permanent magnets leaks into the gap area 108 from the opening 110.

Further, when the thin wound core 101 is laminated while being block skewed, as shown in FIGS. 13A and 13B, the position of the magnet insertion hole 102 of the thin wound core 101 disposed on the upper side is disposed on the lower side. It shifts to one side with respect to the position of the magnet insertion hole 102 of the thin wound core 101. For this reason, except for the thin wound core 101 disposed in the lowermost layer, one side of the lower surface of the permanent magnet 111 inserted into the magnet insertion hole 102 of the thin wound core 101 is the lower side of the thin wound core 101 disposed on the lower side. Although arranged in contact with the upper surface, the other side of the lower surface of the permanent magnet 111 is disposed above the magnet insertion hole 102 of the thin wound core 101 disposed on the lower side. When the height of the permanent magnet 111 is lower than the depth of the magnet insertion hole 102, the other side of the permanent magnet 111 inserted into the magnet insertion hole 102 is a thin wound core 101 laminated on the lower side. The permanent magnet 111 in the magnet insertion hole 102 is tilted downward, except for the permanent magnet 111 inserted into the magnet insertion hole 102 of the lowermost thin wound core 101. There is a problem of being placed in.

The present invention has been made in view of such circumstances, and is formed by bending a strip-shaped core piece, to which a segment core piece is connected via a connecting portion, and winding it in a spiral shape, and a plurality of magnetic pole portions in the circumferential direction. Can be laminated without gaps while gradually shifting the magnetic pole part, and a laminated iron core having a skew that can arrange a permanent magnet in a horizontal state in a magnet insertion hole of the thin wound iron core It aims at providing the manufacturing method of.

According to the first aspect of the invention, there is provided a method of manufacturing a laminated iron core having a skew, wherein the segment core pieces are connected to each other via a connecting portion, and are bent at the connecting portion to be spirally wound. And has a step portion at the beginning and end of winding of the strip-shaped core piece, and the step portion forms a thin wound core formed between adjacent magnetic pole portions in plan view, In the method of manufacturing a laminated core having a skew in the magnetic pole part by laminating a wound iron core in a state where the magnetic pole part is gradually shifted,
Either one or both of the start and end of winding of the strip-shaped core pieces are cut off by a small angle region to form the thin wound core, and in the lamination of the thin wound cores adjacent to each other vertically, The step portion at the end of winding of the iron core and the step portion at the start of winding are brought into contact with each other in the circumferential direction.

In the manufacturing method of a laminated core having a skew according to the first invention, each of the thin wound cores has a magnet insertion hole for inserting a permanent magnet in a radially outer region, and the angle width θ of the cut micro angle region. Is preferably in the range of 0 <θ <α / n, where α is the angle between the ends of the adjacent magnet insertion holes and n is the number of laminated thin cores.

According to the second aspect of the invention, there is provided a method for manufacturing a skewed laminated core, wherein the segment core pieces are connected to each other via a connecting portion, and are bent at the connecting portion to be spirally wound. And has a step portion at the beginning and end of winding of the strip-shaped core piece, and the step portion forms a thin wound core formed between adjacent magnetic pole portions in plan view, In the method of manufacturing a laminated core having a skew in the magnetic pole part by laminating a wound iron core in a state where the magnetic pole part is gradually shifted,
One or both of the start and end of winding of the strip-shaped core pieces are extended by a small angle to form the thin wound core, and in the lamination of the thin wound cores adjacent to each other above and below, The stepped portion at the end of winding of the wound iron core and the stepped portion at the beginning of winding are brought into contact with each other in the circumferential direction.

In the method for manufacturing a laminated iron core having a skew according to the first invention, each of the thin wound cores has a magnet insertion hole for inserting a permanent magnet in a radially outer region, and an angular width θ of the extended minute angle region. Is preferably in the range of 0 <θ <α / n, where α is the angle between the ends of the adjacent magnet insertion holes and n is the number of laminated thin cores.

In the manufacturing method of a laminated core having a skew according to the first and second inventions, the segment core pieces in the lowermost layer of each thin wound core are in areas where the magnet insertion holes of the upper and lower thin wound cores overlap. It is preferable that a magnet tilt prevention means is provided.

In the manufacturing method of a skewed laminated core according to the first and second inventions, the magnet inclination preventing means includes a projecting core part protruding inside the magnet insertion hole of the lowermost segment core piece or the magnet insertion. It can be used as a cross over the hole.

In the method for manufacturing a skewed laminated core according to the first and second inventions, the segment core piece in the lowermost layer of each thin wound core is formed with a closed portion covering a part of the magnet insertion hole. It is preferable.

