JP2014121136A - Method of manufacturing stator core of rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of economically manufacturing a stator core of a rotary electric machine, which can secure high strength and high quality although using a belt-like core sheet as an iron core raw material, by installing simple manufacturing facilities.SOLUTION: A method of manufacturing a stator core includes a first roller 21 and a pair of second rollers 22, 23 arranged inside and outside a winding path W with the winding path therebetween for a winding process (second process) as a main process of the method, and a belt-like core sheet 10 is bent by employing the principle of so-called three-point bending in which the sheet is bent while pressed at three places of inner and outer peripheries thereof, so respective winding layers can be rounded excellently circularly, so that a cylindrical laminate core 1 of high quality with high circularity can be obtained. Further, only simple manufacturing facilities which only have rollers 21-23 arranged in the winding path W are necessary and the laminate core 1 (stator iron core) can be economically manufactured.

Description

  The present invention relates to a method of manufacturing a stator core suitable for a stator core of a rotating electric machine, particularly a stator of an automotive alternator.

[Conventional technology]
In recent years, this type of stator core is formed by punching a ring-shaped plate having teeth and slots on the inner peripheral side from a magnetic plate (for example, a steel plate) and laminating a large number of this ring-shaped plate into a cylindrical shape. Instead of a laminated core, a belt-shaped core sheet with a tooth part and a slot part punched and formed on one side is wound in a spiral shape (helical) for multiple layers in order to reduce waste and improve material yield. Laminated cores formed by winding and laminating have been used exclusively.

  Such a stator core has a plurality of layers in a cylindrical shape while winding a belt-shaped core sheet in a spiral shape (helical) so that one side in the length direction (the teeth portion and the slot portion side) is inside. In winding and laminating over a large area, the biggest issue is how to wind up in a shape close to a perfect circle.

As an effective method for solving such a problem, a manufacturing method for winding a strip-shaped core sheet while rolling a tapered portion on the other side in the length direction (yoke portion side) is currently proposed and practically used. (See, for example, Patent Document 1).
According to the manufacturing method described in Patent Document 1, by using a pair of conical rolling rollers and passing the yoke portion of the core sheet between the pair of rolling rollers, the outer peripheral edge of the yoke portion is disposed on both sides thereof. It is fundamental to perform a taper rolling process that extends thinly from the side to form a double-sided tapered portion.
Thus, by carrying out the taper rolling process, the substantial winding circumference on the yoke part side of the core sheet becomes longer in the formation process of the double-sided tapered part, and the core sheet itself is bent inwardly in a curved shape. It becomes easy to wind up in a spiral shape, and a cylindrical laminated core close to a perfect circle can be obtained.

[Problems of the prior art]
However, as described above, the manufacturing method in which the double-sided tapered portion is provided and spirally wound has a matter of concern as listed below in terms of practical use.

(1) Taper In order to ensure a larger bending length (winding circumference) in the rolling process, the area of the double-sided tapered portion is increased in the radial direction, and the extension length (perimeter) in the circumferential direction is increased. I have to. Forming such a double-sided tapered portion means that the outer peripheral edge of each winding layer of the laminated core becomes thin and becomes a portion vulnerable to external force.
As described in Patent Document 1, the laminated core is subjected to welding for fixing the winding layers and ironing processing for adjusting the outer peripheral shape as the final step, but it becomes thin and is subjected to external force. On the other hand, the outer peripheral edge, which has become a fragile part, is deformed and damaged in the process of transporting to the final process. In addition, a defective weld occurs in the final process, resulting in a fragile part. The outer peripheral edge is deformed into a “bite” at the time of ironing, or breaks, causing problems in strength and quality.
(2) Also, when the rolling process is carried out, the tapered part extends not only in the circumferential direction but also in the radial direction, so the outer diameter shape tends to be “bittery”, and the rounding shape by the above-mentioned ironing process is perfect. It may take a great amount of man-hours to secure this.
(3) Further, in order to effectively use the stator core as a part of the casing of the rotating electrical machine, there are many cases in which notches for inserting through bolts are formed on the outer peripheral edge at intervals of 90 °, for example. However, in this case, since the notch is formed by punching at the stage of the core sheet before winding, there is a concern that a buckling phenomenon occurs in the core sheet in the rolling process. In other words, when rolling the double-sided tapered part on the yoke part of the core sheet, the core sheet is conveyed while applying a constant rolling load, so the load per unit area becomes excessive at the notch part. It was found that an extreme bending (buckling) phenomenon occurred at this notch.

