JP2016116318A - Punching method and manufacturing method of laminated core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a punching method practically useful for preventing a junction generated by welding from being included in a laminated core when manufacturing the laminated core via a step for continuously punching a plate to be processed in which a plurality of electromagnetic steel sheets are laminated.SOLUTION: The punching method according to the present invention includes the steps of: (a) supplying to a progressive metal mold the plate to be processed formed from the plurality of electromagnetic steel sheets which are pulled out of at least two wound bodies including first and second wound bodies and overlapped; (b) continuously punching the plate to be processed in the progressive metal mold; (c) forming a fusion mark with a welding machine at a position in a length direction in the electromagnetic steel sheet of the second wound body and at a position corresponding to an ending terminal of the first wound body; and (d) bonding the ending terminal of the first wound body and a starting terminal of a new wound body by welding.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a method for punching a processed plate made of a plurality of steel plates and a method for manufacturing a laminated core.

  A laminated iron core is a component of a motor, and is formed by stacking a plurality of electromagnetic steel sheets processed into a predetermined shape and fastening them. The motor includes a rotor (rotor) and a stator (stator) made of laminated iron cores, and is completed through a process of winding a coil around the stator, a process of attaching a shaft to the rotor, and the like. A motor employing a laminated core is conventionally used as a drive source for a refrigerator, an air conditioner, a hard disk drive, an electric tool, and the like, and in recent years is also used as a drive source for a hybrid car.

  In recent years, in order to improve the magnetic characteristics of the laminated iron core and thereby improve the efficiency of the motor, a thin electromagnetic steel sheet is used as compared with the conventional one. Along with this, the number of electromagnetic steel sheets used for one laminated iron core tends to increase. Since the electrical steel sheets constituting the laminated iron core are usually manufactured by punching, there is a problem that when the number of the steel sheets increases, the number of times of punching increases, thereby reducing productivity. As means for solving this problem, Patent Document 1 discloses that a plurality of steel plates are simultaneously punched.

JP 2001-16832 A

  By the way, in progressive feeding, a wound body of electromagnetic steel sheets (also referred to as “coil”) is used. The electromagnetic steel sheet drawn from the wound body is supplied to the progressive die. When the remaining winding body in use decreases, a new winding body is prepared, and the end of the winding body in use and the start end of the new winding body are joined by welding (see, for example, Japanese Utility Model Publication No. 61-148212). .

  The inventors of the present invention, in a progressive feed intended for a work plate obtained by superimposing magnetic steel sheets drawn out from a plurality of winding bodies, the end of the winding body with the remaining less and the beginning of the newly prepared winding body, The problems that could occur when welding the materials were investigated. According to the present inventors, in the technical field of laminated iron cores, the following problems may occur if there are welded joints in the electromagnetic steel sheet as the raw material. In other words, the welded joint is different from other parts in terms of hardness, thickness, or undulation. For this reason, if the region including the joint portion is punched, there is a possibility that problems such as chipping of the punched blade or deterioration of product dimensions may occur. Of the many electrical steel sheets that make up a laminated iron core, the product (laminated iron core) must be discarded if it does not meet the product dimension standards due to the joints contained in one electromagnetic steel sheet. Invite up.

  In order to prevent the above problems, it is conceivable to control the punching device so as not to punch the welded joint. However, there is a situation in which it is difficult to detect a joint portion of each electromagnetic steel sheet in a state where the electromagnetic steel sheets drawn out from a plurality of winding bodies overlap each other. For example, if two magnetic steel plates (upper and lower) overlap each other in the vertical direction, even if the upper joint can be confirmed by the camera placed above, the lower joint can be confirmed by the camera. It is difficult to do.

  INDUSTRIAL APPLICABILITY The present invention is useful for preventing a laminated iron core from including a welded joint in the case of producing a laminated iron core through a process of continuously punching a work plate on which a plurality of electromagnetic steel sheets are laminated. It aims at providing the punching method and the manufacturing method of a laminated iron core.