In the method for manufacturing a skewed laminated core according to the first and second inventions, each of the segment core pieces preferably has one or a plurality of magnetic pole pieces.

In the manufacturing method of the laminated core having a skew according to the first invention, a thin wound core is formed by cutting off one or both of the winding start and the winding end of the strip-shaped core piece by a minute angle region (angle width θ). In the thin wound core, the winding start on the bottom surface and the winding end on the top surface are fixed at a certain angle in the circumferential direction when the thin winding core is viewed from the axial direction of the thin winding core (one of the winding start and the winding end is a minute angle). When the region is cut off, the position is shifted by θ, and when both the start and end of winding are cut by a minute angle region, the position is shifted by 2θ). For this reason, in the stack of thin wound cores adjacent to each other in the upper and lower sides, if the stepped portion at the end of winding of each thin wound core and the stepped portion at the beginning of winding are brought into contact in the circumferential direction, the winding of the lower thin wound core is wound. The upper thin wound core can be laminated in a state rotated at a certain angle in the circumferential direction with respect to the lower thin wound core without causing interference or a gap between the end and the beginning of the upper thin wound core. it can. As a result, it is possible to manufacture a laminated iron core with improved magnetic performance by providing a skew in the magnetic pole part with a high material yield.

In the manufacturing method of the laminated core having a skew according to the first invention, each thin wound core has a magnet insertion hole for inserting a permanent magnet in the radially outer region, and the angle width θ of the cut-off micro angle region is When the angle between the end portions of adjacent magnet insertion holes is α, and the number of laminated thin cores is n, the range is 0 <θ <α / n. Then, the magnet insertion hole of the uppermost thin wound core can be rotated by the angle α between the ends. As a result, a laminated iron core having a skew in the magnetic pole part can be manufactured. And when a permanent magnet is inserted into the magnet insertion hole and sealed with resin, there is no gap between the end of winding of each thin wound core and the start of winding, preventing the resin injected into the magnet insertion hole from leaking out. can do.

In the method of manufacturing a laminated iron core having a skew according to the second aspect of the invention, a thin wound core is formed by extending one or both of the winding start and end of the strip-shaped core piece by a minute angle width (angle width θ). Therefore, in the thin wound core, the winding start of the lower surface and the winding end of the upper surface are the same when the thin winding core is viewed from the axial direction of the thin winding core. The position is shifted by θ when the minute angle width is extended, and by 2θ when both the start and end of winding are extended by the minute angle width. For this reason, in the stack of thin wound cores adjacent to each other in the upper and lower sides, if the stepped portion at the end of winding of each thin wound core and the stepped portion at the beginning of winding are brought into contact in the circumferential direction, the winding of the lower thin wound core is wound. The upper thin wound core can be laminated in a state rotated at a certain angle in the circumferential direction with respect to the lower thin wound core without causing interference or a gap between the end and the beginning of the upper thin wound core. it can. As a result, it is possible to manufacture a laminated iron core with improved magnetic performance by providing a skew in the magnetic pole part with a high material yield.

In the method of manufacturing a laminated core having a skew according to the second invention, each thin wound core has a magnet insertion hole for inserting a permanent magnet in the radially outer region, and the angular width θ of the extended minute angle region is When the angle between the end portions of adjacent magnet insertion holes is α, and the number of laminated thin cores is n, the range is 0 <θ <α / n. Then, the magnet insertion hole of the uppermost thin wound core can be rotated by the angle α between the ends. As a result, a laminated iron core having a skew in the magnetic pole part can be manufactured. And when a permanent magnet is inserted into the magnet insertion hole and sealed with resin, there is no gap between the end of winding of each thin wound core and the start of winding, preventing the resin injected into the magnet insertion hole from leaking out. can do.

In the method for manufacturing a skewed laminated core according to the first and second inventions, the magnet core tilt prevention means is provided in a region where the magnet insertion holes of the upper and lower thin wound cores overlap each other in the lowermost segment core piece of each thin wound core. Is provided, it is possible to prevent one side of the permanent magnet inserted into the magnet insertion hole of the upper thin wound core from falling into the magnet insertion hole of the lower thin wound core.

In the manufacturing method of the laminated core having a skew according to the first and second inventions, when the magnet inclination preventing means is a protruding core part protruding inside the magnet insertion hole or a crossing over the magnet insertion hole, the magnet insertion hole And magnet tilt prevention means can be formed simultaneously, and the process can be simplified.
In addition, when a closed portion covering a part of the magnet insertion hole is formed in the magnet insertion hole of the lowermost segment core piece of each thin wound core, the lower surface of the permanent magnet inserted into the magnet insertion hole The permanent magnet can be supported stably.