As a result of repeating various experiments and researches in order to find out such a problem, the present inventor used a belt-like core sheet as an iron core material and wound the core sheet while correcting it from both sides of the inner and outer circumferences. The present inventors have found a production method that satisfies the roundness of the laminated core and can obtain a high-strength, high-quality stator core.
Another problem is how to make such a manufacturing method economically possible with the introduction of simple manufacturing equipment.

JP 2009-081973 A

  The present invention has been made in view of the above circumstances, and an object thereof is to provide a stator core for a rotating electrical machine that can ensure high strength and high quality while using a strip-shaped core sheet as a core material. Another object of the present invention is to provide a method that can be economically manufactured by introducing a simple manufacturing facility.

[Means of Claim 1]
In the first aspect of the present invention, a band-shaped core sheet made of a magnetic plate is basically used as the iron core material, and the stator coil is wound on the inner peripheral side by winding the core sheet in a spiral shape. This is a method for manufacturing a stator core of a rotating electrical machine, in which a cylindrical laminated core having a tooth portion and a slot portion is formed.
And as a 1st process, while having a teeth part and a slot part on one side of a length direction, and having a yoke part which connects a teeth part and a slot part with a predetermined pitch on the other side of a length direction, The second step to be performed subsequently has the following characteristics while using the same steps as before for producing the belt-shaped core sheet.
In the second step, the core sheet is conveyed in the length direction, and bending is performed so that the core sheet is bent along the predetermined winding path so that the yoke portion is on the outer peripheral side. And
In the second step, with respect to the winding path, the first roller is disposed on the radially inner side of the curvature of the winding path, and the first roller is disposed on the radially outer side of the curvature of the winding path. A set of second rollers,
The core sheet is moved along the winding path by rotating the first roller and the second roller in opposite directions while pressing the inner and outer circumferences of the core sheet at three locations by the first roller and the pair of second rollers. It is characterized by bending while being conveyed.

According to the manufacturing method of the present invention having the second step, the belt-like core sheet can be smoothly and well wound spirally by the so-called three-point bending principle of bending while pressing at three locations on the inner and outer circumferences. And a laminated core with high roundness can be obtained. Therefore, a high strength and high quality stator core can be provided.
Moreover, in terms of equipment, a simple configuration in which rollers are arranged in the winding path is sufficient, and the stator core can be manufactured economically.

BRIEF DESCRIPTION OF THE DRAWINGS It shows typically the automotive alternator which applies the stator core manufactured by the method of this invention, (a) is a half sectional view which shows the whole structure of an alternating current generator, (b) is (a). It is a front view of the upper half part which shows the form of a stator core single-piece | unit along AA line (Example 1). The main part of the stator core manufactured by the method of the present invention is shown. (A) is a front view of the core sheet produced in the first step, and (b) is a cross section taken along line BB in (a). (C) is a front view of the core sheet used for description of a winding process, (d) is a perspective view of the laminated core obtained through the 2nd process (Example 1). It is a typical process drawing with which it uses for the outline | summary description of all the processes in this invention method (Example 1). It is used for the detailed explanation of the 2nd process which makes the central process of this invention method, (a) is a flowchart showing a bending process, (b) is a partial sectional view of a roller which meets a CC line of (a). (Example 1). As another embodiment of the method of the present invention, it will be used for detailed description of the second step forming the central step, (a) is a process diagram showing a bending process, (b) is a view in the direction of arrow D in (a). There is (Example 2).

  Hereinafter, the best mode for carrying out the manufacturing method of the present invention will be described in detail according to two embodiments shown in the drawings.

Each example shows a stator core of an automotive alternator (alternator) as a representative example of a stator core to which the manufacturing method of the present invention is applied. In the following description, first, an automotive alternator is shown. The basic structure of the method of the present invention and the basic functions of the method of the present invention will be described in order, and finally the effects of the feature points of the method of the present invention will be summarized and listed.
In each embodiment, the same or equivalent parts are denoted by the same reference numerals, and redundant description is omitted.

[Example 1]
Based on FIG. 1 and FIG. 2, a basic configuration of an AC generator ACG to which the manufacturing method of the present invention is applied will be described.

