JP2015228713A - Method of manufacturing core for dynamo-electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a core for dynamo-electric machine using a soft magnetic quenched alloy ribbon as a material, which allows for production of a core for dynamo-electric machine with high productivity, while enjoying the merits in the etching.SOLUTION: A method of manufacturing a core for dynamo-electric machine has: an etching step of forming a frame 3 having press positioning holes 4 arranged in the longitudinal direction, core parts arranged in the longitudinal direction, and a coupling part 6 for coupling the frame 3 and the core part, by etching a soft magnetic quenched alloy ribbon; a reel formation step of winding up the etching ribbon formed by the etching step on a reel; a core piece formation step of obtaining a core piece by press punching the coupling part 6 with reference to the press positioning hole 4, while unwinding the etching ribbon from the reel; and a lamination step of obtaining a core for dynamo-electric machine by laminating the core pieces.

Description

  The present invention relates to a method for manufacturing a core for a rotating electrical machine that is a core of a generator or a motor.

As generators and motors that are rotating electrical machines, motors that use a soft magnetic material for the stator and rotor that are cores for rotating electrical machines are widely used. Of particular interest is an embedded permanent magnet synchronous motor (IPMSM) that has excellent controllability and has a permanent magnet embedded in a soft magnetic material. This motor uses both magnet torque and reluctance torque and is highly efficient. In addition, a reluctance motor in which an expensive permanent magnet is eliminated and an air gap serving as a magnetic barrier is disposed in the rotor is also attracting attention.
These rotors require the formation of a space for holding a permanent magnet and a space for forming a reluctance, and high-precision processing is necessary.
On the other hand, the stator combined with the rotor needs to have a large number of magnetic poles facing the rotor in order to improve controllability. A typical stator is ring-shaped and has a shape in which magnetic poles are arranged around. Therefore, high-precision processing is required for the stator.

In addition, as a soft magnetic material applied to the core of a rotating electrical machine, a core for a rotating electrical machine using a soft magnetic quenching alloy such as a soft magnetic amorphous alloy or a soft magnetic nanocrystalline alloy has been proposed. (See Patent Document 1, Patent Document 2, and Patent Document 3)
These materials have higher specific resistance than simple crystalline materials such as silicon steel for structural reasons, and are usually 50 μm or less in thickness and are laminated to reduce eddy current loss. There is an advantage that it can be reduced.

By the way, the core of a rotating electrical machine often has the same shape when viewed from the rotating shaft direction of the rotating electrical machine. Therefore, in order to use a ribbon which is a normal form of a soft magnetic quenched alloy as a material, first, the ribbon is pressed or etched so as to have a predetermined core shape to obtain a core piece. And the core for rotary electric machines is formed by laminating | stacking this core piece.
Applying an etching process as a process for obtaining a core piece with a complex shape such as a permanent magnet embedded motor or a reluctance motor is difficult to generate new distortion due to the process. The merit that there is little influence is expected. This advantage is considered to be particularly effective when a soft magnetic quenched alloy ribbon having a mechanical strength higher than that of a general crystalline material is used.

JP 2006-516877 A JP 2008-262944 A JP 2009-5539 A

However, in reality, the production of core pieces by etching is not widespread. The reason for this is considered that the conventional cores for rotating electrical machines did not require a very complicated shape and that press working has the advantage that it can be processed at high speed. On the other hand, as described above, from the viewpoint of the characteristics of the rotating electrical machine, an etching process that can form a complex shape with high dimensional accuracy and has a small deterioration in soft magnetic characteristics due to mechanical strain is suitable for using a soft magnetic quenched alloy ribbon. It is.
In view of the above problems, an object of the present invention is to provide a manufacturing method for obtaining a core for a rotating electrical machine having high productivity while enjoying the merit in etching using a soft magnetic quenched alloy ribbon as a raw material.

The present inventors have found a technique for combining a predetermined etching process and press punching, and have reached the present invention.
That is, the present invention is a method for manufacturing a core for a rotating electrical machine, in which a core piece made of a soft magnetic material is laminated in a rotation axis direction,
Etching the soft magnetic quenching alloy ribbon to form a frame part with press positioning holes arranged in the longitudinal direction, a core part arranged in the longitudinal direction, and a connecting part connecting the frame part and the core part An etching process,
A reel forming step of winding the etching ribbon formed by the etching step on a reel;
A core piece forming step of obtaining a core piece by punching out the connecting portion on the basis of the press positioning hole while unwinding the etching ribbon from the reel;
And a laminating process for obtaining a rotating electrical machine core by laminating core pieces.

In the present invention, in the etching step, as the core portion, a rotor portion, a stator portion arranged outside the rotor portion, and an inter-core portion connecting portion that connects the stator portion and the rotor portion. Form the
In the core piece forming step, it is preferable to press punch in the order of the rotor portion, the inter-core portion connecting portion, and the stator portion.