In the manufacturing method of the laminated core having skew according to the first and second inventions, when each segment core piece has one or a plurality of magnetic pole pieces, the magnetic pole portion of the thin wound core is formed by stacking the magnetic pole pieces. be able to.

In the manufacturing method of the laminated iron core which has the skew which concerns on the 1st Embodiment of this invention, (A) is explanatory drawing of a strip-shaped iron core piece, (B) is explanatory drawing which manufactures a thin wound core from a strip-shaped iron core piece, ( (C) is explanatory drawing which shows the lamination | stacking state of a thin wound iron core. (A) is a perspective view of a laminated iron core, (B) is a perspective view showing the arrangement of permanent magnets in the laminated iron core, and (C) is a partial perspective view of the laminated iron core. In the method for manufacturing a laminated core having the same skew, (A) is an explanatory view of the start and end of winding of the strip-shaped core piece, (B) is a perspective view of the thin wound core, and (C) is a partial plan view of the thin wound core. It is. (A) is explanatory drawing of a protrusion center part, (B) is explanatory drawing of a crosspiece, (C) is explanatory drawing of a obstruction | occlusion part. (A), (B) is explanatory drawing of the manufacturing method of the laminated iron core which has the skew which concerns on a modification. (A) In the manufacturing method of the laminated iron core which has a skew which concerns on the 2nd Embodiment of this invention, (A) Explanatory drawing of the formation method of the winding start of a strip | belt-shaped core piece, and the winding start of a strip | belt-shaped core piece. Explanatory drawing of the end of winding, (C) is a partial plan view of a laminated iron core. (A) is a perspective view of a double wound type thin wound core, and (B) is a perspective view of a laminated core obtained by laminating a two wound type thin wound core. (A) is a perspective view of the thin wound core which concerns on a prior art example, (B) is explanatory drawing which shows the lamination | stacking state of the same thin wound core, (C) is a perspective view of a laminated core. (A) is an explanatory view when the same thin wound core is laminated by rotating it to the right, (B) is a partial plan view of the same thin wound core, and (C) is generated when the same thin wound core is laminated by rotating it to the right. It is explanatory drawing of an interference area. It is explanatory drawing of the position of the interference area produced when laminating | stacking the said thin winding iron core by right rotation. (A) is explanatory drawing when laminating the same thin wound core by left rotation, (B) is a partial plan view of the same thin wound core, and (C) is generated when laminating the same thin wound core by left rotation. It is explanatory drawing of a clearance gap area. (A) is a plan view of a laminated core formed by laminating the thin wound cores by left rotation, (B) is a front view of the laminated core, and (C) is a perspective view of a gap area generated in the laminated core. (A) is a partial plan view of a laminated core formed by laminating the same thin wound iron core by rotating it to the right, and (B) is a portion showing a state of a permanent magnet inserted into a magnet insertion hole of the thin wound core constituting the laminated core. It is sectional drawing.

Next, embodiments of the present invention will be described with reference to the accompanying drawings for understanding of the present invention.
As shown in FIGS. 1 (A) to (C) and FIGS. 2 (A) to (C), in the method for manufacturing a laminated core having skew according to the first embodiment of the present invention, first, a certain number of The strip-shaped core pieces 12 to which the segment core pieces 10 are connected via the connecting portions 11 are formed by bending the connecting portions 11 and spirally winding them. The stepped portions 13 and 14 have thin portions 16 and 14 formed between the adjacent magnetic pole portions 15 in plan view. Next, the manufactured thin wound core 16 is laminated in a state where the magnetic pole portion 15 is gradually shifted (for example, skew angle φ), thereby forming a laminated iron core 17 having a skew in the magnetic pole portion 15. Details will be described below.

As shown in FIG. 1A, a band-shaped material 18 (for example, a magnetic steel sheet) is supplied into the mold 19 from the receiving side of the mold 19 and is connected via the connecting portion 11 using a punch and a die (not shown). The segment core pieces 10 in a connected state are sequentially formed, and the formed segment core pieces 10 are sequentially discharged from the discharge side of the mold 19. At this time, a cutting means 20 having a punch and a die is installed on the discharge side of the mold 19, and every time a certain number of segment core pieces 10 are discharged from the discharge side of the mold 19, the cutting means 20 is connected. Cut both sides of the part 11. Thereby, from the metal mold | die 19, the strip | belt-shaped iron core piece 12 which the fixed number of segment iron core pieces 10 connected via the connection part 11 can be paid out one by one. And the paid-out strip | belt-shaped iron core piece 12 is supplied to the conveyance path 21, and is conveyed by the winding laminating machine 22 shown to FIG. 1 (B).