[Basic configuration of AC generator ACG]
As shown in FIG. 1A, the AC generator ACG is sandwiched between a pair of cup-shaped casings C by a rotor GR attached to a rotating shaft J driven by an engine and through bolts B. The stator GS includes a cylindrical laminated core 1 as shown in FIG. 1B as an iron core to which a stator coil (multi-phase winding) D is attached. A stator core E is used.
The stator core E is used as a part of the casing of the AC generator ACG by being sandwiched and fixed by a pair of cup-shaped casings C. A plurality of teeth (teeth) E1 and slots (grooves) E2 around which the coil D is wound are alternately provided, and yokes (relays) that connect the teeth E1 and the slots E2 in an annular shape at a predetermined pitch on the outer peripheral side. ) The cylindrical laminated core 1 is provided with a portion E3. The annular yoke portion E3 is a non-winding portion on which the stator coil D is not wound, and the stator iron core E is cut so that through bolts B can be inserted into the outer peripheral edge of the yoke portion E3 at intervals of 90 °, for example. A notch E4 is formed. This notch E4 has a semicircular shape.

  In this description, the same structural body as the entity is referred to with the stator core E and the laminated core 1 being distinguished from each other, but basically the final manufacturing process is referred to. The thing of the predetermined shape completed after that is called the stator core E, and the thing in the state in the manufacturing process in the middle shall be called the laminated core 1 from the form.

[Basic structure of laminated core 1]
The laminated core 1 uses a belt-like core sheet 10 as shown in FIGS. 2A and 2B as an iron core material. The core sheet 10 has teeth (teeth) 11 and slots (grooves) 12 for winding the stator coil D on one side in the length direction, and these teeth on the other side in the length direction. A yoke (joint) portion 13 for connecting the portion 11 and the slot portion 12 at a predetermined pitch is provided, and a semicircular notch for inserting through bolts at intervals of 90 ° is provided on the outer peripheral edge of the yoke portion 13, for example. 14 is formed, for example, as a pair of (two) band-shaped core sheets by punching a wide band-shaped magnetic plate so that the teeth 11 and the slots 12 are alternately arranged. A single belt-like core sheet is produced by punching out a manufactured or narrow belt-like magnetic plate so that the teeth 11 and the slots 12 are alternately arranged on one side thereof. It is intended to be produced.
Then, as shown in FIG. 2 (c), the core sheet 10 is wound and laminated over a plurality of layers while being spirally wound so that the yoke portion 13 is on the outer peripheral side. A cylindrical laminated core 1 as shown is used.

Next, a specific method for manufacturing the laminated core 1 having the above configuration will be described with reference to FIG.
FIG. 3 is a process diagram schematically showing an overview of all steps in the production method of the present invention. The production method of the present invention can be roughly divided from the first step (pressing step) for producing the core sheet 10. Then, through the second step (winding step) of winding this in a spiral manner and the third step (fixing step) for cutting and fixing each winding layer by a predetermined lamination dimension, finishing the laminated core 1 such as shaping. It consists of four steps up to the fourth step (finishing step) for processing.

First, the steps from the first step to the fourth step will be outlined in accordance with the schematic process diagram shown in FIG.
○ 1st process (press process)
This first step is a well-known step that is generally employed. For example, a strip-shaped magnetic plate T such as a strip steel (SPCC) is put into appropriate punching means U and V such as a continuous press machine. Punching is sequentially performed, and two continuous core sheets 10 are produced by dividing into two in the length direction. Thus, the core sheet 10 as shown in FIG. 2 (a), that is, the tooth portion 11 and the slot portion 12 are provided on one side in the length direction, and the teeth portion 11 and the slot portion 12 are provided on the other side in the length direction. A band-shaped core sheet 10 having a yoke portion 13 connected at a pitch of and a notch 14 formed on the outer peripheral edge of the yoke portion 13 is obtained.