The first aspect of the punching method according to the present invention includes the following steps.
(A) A step of supplying a workpiece plate constituted by a plurality of electromagnetic steel plates drawn and superimposed respectively from at least two winding bodies including the first and second winding bodies to a progressive die.
(B) A step of continuously punching a workpiece plate in a progressive die.
(C) The process of forming a melt mark with a welding machine in the longitudinal direction position in the electromagnetic steel plate of a 2nd winding body, and the position corresponding to the terminal end of a 1st winding body.
(D) A step of joining the end of the first winding body and the starting end of a new winding body by welding.

  In the punching method according to the first aspect, in the step (c), a melt mark is formed by a welding machine at a position corresponding to the end of the first winding body in the longitudinal direction of the electromagnetic steel sheet of the second winding body. Form. Thereby, for example, when the sensor or the person for detecting the joint portion of the winding body can be disposed due to the configuration restrictions of the punching device is limited to the upper side of the work plate, the electrical steel sheet of the first winding body is Even if it is located below the electromagnetic steel plate of the second winding body and the joint of the first winding body cannot be directly detected, the first winding body can be detected by detecting the melting mark of the second winding body from above. The position of the joint portion can be grasped.

A second aspect of the punching method according to the present invention includes the following steps.
(A) A step of supplying a workpiece plate constituted by a plurality of electromagnetic steel plates drawn and superimposed respectively from at least two winding bodies including the first and second winding bodies to a progressive die.
(B) A step of continuously punching a workpiece plate in a progressive die.
(C1) A step of cutting the electrical steel sheet of the second winding body in accordance with the position and shape of the end of the first winding body to be joined with the starting end of the new winding body.
(C2) The process of joining the cutting parts of the electromagnetic steel plate of the 2nd winding body formed by the said (c1) process by welding.
(D) A step of joining the end of the first winding body and the starting end of a new winding body by welding.

  In the punching method according to the second aspect, in the step (c1), the electrical steel sheet from the second wound body is cut in accordance with the position and shape of the end of the first wound body. The second winding body is cut in accordance with the end of the first winding body, and then the cut portions of the second winding body are joined together by welding in the step (c2). By passing through these steps, it is possible to provide a joint portion (melting mark) having the same shape at the same position as the joint portion of the first winding body with respect to the electromagnetic steel sheet of the second winding body. Thereby, for example, when the sensor or the person for detecting the joint portion of the winding body can be disposed due to the configuration restrictions of the punching device is limited to the upper side of the work plate, the electrical steel sheet of the first winding body is Even if it is located below the electromagnetic steel sheet of the second winding body and the joint of the first winding body cannot be directly detected, the first part can be detected by detecting the joint of the electromagnetic steel sheet of the second winding body from above. The position of the joint part of the wound body can be grasped.

A third aspect of the punching method according to the present invention includes the following steps.
(A) The process of supplying the to-be-processed board comprised with the several electromagnetic steel plate withdrawn from the several winding body containing the 1st and 2nd winding body, respectively, and was piled up to a progressive die.
(B) A step of continuously punching a workpiece plate in a progressive die.
(C3) A step of cutting the end portion of the first winding body to be joined with the starting end of the new winding body.
(C4) A step of cutting the electrical steel sheet of the second winding body in accordance with the cutting position and cutting shape of the first winding body.
(C5) A step of cutting the starting end of a new winding body in accordance with the cutting shape of the first winding body.
(C6) The process of joining the cutting parts of the electromagnetic steel plate of the 2nd winding body formed by the said (c4) process by welding.
(D) The process of joining the terminal end of the 1st winding body formed by the said (c3) process, and the start end of the new winding body formed by the said (c5) process by welding.

  In the punching method according to the third aspect, the end portion of the first winding body is cut in the step (c3), and the second winding is performed in accordance with the cutting position and the cutting shape of the first winding body in the step (c4). Cut heavy electrical steel sheets. In the step (c5), the starting end of the new winding body is cut in accordance with the cutting shape of the first winding body. And by forming the joint part by welding in each of the steps (c6) and (d), the joint part (at the same position as the joint part of the first roll body) with respect to the electromagnetic steel sheet of the second roll body ( Melting marks) can be provided. Thereby, like the above-mentioned 1st aspect, there exists an advantage that it is easy to detect the junction which a to-be-processed board has, for example, even if there exists a restriction | limiting on the structure of a punching apparatus. In addition to this, according to the third aspect, the position of the joint portion in the longitudinal direction of the processed plate can be adjusted by adjusting the cutting position of the terminal end portion of the first wound body in the step (c3).