  The present invention is an effective means for efficiently producing a core for a rotating electrical machine made of a soft magnetic amorphous alloy or a soft magnetic nanocrystalline alloy.

It is a figure which shows an example of the etching pattern applied to the manufacturing method of this invention. It is a figure which shows another example of the etching pattern applied to the manufacturing method of this invention. It is an enlarged view which shows the example of the connection part in the etching pattern applied to the manufacturing method of this invention. It is a figure explaining an example of the core formation process applied to the manufacturing method of this invention.

One of the important features of the present invention is that a frame portion having press positioning holes arranged in the longitudinal direction by etching a soft magnetic quenched alloy ribbon, a core portion arranged in the longitudinal direction, a frame portion, An etching process for forming a connecting portion that connects the core portion is employed.
The etching process is generally performed by patterning a soft magnetic quenched alloy ribbon with a photoresist and spraying an etchant onto the soft magnetic quenched alloy ribbon. That is, if the press positioning hole, the core portion, and the connecting portion are formed by patterning in the etching process, these positions can be accurately determined.
If the press positioning hole is accurately defined, the core portion can be accurately punched from the connecting portion with the press positioning hole as a reference.

  In addition, it is preferable that the press punching avoids generation of new distortion as much as possible. For that purpose, the target portion should be as narrow as possible. In the present invention, the connecting portion that is a target part for press punching connects the core portion and the frame portion, and prevents the frame portion and the core portion from being separated and cannot be handled in the etching process. It is not necessary to have a wide width, and is suitable as a target site for press punching. As a result, the present invention can cope with a portion requiring high-precision processing by etching processing, and can maintain a belt shape with good handling properties before press punching, and thus has high productivity.

Hereinafter, the present invention will be described in detail with reference to the drawings. In addition, what is shown in each figure is an example, Comprising: The range of this invention is not limited to the range shown in each figure.
In the present invention, first, a soft magnetic quenched alloy ribbon is prepared. As the soft magnetic quenching alloy ribbon, for example, an iron-based soft magnetic amorphous alloy ribbon or an iron-based soft magnetic nanocrystalline alloy ribbon can be applied. When a soft magnetic nanocrystalline alloy is used as a core material, a soft magnetic amorphous alloy ribbon capable of expressing a soft magnetic nanocrystalline structure can be used and adjusted to a nanocrystalline structure by heat treatment in a later step. .
These ribbons are obtained by pouring molten alloy on a cooling roll or the like and are often handled in a form wound around a reel.

(Etching process) (Reel forming process)
In the present invention, an etching process is applied to the prepared soft magnetic quenched alloy ribbon.
The etching process is, for example, unwinding a soft magnetic quenched alloy ribbon from a reel, applying a photoresist on both sides of the soft magnetic quenched alloy ribbon, masking, and exposing to press positioning aligned in the longitudinal direction. The frame part having the hole, the core part arranged in the longitudinal direction, and the connecting part for connecting the frame part and the core part are patterned. This is performed for the entire length of the soft magnetic quenched alloy ribbon. It is also possible to mask, expose and pattern both sides of a multi-layered belt obtained by stacking thin strips wound from a plurality of reels.
Next, the soft magnetic quenched alloy ribbon once wound is passed through an etching line, and etching is performed by spraying an etching solution from one side or both sides of the soft magnetic quenched alloy ribbon. Then, after passing through the rinse process which removes etching liquid, the soft-magnetic quenching alloy ribbon in which the etching pattern was formed is wound up on a reel.

FIG. 1 shows an example of an etching pattern of a permanent magnet embedded synchronous motor core to which the manufacturing method of the present invention is applied. FIG. 1 is an example in which two rotor parts 1 and stator parts 2 that are core parts having the same shape are formed in the width direction of a soft magnetic quenched alloy ribbon and arranged in the longitudinal direction. Has a frame portion 3 having press positioning holes 4 arranged in the longitudinal direction.
The rotor portion 1 and the stator portion 2 are connected and supported by the inter-core portion connecting portion 5, and the stator portion 2 and the frame portion 3 are connected and supported by the connecting portion 6. Moreover, in one core part unit, the inter-core part connection part 5 and the connection part 6 are provided at four positions at positions shifted by 90 degrees.
Further, the rotor portion 1 is formed with a rotor guide hole 10 for positioning at the time of lamination, a magnet placement hole 12 for embedding a permanent magnet, and a shaft hole 13 for attaching a central axis.
In addition, the stator portion 2 is provided with a stator guide hole 11 and a magnetic pole 14 for positioning at the time of stacking.