○ 2nd process (winding process)
This second step is a central step of the method of the present invention. While the belt-like core sheet 10 is transported in the length direction, the yoke portion 13 is arranged on the outer circumference along a predetermined winding path W. This is a step of performing a bending process to bend toward the side.
In the second step, a roller device (roller means) 20 is used as the bending means X disposed along the winding path W. The roller device 20 basically includes a first roller 21 disposed radially inward of the curvature of the winding path W with respect to the winding path W, and a radially outer side of the curvature of the winding path W. A pair of second rollers 22 and 23 are provided so as to sandwich the first roller 21 from the circumferential direction. The first roller 21 serves as a driving side, and the pair of second rollers 22 and 23 is driven by the first roller 21 to follow and rotate, and rotate in opposite directions.
When the core sheet 10 is inserted into the roller device 20, the first roller 21 and the second roller 22, while the inner and outer circumferences are pressed at three locations by the first roller 21 and the pair of second rollers 22 and 23, In this process, it is bent along the winding path W and bent into a curved shape.
In this way, the core sheet 10 is formed into a curved shape by the roller device 20, and the core sheet 10 is spirally wound and formed into a cylindrical shape so that the yoke portion 13 is on the outer peripheral side. A laminated core 1 as shown in d) is produced.
The configuration of the roller device 20 and the details of the bending process will be described later in detail.

○ Third step (fixed size step)
Since the laminated core 1 wound in a cylindrical shape is in a continuous laminated state, the laminated core 1 is cut for each predetermined laminated dimension (thickness) and taken out as one laminated core 1 and each wound layer is not displaced. Thus, the outer peripheral edge is appropriately fixed by, for example, welding.

○ Fourth process (finishing process)
Finally, the laminated core 1 is put into the finishing process. This finishing process is a well-known process that is generally employed, and includes an appropriate finishing processing means Y such as a shaping machine, and has a roundness on the outer diameter side and a concentricity on the inner diameter side of the laminated core 1. Various finishing processes for ensuring a predetermined shape such as a degree and a squareness are performed, and the final laminated core 1, that is, the stator core E is obtained.

  Note that the stator core E completed as described above passes through a conventionally known general winding process and assembly process in sequence, as shown in FIG. After the coil D is mounted, the stator GS is incorporated into the AC generator ACG.

  Next, regarding the second step that forms the basis of the method of the present invention, the configuration of the roller device 20 and details of the bending process will be described in detail with reference to FIGS. 4 (a) and 4 (b).

The second step in this embodiment is set to a basic configuration that obtains a predetermined outer diameter of the laminated core 1 by two-stage bending of initial bending and main bending. A two-stage roller device 20 of a first-stage roller device (roller means) 20A for bending and a second-stage roller device (roller means) 20B for main bending is employed.
The roller devices 20 </ b> A and 20 </ b> B at each stage are sequentially arranged along the winding path W.

  Here, the winding path W refers to the inlet side (conveying inlet) of the core sheet 10 so that the band-shaped core sheet 10 is formed in a curved shape in order to finally obtain the laminated core 1 having a predetermined winding diameter. The curvature is set so as to gradually decrease from the side) along the traveling direction (conveying direction), and this curvature is determined stepwise by the roller devices 20A and 20B at each stage as described later. .

  The roller devices 20A and 20B at each stage are configured by a group of rollers having substantially the same combination, and are arranged in a manner opposed to a group of rollers opposed to each other across the winding path W, that is, the first roller (inner roller) 21. A pair of second rollers (outer rollers) 22 and 23 is provided. The first roller 21 is driven by a driving source 24 such as a motor and rotates. On the other hand, a pair of second rollers 22 and 23 are rotatably supported to follow and rotate. The first roller 21 and the second rollers 22 and 23 are in a reverse rotation relationship with each other via the core sheet 10 passed between them.

  In each stage of the roller device 20A, 20B, the first roller 21 on the driving side is disposed radially inside the winding path W, and the pair of second rollers 22, 23 on the driven side includes the winding roller W. Although arranged outside the path W in the radial direction, specifications such as the arrangement relationship of these three rollers 21, 22, 23 and the arrangement relationship of the roller devices 20A, 20B at each stage are set as follows. .

  First, one first-stage roller device 20A is arranged so that each of the rollers 21, 22, 23 satisfies a predetermined curvature R1 required for the first stage (initial bending). The two rollers 22 and 23 are located on both sides of a reference line P1 drawn in the radial direction of the curvature R1 through the rotation center O1 of the first roller 21, and are spaced apart so as to sandwich the first roller 21. It is installed. Each roller surface of each roller is formed into V grooves 21a, 22a, 23a having a radial direction along the circumferential direction, and the inner and outer peripheral edges of the core sheet 10 are in contact with each other in these V grooves. Touch. In other words, the tooth portion 11 of the core sheet 10 contacts the V groove 21a, and the yoke portion 13 of the core sheet 10 contacts the V grooves 22a and 23a.