  According to the 3rd aspect, a cutting shape (shape of a junction part) can be set according to the aspect of a punching process, or the shape of a process body. For example, the cut shape in the step (c3), the step (c4) and the step (c5) may have a line inclined with respect to the longitudinal direction of the processed plate. By adopting such a configuration, it is possible to prevent the material from shifting in the width direction of the workpiece plate during welding. Moreover, when the punching process in the step (b) is a multi-row cutting process in which the pitch is shifted, the cutting shapes in the process (c3), the process (c4) and the process (c5) are as follows. You may have a some line each extended in the width direction of a to-be-processed board in the position mutually shifted | deviated to the longitudinal direction. By adopting such a configuration, it is easy to punch the processed plate so as to avoid the joint. In other words, it is easy to place the joint portion in a portion (called “skeleton”) that is not a product of the processed plate.

The punching method according to the first and second aspects may further include the following steps.
(E) The process of detecting the junction part of the electromagnetic steel plate of a 2nd winding body.
(F) The joining obtained in step (e) so that the punching tool does not punch the workpiece when there is a welded joint at the position of the magnetic steel sheet from the second roll to be punched. The process of shortening the protrusion length of a punching cutter based on the position data of a part.

  By performing the step (f) based on the data in the step (e), it is possible to more reliably prevent the region including the joint portion from being punched out in the mold. In the magnetic steel sheet from the second winding body, in addition to the joint portion formed when the second winding body itself is switched to the new winding body, the joint portion of the first winding body with the new winding body; Joints are formed at similar positions. Therefore, in the step (e), it is sufficient to measure at least the position of the joint formed on the electromagnetic steel sheet from the second wound body. In the step (f), it is not necessary to shorten the protruding length of all the punching tools included in the mold, and at least the outer peripheral punching of the workpiece (also referred to as “blank punching”) from the workpiece plate. What is necessary is just to shorten the protrusion length of a cutter for performing. By controlling the punching blade so as not to punch the outer periphery of the region including the joint, it is possible to prevent the workpiece including the joint from being included in the product.

  The method for producing a laminated core according to the present invention includes a step of continuously producing a workpiece by the punching method according to the first or second aspect, and a laminate obtained by superimposing a plurality of workpieces, And a step of obtaining a laminated iron core by fastening with welding or resin.

  ADVANTAGE OF THE INVENTION According to this invention, when manufacturing a laminated core through the process of carrying out the continuous punching process of the to-be-processed board in which the some electromagnetic steel plate was laminated | stacked, it can fully prevent that the junction part by welding is contained in a laminated core. .

It is a perspective view which shows an example of the stator (stator) which consists of a laminated iron core. It is sectional drawing which shows typically the part in which the crimping in the laminated iron core was formed. It is a perspective view which shows an example of the rotor (rotor) which consists of a laminated iron core. It is a schematic diagram which shows an example of the apparatus for manufacturing a laminated iron core. (A) and (b) are the states before and after cutting the electrical steel sheet of the second winding body in accordance with the position and shape of the end of the first winding body to be joined with the starting end of the new winding body, respectively. It is sectional drawing shown typically. (A) is sectional drawing which shows typically the state which welded both the electromagnetic steel plate of a 1st and 2nd winding body, (b) is a model which shows the state which welded only the electromagnetic steel plate of the 2nd winding body. FIG. (A)-(d) is a top view which shows the variation of the structure for making it easy to detect a junction part with a sensor. (A)-(e) is a top view which shows an example of the to-be-processed board in which various punching processes were given, (f) is a top view which shows the processed body processed into the predetermined shape. (A)-(c) is sectional drawing which shows typically the process of manufacturing a processed body by continuous stamping, avoiding the area | region containing a junction part. (A)-(c) is a top view which shows typically the cutting shape of an electromagnetic steel plate, respectively. It is a top view which shows typically the to-be-processed board (skeleton) after a processed body is punched. It is a schematic diagram which shows the other example of the apparatus for manufacturing a laminated iron core. It is a top view which shows a division type laminated iron core for stators.