When cutting both sides of the connecting portion 11 with the cutting means 20, as shown in FIG. 3A, with respect to the preceding segment core piece 10 around the connecting portion 11 to be cut, for example, the segment core piece 10 Rotated by a minute angle θ that is half of the skew angle φ with respect to the end face 23 of the core (the center of rotation coincides with the center of the circle of the preceding segment core piece 10, for example, the inner periphery being a part of the circumference) The position is set to the end face 24 at the end of winding of the preceding strip-shaped iron core piece 12. As a result, the end surface 24 at the end of winding of the preceding segment core piece 10 is formed by being cut off by a minute angle θ (shifted forward). Further, the subsequent segment core piece 10 is rotated, for example, by a minute angle θ with respect to the tip surface 25 of the segment core piece 10 (the center of rotation is, for example, the inner peripheral portion of the subsequent segment core piece 10). The position that coincides with the center of a circle that is a part of the circumference is the leading end surface 26 of the winding start of the subsequent strip-shaped core piece 12. As a result, the leading end surface 26 at the beginning of the subsequent segment core piece 10 is formed by cutting (shifting backward) by a minute angle θ.
The winding end of the preceding strip-shaped core piece 12 and the winding start of the subsequent strip-shaped core piece 12 were each cut down by a minute angle θ that is half the skew angle φ, depending on the shape of the strip-shaped core piece, The cutting position (the position of the end surface of the preceding segment core piece and the position of the tip surface of the subsequent segment core piece) is changed as appropriate.

The strip-shaped iron core piece 12 supplied to the winding laminator 22 is placed on a turntable (not shown), bent at the connecting portion 11 and wound spirally, thereby forming the thin core iron core 16. When the thin wound core 16 is formed, the turntable is rotated by a skew angle φ, and the trailing surface of the stepped portion 14 of the thin wound core 16 composed of the preceding strip-shaped iron core piece 16 at the end of the winding is formed. The leading end surface 26 of the iron core piece 12 at the start of winding is brought into contact, and the subsequent strip-shaped iron core piece 12 is wound spirally while being bent at the connecting portion 11. As a result, the thin wound core 16 formed of the succeeding strip-shaped core 12 can be laminated on the thin wound core 16 formed of the preceding strip-shaped core 12.

Here, as shown in FIG. 3C, in the thin wound core 16, the leading end surface of the step portion 13 at the start of winding is connected to the connecting line 27 between the segment core pieces 10 arranged on both upper sides of the step portion 13. On the other hand, the end surface of the stepped portion 14 at the end of winding is cut off by a minute angle θ, and the end surface of the stepped portion 14 is connected to the segment core pieces 10 arranged on both lower sides of the stepped portion 14. Is arranged at the front side by a minute angle θ. For this reason, as shown in FIG. 3B, in the thin wound core 16, the leading end surface of the step 13 at the beginning of winding and the end surface of the step 14 at the end of winding are viewed from the axial direction of the thin wound core 16. Therefore, the skew angle φ is shifted.

Each thin wound core 16 has a magnet insertion hole 29 into which a permanent magnet 28 (including an unmagnetized permanent magnet) is inserted in the radially outer region. Here, as shown in FIG. 3A, the magnet insertion holes 29 are formed in a plurality of (2 in FIG. 3A) magnetic pole piece portions 30 formed in each segment core piece 10, for example, rectangular. It is formed by stacking shaped openings 31.
In the thin wound core 16, the angle width θ of the minute angle region cut off when forming the leading end surface at the start of winding and the terminal end surface at the end of winding is the angle between the end portions of the adjacent magnet insertion holes 29 (see FIG. 3). (See (B)), where n is the number of laminated thin cores 16, the range is 0 <θ <α / n. For this reason, each time the thin wound core 16 is formed, the permanent magnets 28 are inserted into the respective magnet insertion holes 29 of the thin wound core 16, and the thin wound core 16 formed first is shown in FIG. As shown, the thin wound cores 16 formed next are sequentially laminated (the end surface 24 of the stepped portion 14 at the end of winding of the thin wound cores 16 adjacent to the upper and lower sides and the tip end surface 26 of the stepped portion 13 at the beginning of winding are circumferentially arranged. 2), the laminated core 17 shown in FIG. 2A is formed.