  Therefore, the core sheet 10 is pressed from the inner and outer peripheral sides while being sent in the rotation direction by the rotation of the first roller 21 and the second rollers 22, 23, and the contact point with the first roller 21 is a fulcrum. Based on the so-called three-point bending principle in which the point of contact with the second rollers 22 and 23 is the point of action of the bending force, bending is performed with a predetermined curvature R1 in the width direction while extending in the length direction (conveying direction). Will be.

  Next, the other second-stage roller device 20B has a predetermined curvature in which each of the rollers 21, 22, and 23 is further smaller than the predetermined curvature R1 in the first stage, that is, a required curvature in the second stage (main bending). R2 is arranged so as to satisfy R2, and the pair of second rollers 22, 23 is positioned on both sides with respect to a reference line P2 drawn in the radial direction of the curvature R2 through the rotation center O2 of the first roller 21. The first roller 21 is disposed so as to be sandwiched therebetween. And each roll surface of each roller 21, 22, 23 is formed in V groove 21a, 22a, 23a which makes a radial direction the depth direction along the circumferential direction like 20A of roller apparatuses of the 1st step. In addition, the inner and outer peripheral edges of the core sheet 10 come into contact with each other in these V grooves. In other words, the tooth portion 11 of the core sheet 10 contacts the V groove 21a, and the yoke portion 13 of the core sheet 10 contacts the V grooves 22a and 23a.

  Therefore, the core sheet 10 that has passed through the first-stage roller device 20A passes through the second-stage roller device 20B, and similarly, the contact point with the first roller 21 serves as a fulcrum, and the second roller Based on the principle of so-called three-point bending, where the contact point with 22 and 23 is the point of action of the bending force, bending is performed at the second stage curvature R2 in the width direction while further extending in the length direction (conveying direction). Will be given.

  In this way, the core sheet 10 passes smoothly through the two-stage roller device 20 to be smoothly and satisfactorily wound into a spiral shape and formed into a cylindrical laminated core 1 having a desired outer diameter. As a result, a desired stator core E is finally obtained.

[Effect of Example 1]
In the stator core E obtained by the manufacturing method of the present invention described above, the main functions and effects on the manufacturing surface particularly in the second step are summarized and listed below.

[1] High strength and high quality laminated core 1 (stator core E) with high roundness can be obtained.
[1-1] The core sheet 10 is bent by utilizing the principle of so-called three-point bending in which the belt-shaped core sheet 10 is bent while being pressed at three locations on the inner and outer circumferences. According to the curvature of the three rollers, that is, the pair of second rollers 22 and 23, the yoke portion 13 is curved in the width direction while extending mainly in the length direction (conveying direction; circumferential direction). Therefore, each winding layer can be favorably rounded into a circular shape, and a laminated core 1 having a predetermined winding diameter can be obtained. Therefore, a high-quality cylindrical laminated core 1 with high roundness can be obtained.
When the rolling process is performed, the tapered portion extends not only in the circumferential direction but also in the radial direction, so that the outer diameter shape tends to be “distorted”, but there is no such concern.
Moreover, since the bending process utilizes the principle of three-point bending, even when the notch 14 for inserting the through bolt is punched and formed at the stage of the core sheet 10 before winding, the load is concentrated locally. Thus, an extreme bending (buckling) phenomenon does not occur in the notch 14 portion.

[1-2] Further, since the outer peripheral edge of the yoke portion 13 is not particularly thinned with respect to the core sheet 10, no fragile portion is formed on the outer peripheral edge of each winding layer. There is substantially no gap between the entire layers. Therefore, even if an external force is applied in the process of transporting the laminated core 1 to the next process, the outer peripheral edge of the laminated core 1 is not deformed or damaged.
Similarly, in the next step (third step, fourth step), when carrying out welding processing for fixing the winding layer and ironing processing for adjusting the outer peripheral shape on the outer peripheral portion of the laminated core 1, The welding core and the outer peripheral edge are not deformed or damaged, and the stator core E can have high strength and high quality.

[1-3] As bending means X, there are two stages: a first stage roller apparatus (roller means) 20A for initial bending and a second stage roller apparatus (roller means) 20B for final bending. By adopting the type of roller device 20, the predetermined outer diameter of the laminated core 1 can be ensured by two-stage bending of initial bending and main bending, so that the core sheet 10 can be spiraled more smoothly. It can be rolled up.
[1-4] The roller surfaces of the rollers 21, 22, and 23 of the roller device 20 are V-grooves 21a, 22a, and 23a. The V-grooves 21a, 22a, and 23a are used to form the core sheet 10 as shown in FIG. Therefore, the core sheet 10 can be bent while absorbing the dimensional tolerances in the width direction and the plate thickness direction of the core sheet 10 by a so-called aligning action.