  Embodiments of the present invention will be described in detail with reference to the drawings. In the following description, the same reference numerals are used for the same elements or elements having the same functions, and redundant description is omitted.

<Laminated iron core constituting the stator>
FIG. 1 is a perspective view of a laminated iron core S constituting a stator. The shape of the laminated iron core S is substantially cylindrical, and the opening Sa located at the center is for arranging the laminated iron core (rotor) R shown in FIG. The laminated iron core S has a substantially annular yoke portion Sy and a teeth portion St extending in the center direction from the inner peripheral side of the yoke portion Sy. Depending on the application and performance of the motor, the width of the yoke portion Sy (W in FIG. 1) is about 2 to 40 mm. The laminated iron core S shown in FIG. 1 has six teeth portions St. The number of teeth portions St is not limited to six.

  As shown in FIGS. 1 and 2, the laminated iron core S includes a laminated body 10 composed of a plurality of electromagnetic steel plates MS processed into a predetermined shape. The plurality of electromagnetic steel plates MS each have a crimp 2S. The laminated body 10 is comprised by the electromagnetic steel plates MS adjacent in the up-down direction being fastened by the caulking 2S. A pair of electrical steel sheets MS positioned on the lowermost surface has perforations 3 instead of caulking 2S as shown in FIG. 2 so that the laminated bodies 10 are not fastened together when a plurality of laminated bodies 10 are stacked. When the lowermost electromagnetic steel plate MS is not joined to the upper electromagnetic steel plate MS that forms a pair with the lowermost electromagnetic steel plate MS, the lowermost electromagnetic steel plate MS shown in FIG. For example, by forming the caulking 2S deeper than the thickness of the third electromagnetic steel plate MS from the bottom, the second electromagnetic steel plate MS from the bottom and the lowermost electromagnetic steel plate MS can be fastened.

<Laminated iron core constituting the rotor>
FIG. 3 is a perspective view of the laminated iron core R constituting the rotor. The shape of the laminated iron core R is substantially cylindrical, and the opening Ra located at the center is for mounting a shaft (not shown). A convex key Rc is provided on the inner peripheral surface Rb constituting the opening Ra.

  The laminated iron core R includes a laminated body 20 made of a plurality of electromagnetic steel plates MR and a plurality of magnet fixing openings 25. The plurality of electromagnetic steel plates MR each have a crimp 2R. The laminated body 20 is comprised by joining the electromagnetic steel plates MR adjacent in the up-down direction by caulking 2R. The laminate 20 has a total of 16 openings 25. Two adjacent openings 25 form a pair, and eight pairs of openings 25 are arranged at equal intervals along the outer periphery of the stacked body 20. Each opening 25 extends from the upper surface 20 a to the lower surface 20 b of the stacked body 20. The total number of openings 25 is not limited to 16, but may be determined according to the application of the motor, the required performance, and the like. Further, the shape and position of the opening 25 may be determined according to the use of the motor, the required performance, and the like.

  A magnet (not shown) is accommodated in the opening 25. The magnet is a permanent magnet, and for example, a sintered magnet such as a neodymium magnet can be used. The number of magnets put in each opening 25 may be one or two or more. The type of magnet may be determined according to the application of the motor, the required performance, and the like, and for example, a bonded magnet may be used instead of the sintered magnet. Moreover, you may use the magnet divided | segmented into multiple in the thickness direction or the width direction, or both. After putting the magnet of the opening 25, the magnet can be fixed in the opening 25 by filling the opening 25 with a resin (for example, a thermosetting resin composition). In addition, a pair of electromagnetic steel sheets MR positioned on the lowermost surface have the perforations 3 in the same manner as the laminate 10 instead of the caulking 2R so that the laminates 20 are not joined to each other when the plurality of laminates 20 are stacked ( (See FIG. 2).