In the formed laminated core 17, as shown in FIG. 2C, the thin wound cores 16 adjacent to each other in the vertical direction are laminated with a skew angle φ shifted, and therefore, between the thin wound cores 16 adjacent to each other in the vertical direction. The circumferential angle position of the magnet insertion hole 29 is shifted by the skew angle φ. For this reason, as shown in FIG. 2 (B), the circumferential angular position of the permanent magnet 28 inserted into each magnet insertion hole 29 of the thin wound core 16 is between the permanent magnets 28 of the thin wound core 16 adjacent vertically. The skew angle is shifted by φ.

Here, when the thin wound cores 16 are stacked, a plurality of projecting cores 32, which are an example of magnet tilt prevention means, are provided inside the magnet insertion holes 29 in the region where the magnet insertion holes 29 of the upper and lower thin wound cores 16 overlap. Are projected in the opening 31 provided in the magnetic pole piece 30 of each segment core piece 10 constituting the lowermost layer of each thin wound core 16 (see FIG. 4 (A)). For this reason, when the permanent magnet 28 is inserted into the magnet insertion hole 29 formed by stacking the openings 31 from above, the lower surface of the permanent magnet 28 comes into contact with the plurality of projecting cores 32 to bring the permanent magnet 28 into a horizontal state. While keeping, it prevents falling out of the magnet insertion hole 29.

Instead of providing the projecting core 32 at the opening 31 of each segment core piece 10 constituting the lowermost layer of the thin wound core 16, as shown in FIG. 4B, the segment core piece 33 constituting the lowermost layer is provided. A plurality of crosspieces 35 may be provided in the opening 34 so as to straddle the opening 34. Further, as shown in FIG. 4C, the opening 34a of the segment core piece 33a constituting the lowermost layer is covered with a part of the opening 34a (the central region of the opening 34a in FIG. 4C). In addition, a blocking portion 35a may be provided. In this case, both side portions of the opening 34a where the blocking portion 35a does not exist are locations where the resin passes during resin sealing.

In the method for manufacturing a skewed laminated core according to the present embodiment, the cutting means 20 is installed on the discharge side of the mold 19 that forms the segment core piece 10 connected from the band-shaped material 18 via the connecting portion 11. The strip-shaped core piece 12 was produced, and the produced strip-like core piece 12 was conveyed to the winding laminator 22 to form the laminated core 17. However, as shown in FIG. The segment core pieces 10 that are supplied to the connecting portion 11 and connected via the connecting portion 11 are manufactured and transferred to a winding machine (not shown) via the discharge conveying path 36 to form a coil. As shown in FIG. 5 (B), the connected segment core pieces 10 unwound from the coil are supplied to the winding laminator 22 via the receiving transfer path 37 to form a thin wound core in order. Laminated and laminated iron core It may be formed. A cutting means 38 provided with a punch and a die is installed on the outlet side of the receiving conveyance path 37, and every time a certain number of segment core pieces 10 are discharged from the outlet of the receiving conveyance path 37, the cutting means 38, the both sides of the connection part 11 are cut | disconnected, and it is made to supply to the winding laminating machine 22 in the state of the strip | belt-shaped iron core piece 12. FIG.

Then, the effect | action of the laminated core 17 manufactured with the manufacturing method of the laminated core with a skew which concerns on the 1st Embodiment of this invention is demonstrated.
As shown in FIGS. 2A and 2C, the laminated core 17 is formed by laminating a plurality (three in FIGS. 2A and 2C) of thin wound cores 16. Here, as shown in FIG. 3 (B), the thin wound core 16 is formed in a spiral shape by bending the strip-shaped core pieces 12 in which the segment core pieces 10 are connected via the connecting portions 11 at the connecting portions 11. Since it is formed by winding, there are stepped portions 13 and 14 at the beginning and end of winding of the thin wound core 16. In the thin wound core 16, the leading end surface of the step portion 13 at the beginning of winding is a minute angle θ (half the skew angle φ) with respect to the connecting line 27 between the segment core pieces 10 arranged on both upper sides of the step portion 13. ) And the end surface of the stepped portion 14 at the end of winding is on the front side by a minute angle θ with respect to the connecting line 27a between the segment core pieces 10 arranged on both lower sides of the stepped portion 14. Truncated.