[2] The essential second step (winding step) can be performed with simple manufacturing equipment.
Since the bending process for winding is performed by a three-point bending method in which a fulcrum and an action point are formed by three rollers of the first roller 21 and a pair of second rollers 22 and 23, the taper rolling method is used. Such a large processing load is not required, and a simple configuration in which the roller device 20 is disposed in the winding path W is sufficient, and the stator core E can be manufactured economically.

[Example 2]
Next, a second embodiment of the manufacturing method of the present invention will be described based on FIGS. 5A and 5B with a focus on differences from the first embodiment.

  The second embodiment basically uses a two-stage roller device 20 as the bending means X that performs the central function in the second step (winding step), but a part of the specific combination configuration is used. The other configurations are substantially the same as those of the first embodiment.

Also in the present embodiment, as the bending means X, as shown in FIG. 5A, a curvature R1 is obtained in order to obtain a predetermined outer diameter of the laminated core 1 in two stages of initial bending and main bending. A first-stage roller device (roller means) 20A for initial bending and a second-stage roller device (roller means) 20B for main bending to obtain the curvature R2. A roller device 20 is employed. The roller devices 20 </ b> A and 20 </ b> B at each stage are sequentially arranged along the winding path W.
Here, a specific difference from the first embodiment is that in the first-stage roller device 20A for the initial bending process, one (input side) of the pair of second rollers (22, 23). The roller (22) is replaced with the taper forming roller means 25.

As shown in FIG. 5B, the taper forming roller means 25 is composed of a pair of rollers of a conical roller 25a on the driving side and a planar roller 25b on the driven side. By pressing the outer peripheral edge of the yoke portion 13 from one side and forming a one-side tapered portion 13a at this portion, the yoke portion 13 extends in the length direction and the core sheet 10 is easily bent. .
Each of the rollers 25a and 25b has an axis positioned in the radial direction of the winding path W, and the roller means 25 also applies the load to the core sheet 10 from the axial direction. It has a function of pressing in the radial direction from the side.
Accordingly, the taper forming roller means 25 also functions as an initial bending process in accordance with a so-called three-point bending principle in cooperation with the first roller 21 and the second roller 23.

  Thus, in this embodiment, in the first stage roller device 20A for the initial bending process, the taper forming roller means 25 forms the one-side tapered portion 13a on the outer peripheral edge of the yoke portion 13 of the core sheet 10, By extending the yoke portion 13 in the length direction, the core sheet 10 is bent by a so-called three-point bending action by the cooperation of the first roller 21, the second roller 23, and the roller means 25 while the core sheet 10 is curved. On the other hand, an initial bending process with a curvature R1 can be performed.

Also in this embodiment, the bending is performed by utilizing the principle of so-called three-point bending in which the belt-shaped core sheet 10 is bent while being pressed at three locations on the inner and outer circumferences. An effect can be obtained.
In particular, according to the present embodiment, by forming the one-side tapered portion 13a on the outer peripheral edge of the yoke portion 13, the core sheet 10 can be easily bent, so that the curvature in the initial bending process and the main bending process can be increased. it can.
Moreover, since the tapered portion 13a is a single side and is used for pre-processing for promoting the initial bending process and can reduce the taper amount, an extremely thin portion (part) is formed on the outer peripheral edge of the laminated core 1. The desired strength and quality can be ensured for the stator core E as well as the laminated core 1 without being formed.

[Modification]
Although the method of the present invention has been described in detail for two embodiments, various modifications can be made without departing from the spirit of the present invention, and some of the modifications will be exemplified.

(1) Modification of Embodiment 1 In Embodiment 1 described above, the bending device X is a two-stage roller device 20 that obtains a predetermined outer diameter of the laminated core 1 in two stages of initial bending and main bending. However, depending on the required outer diameter of the laminated core 1 and the required processing speed, the one-stage roller device 20 that is implemented only by the main bending roller device 20B may be used, or the initial bending processing may be performed. It is also possible to employ a multistage roller device 20 in which at least one of the roller device 20A and the main bending roller device 20B is arranged in two or more stages, and bending is performed over three or more stages as a whole.
In particular, when the multistage roller device 20 is adopted, the laminated core 1 can be formed in a perfect circle while changing the curvature little by little at each stage, so that the load burden at each stage is reduced. It is possible to manufacture the laminated core 1 having a highly accurate outer diameter while keeping it small. Further, the curvature can be changed (adjusted), for example, from large to small by changing the interval between the rollers in each stage from large to small.