<Punching device>
FIG. 4 is a schematic diagram showing an example of a punching device for manufacturing the electromagnetic steel sheet MS and the electromagnetic steel sheet MR constituting the laminated iron core S and the laminated iron core R by punching. The punching apparatus 100 shown in the figure includes an uncoiler 111 on which a winding body C1 (first winding body) of the electromagnetic steel sheet M1 is mounted and an uncoiler on which a winding body C2 (second winding body) of the electromagnetic steel sheet M2 is mounted. 112, a feeding device 120 for the workpiece W, a progressive die 130 for punching the workpiece W, and a press machine 140 for operating the die 130. Further, the punching device 100 includes a cutter 152 for cutting the electromagnetic steel sheet M2, a welding machine 161 for performing welding on the electromagnetic steel sheet M1, a welding machine 162 for performing welding on the electromagnetic steel sheet M2, and an electromagnetic And a sensor 170 for detecting a welded portion formed on the steel plate M2. Moreover, the punching apparatus 100 includes a control unit 180 for controlling the above-described components. Each configuration will be described below.

  The uncoilers 111 and 112 respectively hold the winding bodies C1 and C2 rotatably. The lengths of the electromagnetic steel plates M1 and M2 constituting the wound bodies C1 and C2 are, for example, 500 to 10,000 m. When the remainder of the winding body in use decreases, a new winding body is prepared, and the starting end portion of the new winding body and the terminal end portion of the winding body in use are joined by welding, for example. FIG. 4 shows a state in which the remaining winding body C1 is in use and a new winding body C1 is prepared. The work plate W is configured by superimposing the electromagnetic steel plates M1 and M2 drawn from the wound bodies C1 and C2, respectively. In the work plate W, the electromagnetic steel plate M1 is a lower material, and the electromagnetic steel plate M2 is an upper material.

  The thickness of each of the electromagnetic steel sheets M1 and M2 may be about 0.1 to 0.5 mm, and from the viewpoint of achieving more excellent magnetic characteristics of the laminated cores S and R, about 0.1 to 0.3 mm, respectively. It may be. The widths of the electromagnetic steel plates M1 and M2 may be about 50 to 500 mm, respectively. The widths of the electromagnetic steel sheets M1 and M2 may be the same or different from each other.

  The feeding device 120 includes a pair of rollers 120a and 120b that sandwich the electromagnetic steel plates M1 and M2 (work plate W) from above and below. The work plate W is introduced into the progressive die 130 via the feeding device 120. Prior to introducing the electromagnetic steel sheets M1 and M2 into the feeder 120, oil is sprayed between the electromagnetic steel sheets M1 and M2, or oil is applied to the surface of the electromagnetic steel sheet M1 and / or the back surface of the electromagnetic steel sheet M2. May be. An oil film may be interposed between the electromagnetic steel plate M1 and the electromagnetic steel plate M2, and the electromagnetic steel plates M1 and M2 may be bonded together. By attaching the electromagnetic steel plates M1 and M2 with an oil film, the occurrence of residue rise can be sufficiently suppressed. “Left-up” means a phenomenon in which a material punched into a punch or the like of a mold (referred to as “cass” or “scraping”) adheres.

  The progressive die 130 is for continuously punching the workpiece plate W. The mold 130 is operated by a press machine 140. The progressive die 130 includes a movable outer peripheral punching tool 130a (see FIG. 9). More specifically, the outer perforated cutting tool 130a is designed to prevent the outer perforating tool 130a from being punched out of the mold so that the outer periphery of the workpiece WS is not punched when the joint portion WL is in the region of the workpiece W to be punched. The projecting length can be shortened. The change of the protruding length of the outer perforated cutting tool 130a may be performed based on the data of the sensor 170 that detects the position of the joint portion WL. As a mechanism for shortening the protruding length of the outer punching tool 130a (a mechanism for retracting the outer punching tool 130a), a conventionally known one may be employed (see, for example, FIG. 8 of Japanese Patent Laid-Open No. 63-228945).