For this reason, as shown in FIG. 3B, in the thin wound core 16, the leading end surface and the end surface of the winding end are shifted by a skew angle φ when the thin wound core 16 is viewed from the axial direction. . Therefore, as shown in FIG. 1C, the lower end of the thin wound core 16 on the lower side is brought into contact with the end face of the winding end of the upper thin wound core 16 in the circumferential direction while being thinned. When the laminated iron core 16 is formed by laminating the wound iron cores 16, there is no interference or gap between the winding end and the beginning of winding of the upper and lower thin wound iron cores 16, and the upper thin iron core 16 is placed on the upper side. The thin wound core 16 can be laminated in a state where it is rotated by a certain angle φ in the circumferential direction. As a result, a skew can be provided in the magnetic pole part 15 of the laminated iron core 17, and the laminated iron core 17 having excellent magnetic performance can be manufactured with a high material yield.

Further, since the upper and lower thin wound cores 16 are laminated while rotating in the circumferential direction by an angle φ, the position of the magnet insertion hole 29 of each thin wound core 16 is shifted with respect to the lamination direction. Even if areas where the magnet insertion holes 29 do not overlap each other are formed on the lower one side and the upper other side of 29, there is no gap between the end surface and the front end surface of the upper and lower thin wound cores 16; The non-overlapping region 29a on the lower side of the hole 29 (see FIG. 1C) is the non-overlapping region 29b on the other side of the upper side of the magnet insertion hole 29. (See FIG. 1C), the lower surfaces of the thin wound cores 16 laminated on the upper side are respectively covered to be in a closed state. For this reason, when the permanent magnet 28 inserted into the magnet insertion hole 29 of each thin wound core 16 is resin-sealed, the laminated core 17 is sandwiched from above and below with a resin injection mold (not shown), for example, the uppermost stage When the resin is injected into the magnet insertion hole 29 of the thin wound iron core 16 and the resin is supplied into the magnet insertion hole 29 of the lower thin wound core 16 using the overlapping region of the magnet insertion hole 29, the resin Leakage from the magnet insertion hole 29 can be prevented.

As shown in FIG. 6A, the method for manufacturing a laminated core having a skew according to the second embodiment of the present invention is compared with the method for producing a laminated core having a skew according to the first embodiment. The segment core piece 40 located on the rear end side of the strip-shaped core piece 39, the segment core piece 41 following the segment core piece 40, and the segment core piece 41 following the strip-type core piece 41 and following the strip-shaped core piece 39. The method is characterized in that the method of forming the segment core piece 43 located on the tip side of the piece 42 is different from the method of cutting when forming the strip-shaped core pieces 39 and 42 from the continuous segment core pieces. The other segment core pieces excluding the segment core pieces 40, 41 and 43 have the same shape as the segment core piece 10. For this reason, only the formation method of the segment core pieces 40, 41, 43 and the formation method of the strip-shaped core pieces 39, 42 will be described.

As shown in FIG. 6A, the formation of the segment core pieces 40, 41 does not form the end of the segment core piece 40 and the tip of the segment core piece 41, and the end side of the segment core piece 40 is the segment core piece. 40, each of the radially inner and outer contour lines is extended to the end side (segment core piece 41 side), and the distal end side of the segment core piece 41 has a radially inner side and a radial direction of the segment core piece 41. Each outer contour line is formed to extend to the tip side (segment core piece 40 side). As a result, the segment core pieces 40 and 41 are connected to each other by the extension portions 44 and 45, respectively. Further, the formation of the segment core pieces 41 and 43 does not form the end of the segment core piece 41 and the tip of the segment core piece 43, and the end side of the segment core piece 41 is the inner side in the radial direction and the radial direction of the segment core piece 41. Each outer contour line is formed to extend to the end side (segment core piece 43 side), and the distal end side of the segment core piece 43 has the radially inner and outer contour lines of the segment core piece 43 at the distal end side. It extends to the segment core piece 41 side. As a result, the segment core pieces 41 and 43 are connected by the extension portions 46 and 47, respectively.

And if the extension parts 44 and 45 which are going to cut | disconnect enter into the cutting means which is not shown in figure, the extension parts 44 and 45 will be cut | disconnected. At this time, as shown in FIG. 6B, for the preceding segment core piece 40, for example, the end surface 48 of the segment core piece 40 is the other segment core piece excluding the segment core pieces 40, 41, 43. The position of the fan-shaped segment core piece 40 is extended in the direction in which the central angle increases by a minute angle θ that is half the skew angle φ from the position of the flat portion of the end face 49. For the subsequent segment core piece 41, the tip end surface 50 of the segment core piece 41 is skewed more than the position of the flat end of the tip end face 51 of the other segment core pieces excluding the segment core pieces 40, 41, 43. Only the minute angle θ which is half of the angle φ is a position moved in the direction in which the central angle of the fan-shaped segment core piece 40 decreases.