FIG. 2 is a view showing another example of the etching pattern of the core portion according to the present invention, in which the frame portion 3 is omitted.
FIG. 2A is a diagram showing the same pattern as FIG. 1 for reference, and FIG. 2B shows the rotor guide hole 10 and the stator guide hole 11 with respect to the pattern of FIG. It is a figure which shows the pattern which does not form.
The guide holes 10 and 11 are effective for improving the assembling accuracy for alignment in stacking formed in FIG. 2A. On the other hand, if a gap is provided in a part of the magnetic path, the magnetic characteristics are localized. Change, which may promote non-uniformity of the generated torque. Therefore, the configuration shown in FIG.
In the configuration shown in FIG. 2B, the positioning of the rotor portion 1 when the rotor portion 1 is stacked can use the magnet placement hole 12, and the positioning of the stator portion 2 can be performed by the magnetic pole of the stator portion 2. Fourteen side surfaces can be used.

FIG.2 (c) makes shaft hole 13 shape key groove shape with respect to FIG.2 (b). Since the shape near the shaft hole 13 has little influence on the magnetic characteristics, it is effective as an alignment pattern when the rotor portion 1 is stacked. In FIG. 2C, the keyway shape is exaggerated, but it may be a guide shape, and may be a V-shaped or U-shaped notch or protrusion, and the number is not limited. .
FIG. 2D is a diagram in which the positional relationship between the inter-core connecting portion 5 and the connecting portion 6 is changed with respect to FIG. As shown in FIG. 2B, when there are the inter-core portion connecting portion 5 and the connecting portion 6 at the leading end and the trailing end of the specific magnetic pole 4, respectively, this position becomes the press punching position, and the specific magnetic pole 4 is subjected to processing distortion. Will concentrate. Therefore, the pattern shown in FIG. 2D is effective for dispersing the processing strain.

(Core piece forming process) (Lamination process)
After the etching process, the soft magnetic quenched alloy ribbon having an etching pattern is unwound from a reel and punched out to obtain a core piece. Hereinafter, a description will be given with reference to FIGS. 3 and 4.
FIG. 3 is an enlarged view showing an example of the inter-core portion connecting portion 5 and the connecting portion 6 in the etching pattern applied to the manufacturing method of the present invention, and FIG. 3A is an example of the same etching pattern as FIG. FIG. 3B shows another example of the etching pattern.
As a core part shown in FIG. 3, the rotor part 1, the stator part 2 arrange | positioned on the outer side of this rotor part 1, and the connection part 5 between core parts which connect a stator part and a rotor part, In the etching pattern having the above, it is necessary to use the inter-core portion connecting portion 5 and the connecting portion 6 as press punched portions.
As described above, in the present invention, since it is possible to perform punch punching using the press positioning hole 4 formed in the etching process as a reference, a core portion with high shape accuracy can be obtained.

In order to perform press punching by reel-to-reel, it is preferable to apply a method in which the frame 3 is continuous between the reels for unwinding and winding, and necessary core pieces are sequentially punched by press punching. Specifically, in the etching pattern shown in FIG. 3, it is preferable that the rotor part, the inter-core part connection part, and the stator part are press punched in this order.
A specific operation will be described with reference to FIGS. FIG. 4 is a diagram showing an outline of a press punching apparatus applied to the present invention. In FIG. 4, a part is enlarged for the sake of explanation, and non-main parts such as a support member are omitted.

First, in order to press punch the rotor portion 1, the soft magnetic quenched alloy ribbon 20 having an etching pattern is sent to the apparatus shown in FIG. 4 (a), and the inter-core portion connecting portion 5 shown in FIG. 3 (a). The rotor side cutting position 5a is used as a cutting position for press punching.
The apparatus shown in FIG. 4A has a first lower punch 21 and a first upper punch 22 that perform press punching in cooperation with each other, and a cutting line formed by them includes a rotor side cutting shown in FIG. The soft magnetic quenched alloy ribbon 20 is positioned so as to come to the position 5a. The press punching can be performed by lowering the first upper punch 22 with respect to the fixed first lower punch 21.
4A includes a guide pin 24 that is inserted into the rotor guide hole 10 to fix the position of the rotor portion 1 after press punching, and a rotor that receives the rotor portion 1 that is press punched. It has a bearing 23 and is configured to be laminated simultaneously with press punching.

Next, in order to press punch the connecting part 5 between the core parts, the soft magnetic quenched alloy ribbon 20 is sent to the apparatus of FIG. 4B, and the stator in the connecting part 5 between the core parts shown in FIG. The press cutting is performed with the side cutting position 5b as the cutting position.
The apparatus shown in FIG. 4B has a second lower punch 31 and a second upper punch 32 that perform press punching in cooperation with each other, and the cutting line formed by these is the stator side cutting shown in FIG. The soft magnetic quenched alloy ribbon 20 is positioned so as to come to the position 5b. The press punching can be performed by lowering the second upper punch 32 with respect to the fixed second lower punch 31.