  The cutter 152 is for cutting the electromagnetic steel plate M2 constituting the upper material of the work plate W. More specifically, the cutter 152 is for cutting the electromagnetic steel plate M2 of the winding body C2 in accordance with the position and shape of the terminal end C1e of the winding body C1 that has remained small (see FIG. 5). As the cutter 152, a cutter, punching, shear cutting, laser cutting, or the like can be used.

  The welding machine 161 is for welding the electromagnetic steel plate M1 constituting the lower material of the work plate W. More specifically, it is for welding the remaining end C1e of the wound body C1 and the starting end C1s of the newly prepared wound body C1 (see FIG. 6A).

  The welding machine 162 is for welding the electromagnetic steel plate M2 constituting the upper material of the work plate W. More specifically, it is for welding the cut portions M2a of the electromagnetic steel sheet M2 cut by the cutter 152 (see FIG. 6A). The welder 162 is also used for welding the remaining end C2e of the wound body C2 (upper material) and the start end C2s of the newly prepared wound body C2 (see FIG. 6B).

  The sensor 170 is for detecting the position of the joint WL by welding of the electromagnetic steel sheet M2. As long as the position of the joint portion WL formed of a weld line can be detected, the type of the sensor 170 is not limited, and the installation location is not particularly limited. As the sensor 170, for example, a camera that detects a joint portion by identifying a color difference from another region can be used. In order to easily detect the joint portion WL, the unjoined portion 5 is left on the end face in the width direction of the processed plate W (FIG. 7A), and the notch 6 is provided in the joint portion WL (FIG. 7B). ), An identification hole 7 may be provided at or near the joint WL (FIGS. 7C and 7D).

  The control unit 180 is for controlling the above-described components of the punching apparatus 100. As the control unit 180, for example, a computer in which a program is incorporated can be used.

<Manufacturing method of laminated core>
Next, a method for manufacturing the laminated iron core S will be described. The laminated iron core S integrates a process (the following (A) to (F) steps) for obtaining the electromagnetic steel sheet MS by punching the workpiece W and a plurality of stacked electromagnetic steel sheets MS (laminated body 10). Manufactured through the process (step (G) below). More specifically, the method for manufacturing the laminated iron core S includes the following steps.
(A) A step of supplying a work plate W constituted by two electromagnetic steel plates M1 and M1 drawn and superimposed from the two wound bodies C1 and C2 to the progressive die 130, respectively.
(B) A step of continuously punching the workpiece plate W in the progressive die 130.
(C1) A step of cutting the electromagnetic steel sheet M2 of the wound body C2 by the cutter 152 in accordance with the position and shape of the end C1e of the wound body C1.
(C2) A step of joining the cut portions M2a of the electromagnetic steel sheet M2 formed by the step (C1) with the welding machine 162.
(D) A step of joining the end C1e of the wound body C1 and the starting end C1s of the new wound body C1 by the welding machine 161.
(E) A step of detecting by the sensor 170 the joint WL of the electromagnetic steel plate M2 in the longitudinal direction of the work plate W.
(F) A step of shortening the protruding length of the punching cutter 130a so that the punching cutter does not punch the workpiece W when the electromagnetic steel plate M2 of the electromagnetic steel plate M2 to be punched has the joint portion WL.
(G) The process of obtaining the laminated iron core S by fastening the laminated body obtained by superimposing the some processed body WS with the crimp 2S.

  First, windings C1 and C2 of electromagnetic steel sheets are prepared, and these are mounted on the uncoilers 111 and 112, respectively. The magnetic steel plates M1 and M2 drawn from the winding bodies C1 and C2 are superposed and supplied to the progressive die 130 (step (A)).