(2) Modification of Example 2 The present bending roller device 20B is not limited to one stage, and the bending roller apparatus 20B is arranged in two or more stages in the same manner as the modification of Example 1 above. Of course, it is of course possible to employ a multistage roller device 20 that performs bending over three or more stages as a whole.
In the second embodiment, the taper forming roller means 25 is utilized (concurrently used) as a part of the first stage roller device 20A for the initial bending process. By using independently as a means for preliminary bending or initial bending in the bending means X, a tapered portion 13a is formed on the outer peripheral edge of the yoke portion 13 of the core sheet 10 to perform preliminary bending or initial bending. Can be bent while pressing the inner and outer periphery of the core sheet 10 at three locations.
As a specific example, for example, (A) the taper forming roller means 25 is used as the processing means (preliminary bending processing means) in the previous stage of the initial bending processing means, and then in two stages as in Example 1 (initial bending processing and (B) The method of performing the bending process (B), in Example 1, the initial bending means itself is constituted only by the taper forming roller means 25, and the initial bending process is performed only by the taper forming roller means 25. There is a way.

(3) In Examples 1 and 2 and the above-described modification, when the core sheet 10 is spirally wound along the winding path W, the core sheet 10 is shifted in the axial direction by the thickness of one turn of the spiral winding. Therefore, in order to practice smoother winding, if each roller of the roller device 20A for initial bending and the roller device 20B for main bending is gradually shifted in the axial direction along the winding path W, it is arranged. It is effective.
In the above-described example, the first roller (inner roller) 21 is driven on the roller device 20, but the present invention is not limited to this, and a means for forcibly feeding the core sheet 10 in the transport direction is additionally provided. In this case, even if the first roller (inner roller) 21 is made free (rotatable) together with a pair of second rollers (outer rollers) 22, 23, the first roller 21 and a pair of second rollers 22, Of course, a three-point bending method in which the fulcrum and the action point are formed and bent by the three rollers 23 and 23 can be implemented.

  In the above embodiment, the case where the manufacturing method of the present invention is applied to a stator iron core of an automotive alternator (alternator) has been described. However, the present invention is not limited to this, and a belt-like core sheet made of a magnetic plate as a core material. The present invention can be applied to a rotary electric machine having a stator core in which is used, for example, a high voltage drive motor, and the same effect can be obtained.

  DESCRIPTION OF SYMBOLS 1 ... Laminated core, 10 ... Core sheet, 11 ... Teeth part, 12 ... Slot part, 13 ... Yoke part, 20 ... Roller apparatus (bending process means X), 21 ... 1st roller, 22, 23 ... 2nd roller, ACG: AC generator (rotary electric machine) for automobile, D: stator coil, E: stator core, W: winding path.

Claims (8)