Further, when the extension portions 46 and 47 to be cut enter a cutting means (not shown), both side regions of the extension portions 46 and 47 are cut. At this time, for the subsequent segment core piece 43, for example, the tip end surface 52 of the segment core piece 43 is the position of the flat end portion of the tip end face 53 of the other segment core piece excluding the segment core pieces 40, 41, 43. The fan-shaped segment core piece 43 is positioned so as to extend in the direction in which the central angle increases by a minute angle θ that is half the skew angle φ. As for the preceding segment core piece 41, the end face 52a of the segment core piece 41 is skewed more than the flat end position of the end face 53a of the other segment core pieces excluding the segment core pieces 40, 41, 43. Only the minute angle θ which is half of φ is a position where the central angle of the fan-shaped segment core piece 40 has moved in the decreasing direction.

When the strip-shaped core pieces 39 and 42 are formed, the segment core pieces 41 separated from the strip-shaped core pieces 39 and 42 are discarded.
Further, by adjusting the position of the end surface 48 of the segment core piece 40 and the position of the tip end face 52 of the segment core piece 43, the center angle of the fan-shaped segment core pieces 40, 43 is a minute angle θ that is half the skew angle φ. However, depending on the shape of the strip core piece, the position of the end face of the segment core piece on the end side of the strip core piece and the position of the tip face of the segment core piece on the tip side can be changed The center angle of each of the segment core pieces and the segment core pieces on the front end side can be appropriately changed.

Then, as shown in FIG. 6C, the end surface of the stepped portion at the end of winding of the thin wound core 54 formed from the strip-shaped core piece 39 and the step portion at the beginning of winding of the thin wound core 55 formed from the strip-shaped core piece 42. When the laminated core is formed by abutting the front end surface of the laminated core in the circumferential direction, the thin wound core 55 is formed with respect to the magnet insertion hole 56 formed in the thin wound core 54 as viewed from the axial direction of the laminated core. The magnet insertion holes 57 formed in the are arranged with a skew angle φ shifted. For this reason, when permanent magnets (not shown) are respectively inserted into the magnet insertion holes 56 and 57 of the thin wound cores 54 and 55, the permanent magnets inserted into the magnet insertion holes 57 with respect to the permanent magnets inserted into the magnet insertion holes 56. The magnets can be arranged with a skew angle φ shifted in the circumferential direction.
The angle width θ of the extended minute angle region is 0 <θ <α when the angle between the end portions of the adjacent magnet insertion holes 56 (57) is α and the number of laminated thin cores 54 (55) is n. It is preferably in the range of / n.
The operation of the laminated core manufactured by the method for manufacturing a laminated core having skew according to the second embodiment of the present invention is the same as that of the laminated core manufactured by the method for manufacturing the laminated core having skew according to the first embodiment. Since the operation is the same as that of the iron core 17, the description thereof is omitted.

As described above, the present invention has been described with reference to the embodiment. However, the present invention is not limited to the configuration described in the above-described embodiment, and the matters described in the scope of claims. Other embodiments and modifications conceivable within the scope are also included.
Further, the present invention also includes a combination of components included in the present embodiment and other embodiments and modifications.
For example, in the method of manufacturing a laminated core having a skew according to the first embodiment, both the beginning and end of winding of the strip-shaped core piece are cut off by a small angle region to form a thin wound core. Either the beginning or the end of winding may be cut off by a small angle region to form a thin wound core.
Further, in the method for manufacturing a skewed laminated core according to the second embodiment, a thin wound core is formed by extending both the winding start and end of the strip-shaped core piece by a small angle width. Either the winding start or the winding end may be extended by a minute angle to form a thin wound core.

Furthermore, in the method for manufacturing a laminated core having a skew according to the first and second embodiments, the thin wound core is formed by using one strip-shaped core, but the method for producing a laminated core having a skew according to the present invention. 7 has a skew as shown in FIG. 7B by laminating a plurality of two-strand-type thin wound cores 60 shown in FIG. 7A, which are formed by using two strip-like core pieces 58 and 59. The present invention can also be applied when the laminated iron core 61 is manufactured. In this case, either one or both of the winding start and the winding end of each of the strip-shaped core pieces 58 and 59 are cut off by a minute angle region, or one or both of the winding start and the winding end are extended by a minute angle width, The winding start and end of the strip-shaped core pieces 58 and 59 are shifted by a skew angle.
Moreover, in the said embodiment, although two magnetic pole piece parts were provided in each segment iron core piece, one or more (three or more) magnetic pole piece parts can also be provided.