  The workpiece WS is continuously manufactured by punching the workpiece plate W in the progressive die 130 (step (B)). The step (B) will be described with reference to FIG. FIG. 8A shows a state in which pilot holes P for alignment are formed in the work plate W. FIG. FIG. 8B shows a state in which a total of six openings H1 constituting the inner peripheral surface of the yoke portion Sy and the side surface of the tooth portion St are further formed. FIG. 8C shows a state in which the crimp 2S is further formed in the portion that becomes the tooth portion St. By forming the crimp 2S on the workpiece W, the two electromagnetic steel plates M1 and M2 constituting the workpiece W are fixed by the crimp 2S. The caulking 2S is also used for fastening a plurality of workpieces WS. FIG. 8D shows a state in which an opening H2 to be the opening Sa is further formed. FIG. 8E shows a state in which an opening H3 constituting the outer peripheral surface of the yoke portion Sy is further formed. By forming the opening H3 with the outer perforated cutting tool 130a, a processed body WS having the shape shown in FIG. 8F is obtained. Two electromagnetic steel plates MS are overlaid on the workpiece WS.

  However, when the sensor 170 that monitors the upper surface of the work plate W (the upper surface of the electromagnetic steel plate M2) detects the joint WL by welding of the magnetic steel plate M2 and directly performs the perforation punching, the joint WL becomes the workpiece WS. When the control unit 180 determines that it is included, the protruding length of the outer punching tool 130a is shortened, and the punching operation (formation of the opening H3) of the workpiece WS is not performed ((E) step and (F) step). . That is, the joining portion WL (melting mark) serves as a mark for detecting a welded portion, and as shown in FIG. 9, the joining portion WL is formed on the electromagnetic steel plate M2 and the electromagnetic steel plate M1 that the outer perforated cutting tool 130a tries to punch. In some cases (FIG. 9 (a)), the punching operation of the work plate W is not performed by preventing the tip 130b of the outer punching tool 130a from reaching the electromagnetic steel plate M2 (FIG. 9 (b)). After the joint passes through the position of the outer punching tool 130a, the projecting length of the outer punching tool 130a is returned to the original position to perform the punching operation (FIG. 9C). Although not shown in the drawing, the same process may be performed when the outer peripheral punching blade 130a has the joint portion WL only in the electromagnetic steel sheet M2 to be punched. By these steps, it is possible to prevent the laminated iron core S from containing the processed body WS including the joint portion WL.

  Next, the operation of switching to a new winding body C1 when the remainder of the winding body C1 is reduced will be described. Here, the case where both the end C1e of the winding body C1 in use and the starting end C1s of the new winding body C1 extend in a direction orthogonal to the longitudinal direction of the electromagnetic steel sheet M1 will be described as an example.

  First, a new wound body C1 is prepared (see FIG. 4). As shown in FIG. 5, the electromagnetic steel plate M2 of the winding body C2 is cut by the cutter 152 in accordance with the position and shape of the terminal end C1e of the winding body C1 in use (step (C1)). On the other hand, the magnetic steel sheet M1 is pulled out from the new winding body C1 so that the starting end C1s of the new winding body C1 reaches the position of the end C1e of the winding body C1 in use (see FIG. 5B). Then, as shown to Fig.6 (a), the terminal C1e of the winding body C1 in use and the starting end C1s of the new winding body C1 are joined by the welding machine 161 ((D) process), on the other hand, said (C1 ) The cut portions M2a of the electromagnetic steel sheet M2 formed by the process are joined together by the welder 162 (process (C2)).

  The remaining of the winding body C2 is reduced, and the operation of switching to a new winding body C2 may be performed as follows. First, a new wound body C2 is prepared. The magnetic steel sheet M2 is pulled out from the new winding body C2 so that the starting end C2s of the new winding body C2 reaches the position of the end C2e of the winding body C2 in use. After that, as shown in FIG. 6B, the end C2e of the winding body C2 in use and the starting end C2s of the new winding body C2 are joined by the welder 162.

  A predetermined number of workpieces WS obtained through the above steps are overlapped and joined together by these crimps 2S to obtain a laminated core S shown in FIG. 1 (step (G)). The processed body for the rotor can be manufactured through the same process as the manufacturing method of the laminated core S described above by using the progressive die 130 corresponding to the shape.