A belt-shaped core sheet (10) made of a magnetic plate is used as the iron core material, and the teeth for winding the stator coil (D) on the inner peripheral side by winding the core sheet (10) in a spiral shape A method of manufacturing a stator core (E) of a rotating electrical machine (ACG), in which a cylindrical laminated core (1) having a portion (11) and a slot portion (12) is configured,
The teeth portion (11) and the slot portion (12) are provided on one side in the length direction, and the teeth portion (11) and the slot portion (12) are connected to the other side in the length direction at a predetermined pitch. A first step of producing the core sheet (10) so as to have a yoke portion (13)
While conveying the core sheet (10) in the length direction, the core sheet (10) is bent along the predetermined winding path (W) so that the yoke portion (13) is on the outer peripheral side. And a second step of performing bending for
In the second step, the first roller (21) disposed radially inward of the curvature of the winding path (W) with respect to the winding path (W), and the curvature of the winding path (W). Bending means X (20) composed of a pair of second rollers (22, 23) arranged so as to sandwich the first roller (21) on the outside in the radial direction of
The first roller (21) and the second roller (22, 22) while pressing the inner and outer periphery of the core sheet (10) at three locations by the first roller (21) and a pair of second rollers (22, 23). 23) are rotated in opposite directions to bend the core sheet (10) while being conveyed along the winding path (W). Manufacturing method of iron core (E). In the manufacturing method of the stator core (E) of the rotating electrical machine (ACG) according to claim 1,
As the bending means X (20), the first-stage roller means (20A) composed of the first roller (21) and the second roller (22, 23) for initial bending and the bending means X (20). A second-stage roller means (20B) comprising a first roller (21) and a second roller (22, 23), and performing the bending process in two stages of an initial bending process and a main bending process. The manufacturing method of the stator core (E) of a rotary electric machine (ACG) characterized by these. In the manufacturing method of the stator core (E) of the rotating electrical machine (ACG) according to claim 1 or 2,
Each of the rollers (21, 22, 23) constituting the bending means X (20) has V-grooves (21a, 22a, 23a) in which the respective roll surfaces have a radial direction along the circumferential direction. A method of manufacturing a stator core (E) of a rotating electrical machine (ACG), characterized in that the inner and outer peripheral edges of the core sheet (10) are pressed by the V-groove. In the manufacturing method of the stator core (E) of the rotating electrical machine (ACG) according to any one of claims 1 to 3,
As a means for preliminary bending or initial bending in the bending means X (20), for forming a taper by pressing the outer peripheral edge of the yoke portion (13) of the core sheet (10) from above and below. Comprising roller means (25),
Bending while pressing the inner and outer peripheries of the core sheet (10) after forming a tapered portion (13A) on the outer peripheral edge of the yoke (13) of the core sheet (10) and performing pre-bending or initial bending. The manufacturing method of the stator core (E) of a rotary electric machine (ACG) characterized by performing. A belt-shaped core sheet (10) made of a magnetic plate is used as the iron core material, and the teeth for winding the stator coil (D) on the inner peripheral side by winding the core sheet (10) in a spiral shape A method of manufacturing a stator core (E) of a rotating electrical machine (ACG), in which a cylindrical laminated core (1) having a portion (11) and a slot portion (12) is configured,
The teeth portion (11) and the slot portion (12) are provided on one side in the length direction, and the teeth portion (11) and the slot portion (12) are connected to the other side in the length direction at a predetermined pitch. A first step of producing the core sheet (10) so as to have a yoke portion (13)
While conveying the core sheet (10) in the length direction, the core sheet (10) is bent along the predetermined winding path (W) so that the yoke portion (13) is on the outer peripheral side. And a second step of performing bending for
In the second step, the first roller (21) disposed radially inward of the curvature of the winding path (W) with respect to the winding path (W), and the curvature of the winding path (W). A bending means (20) composed of a pair of second rollers (23, 25) arranged so as to sandwich the first roller (21) on the outside in the radial direction of
Of the pair of second rollers (23, 25), a second roller disposed on the front side in the conveying direction presses the outer peripheral edge of the yoke portion (13) of the core sheet (10) from above and below to taper. It is composed of taper forming roller means (25) which is formed into a shape,
The first roller (21) and the second roller (23, 23) while pressing the inner and outer periphery of the core sheet (10) at three locations by the first roller (21) and a pair of second rollers (23, 25). 25), the core sheet (10) is bent while being conveyed along the winding path (W), and the stator core (E) of the rotating electrical machine (ACG) is bent. Production method. In the manufacturing method of the stator core (E) of the rotating electrical machine (ACG) according to claim 5,
The taper forming roller means (25) includes a conical roller (25a) and a planar roller (25b), and the outer peripheral edge of the yoke portion (13) of the core sheet (10) is formed into a single-side taper shape. The manufacturing method of the stator core (E) of a rotary electric machine (ACG) characterized by performing. In the manufacturing method of the stator core (E) of the rotating electrical machine (ACG) according to claim 5 or 6,
Of the rollers constituting the bending means X (20), each of the rollers (21, 22) excluding the taper forming roller means (25) is such that each roll surface has a depth in the radial direction along the circumferential direction. The stator core (E) of a rotating electrical machine (ACG) is formed in a V-groove (21a, 22a) having a direction, and the inner and outer peripheral edges of the core sheet (10) are pressed by the V-groove. Method. In the manufacturing method of the stator core (E) of the rotating electrical machine (ACG) according to any one of claims 1 to 7,
In the first step, notches (14) are formed at predetermined intervals in the yoke portion (13) of the core sheet (10), and the stator core (E) for a rotating electrical machine (ACG) is manufactured. .

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