  The apparatus of FIG.4 (b) removes the connection part 5 between core parts used as an unnecessary thing, and ensures the shape of the inner peripheral side of the stator part 2. FIG. At this time, if the core-to-core connecting portion to be cut is a very small piece, it may become a problem due to being caught or scattered by the movable portion of the press punching device. When there is such a concern, for example, as shown in FIG. 3B, the inter-core connecting portion 5 is not formed at the shortest portion of the rotor portion 1 and the stator portion 2, but the base portion of the magnetic pole 4 is formed. The structure which forms the connection part 5 between core parts between the rotor part 1 can be employ | adopted. In this configuration, since the size of the inter-core portion connecting portion 5 can be increased, the above problem can be solved. Further, if the inter-core connecting portion 5 in FIG. 3B is widened at a portion other than the stator-side cutting position 5b, the amount of metal dissolved by etching can be suppressed, and the deterioration of the etching solution can be prevented. It is valid.

Next, in order to press punch the stator portion 2, the soft magnetic quenched alloy ribbon 20 is sent to the apparatus shown in FIG. 4C, and the stator outer cutting position 6a in the connecting portion 6 shown in FIG. Press punching as the cutting position.
The apparatus shown in FIG. 4C has a third lower punch 41 and a third upper punch 42 that perform press punching in cooperation with each other. The soft magnetic quenched alloy ribbon 20 is positioned so as to come to the position 6a. The press punching can be performed by lowering the third upper punch 42 with respect to the fixed third lower punch 41.
Further, the apparatus of FIG. 4C includes a guide pin 44 that is inserted into the stator guide hole 11 and fixes the position of the stator part 2 after press punching, and a stator that receives the stator part 2 to be press punched. It has a bearing 43 and is configured so that it can be stacked simultaneously with press punching.

The remaining material of the soft magnetic quenched alloy ribbon 20 that has passed through the apparatus shown in FIGS. 4A to 4C is collected by a take-up reel (not shown).
4 (a) to 4 (c) are arranged in series between the unwinding reel and the take-up reel, and the soft magnetic quenching alloy ribbon 20 is intermittently fed, so that the structure shown in FIG. The apparatus shown in FIG. 4C is sequentially activated, and the core formation process and the lamination process can be continuously performed.
After a predetermined number of presses, the laminated rotor part 1 and stator part 2 can be taken out and integrated by a resin impregnation process or the like.

In this example, the rotor part and the stator part in the permanent magnet embedded synchronous motor are arranged in the same arrangement as those in the motor, and the etching pattern is formed. As in this example, the method of forming the rotor portion and the stator portion at the same time is effective with less generation of remaining material.
In order to achieve the effect of the present invention that the connecting portion can be punched out based on the press positioning hole 4 formed in the etching process, only one of the rotor portion and the stator portion is combined with the press positioning hole. An etching pattern may be used. In this case, the connection part between core parts does not exist.
Moreover, although the press positioning hole 4 shown in this example showed the example which provided two simple circular holes for every core part unit, in order to perform more highly accurate punching, it is three or more places for every core part unit. It is preferable to provide it, and it is possible to use a combination of a rectangle and a circle instead of a simple circle.

DESCRIPTION OF SYMBOLS 1 Rotor part, 2 Stator part, 3 Frame part, 4 Press positioning hole, 5 Inter-core part connection part 5a Rotor side cutting position 5b Stator side cutting position 6 Connection part, 6a Stator outer side cutting position 10 Rotor Guide hole, 11 Stator guide hole, 12 Magnet placement hole 13 Shaft hole

Claims (2)

A method for manufacturing a core for a rotating electrical machine in which a core piece made of a soft magnetic material is laminated in the direction of the rotation axis,
Etching the soft magnetic quenching alloy ribbon to form a frame part with press positioning holes arranged in the longitudinal direction, a core part arranged in the longitudinal direction, and a connecting part connecting the frame part and the core part An etching process,
A reel forming step of winding the etching ribbon formed by the etching step on a reel;
A core piece forming step of obtaining a core piece by punching out the connecting portion on the basis of the press positioning hole while unwinding the etching ribbon from the reel;
A method of manufacturing a core for a rotating electrical machine, comprising: a step of stacking core pieces to obtain a core for a rotating electrical machine. In the etching step, as the core part, a rotor part, a stator part arranged outside the rotor part, and an inter-core part connecting part for connecting the stator part and the rotor part are formed,
The method for manufacturing a core for a rotating electrical machine according to claim 1, wherein, in the core piece forming step, the rotor part, the inter-core part connecting part, and the stator part are press punched in this order.

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