10: segment core piece, 11: connecting part, 12: strip-shaped iron core piece, 13, 14: stepped part, 15: magnetic pole part, 16: thin wound core, 17: laminated core, 18: material, 19: mold, 20 : Cutting means, 21: transport path, 22: winding laminator, 23, 24: end surface, 25, 26: tip surface, 27, 27a: connecting wire, 28: permanent magnet, 29: magnet insertion hole, 29a, 29b : Non-overlapping region, 30: magnetic pole piece part, 31: opening part, 32: protruding core part, 33, 33a: segment iron core piece, 34, 34a: opening part, 35: crosspiece, 35a: blocking part, 36: payout Transport path, 37: receiving transport path, 38: cutting means, 39: strip iron core piece, 40, 41: segment iron core piece, 42: strip iron core piece, 43: segment iron core piece, 44, 45, 46, 47: Extension part, 48, 49: End surface, 50, 5 , 52, 53: front end face, 52a, 53a: end surface, 54, 55: thin-wound core, 56, 57: magnet insertion holes, 58, 59: strip core piece, 60: thin-wound core, 61: laminated core

Claims (8)

Each segment core piece is formed by bending a strip-shaped core piece connected by a connecting portion and winding it in a spiral manner, and has a step portion at the start and end of winding of the strip-shaped core piece. In addition, the stepped portion forms a thin wound core formed between adjacent magnetic pole portions in plan view, and the thin wound core is laminated in a state where the magnetic pole portions are gradually shifted to form the magnetic pole portion. In a method of manufacturing a laminated iron core having a skew in
Either one or both of the start and end of winding of the strip-shaped core pieces are cut off by a small angle region to form the thin wound core, and in the lamination of the thin wound cores adjacent to each other vertically, A method of manufacturing a laminated core having a skew, wherein the stepped portion at the end of winding of the iron core and the stepped portion at the start of winding are brought into contact with each other in the circumferential direction. 2. The manufacturing method of a laminated core having a skew according to claim 1, wherein each of the thin wound cores has a magnet insertion hole for inserting a permanent magnet in a radially outer region, and an angle width θ of the cut minute angle region is When the angle between the end portions of the adjacent magnet insertion holes is α, and the number of laminated thin cores is n, the laminated core having a skew is in the range of 0 <θ <α / n. Production method. Each segment core piece is formed by bending a strip-shaped core piece connected by a connecting portion and winding it in a spiral manner, and has a step portion at the start and end of winding of the strip-shaped core piece. In addition, the stepped portion forms a thin wound core formed between adjacent magnetic pole portions in plan view, and the thin wound core is laminated in a state where the magnetic pole portions are gradually shifted to form the magnetic pole portion. In a method of manufacturing a laminated iron core having a skew in
One or both of the start and end of winding of the strip-shaped core pieces are extended by a small angle to form the thin wound core, and in the lamination of the thin wound cores adjacent to each other above and below, A method of manufacturing a laminated core having a skew, wherein the stepped portion at the end of winding of the wound core and the stepped portion at the start of winding are brought into contact with each other in the circumferential direction. 4. The manufacturing method of a laminated core having skew according to claim 3, wherein each of the thin wound cores has a magnet insertion hole for inserting a permanent magnet in a radially outer region, and an angular width θ of the extended minute angle region is When the angle between the end portions of the adjacent magnet insertion holes is α, and the number of laminated thin cores is n, the laminated core having a skew is in the range of 0 <θ <α / n. Production method. 5. The manufacturing method of a laminated core having a skew according to claim 2 or 4, wherein the segment core piece in the lowermost layer of each thin wound core has a magnet inclination in a region where the magnet insertion holes of the upper and lower thin wound cores overlap. A manufacturing method of a laminated iron core having a skew, characterized in that a prevention means is provided. 6. The method for manufacturing a skewed laminated iron core according to claim 5, wherein the magnet inclination preventing means includes a projecting core portion projecting inside the magnet insertion hole of the lowermost segment core piece or a beam straddling the magnet insertion hole. A method for manufacturing a laminated iron core having a skew, characterized in that: In the manufacturing method of the laminated iron core which has a skew of Claim 2 or 4, The block part which covers a part of said magnet insertion hole is formed in the said segment core piece of the lowest layer of each said thin wound core. A method of manufacturing a laminated iron core having a characteristic skew. 8. The method of manufacturing a laminated core having a skew according to claim 1, wherein each segment core piece has one or a plurality of magnetic pole pieces. .

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