As mentioned above, although one Embodiment of this invention was described in detail, this invention is not limited to the said embodiment. For example, in the above embodiment, in the step (C1), the electromagnetic steel sheet M2 is cut in accordance with the position and shape of the terminal end C1e of the winding body C1 in use (perpendicular to the longitudinal direction of the electromagnetic steel sheet M1). Although illustrated, you may cut | disconnect the terminal part of the winding body C1 in use, the start end part of the new winding body C1, and the electromagnetic steel plate M2 in a desired position and shape. In this case, the following steps (C3) to (C6) may be performed instead of the step (C1).
(C3) A step of cutting the end portion of the winding body C1 in use to be joined to the starting end C1s of the new winding body C1 into a desired shape.
(C4) A step of cutting the electromagnetic steel sheet M2 in accordance with the cutting position and cutting shape of the wound body C1 in use.
(C5) A step of cutting the starting end of a new wound body C1 in accordance with the cut shape of the wound body C1 in use.
(C6) The process of joining the cutting part M2a of the electromagnetic steel plate M2 of the wound body C2 formed by the said (C4) process by welding.

  FIG. 10 shows the end C1e (FIG. 10 (a)) of the wound body C1 formed by the steps (C3) to (C5), the cut portion M2a (FIG. 10 (b)) of the magnetic steel sheet M2, and the new wound body C1. It is a top view which shows typically an example of the shape of a start end (FIG.10 (c)). The cutting shape of the terminal end C1e of the wound body C1 has two lines L1e inclined with respect to the longitudinal direction of the work plate W. The cut shape of the starting end C1s of the wound body C1 also has two lines L1s inclined with respect to the longitudinal direction of the work plate W. By adopting such a configuration, it is possible to prevent the electromagnetic steel sheet from shifting in the width direction of the work plate W during welding. As shown in FIG. 10 (b), the two cut portions M2a of the electromagnetic steel sheet M2 also have the same shape as the end C1e and the start C1s.

  The cutting shape shown in FIG. 10 assumes a case where two-row machining is performed with the half pitch shifted in the step (B). In order to be suitable for this, as shown in FIG. 10, each cut shape has two lines L2a and L2b extending in the width direction of the processed plate W at positions shifted from each other in the longitudinal direction of the processed plate W. Have By performing welding along this cut shape, the joint portion WL having that shape can be formed. Thereby, there exists an advantage that it is easy to carry out the outer periphery punching of the to-be-processed board W so that the junction part WL may be avoided (refer FIG. 11).

  When the steps (C3) to (C6) are performed, the steps (E) and (F) described above are not necessarily performed. That is, when the distance from the welding machine to the mold is fixed to an integral multiple of the product pitch, the joint WL is not included in the workpiece (so that the joint WL is included in the skeleton). If the position is adjusted, the step (F) and the step (G) may not be performed. After the outer peripheral punching, the sensor placed in the progressive die 130 or at the subsequent stage detects the joint WL of the workpiece plate after the workpiece has been punched, thereby appropriately performing the outer peripheral punching. It may be determined whether or not it has been broken.

  In the said embodiment, although the case where the junction part WL (melting mark) formed in the electromagnetic steel plate M2 played the role of a mark was illustrated, it joins by cut | disconnecting the electromagnetic steel plate M2, and welding the cut part M2a mutually. Instead of forming WL, the electromagnetic steel sheet M2 is not cut, and a part of the electromagnetic steel sheet M2 is melted by the welding machine 161 at a position corresponding to the end C1e of the wound body C1 in the longitudinal direction of the electromagnetic steel sheet M2. In this way, melt marks may be formed. What is necessary is just to make the shape of a fusion mark the same shape as the junction part formed in the electromagnetic steel plate M1, for example.

  In the said embodiment, although the welding machine 161 was made under the to-be-processed board W and the welding of the electromagnetic steel plate M1 was implemented from the lower side, prior to welding of the electromagnetic steel plate M1, cutting | disconnection of the electromagnetic steel plate M1 was illustrated. If it implements, welding machine 161 may be used instead of using welding machine 162, and welding of electromagnetic steel plate M1 may be performed from the upper part. In addition, the positional relationship of the up-down direction of the electromagnetic steel plates M1, M2, the cutter 152, and the welding machines 161, 162 may be reversed.

  In the above embodiment, the punching device 100 including the cutter 152 for cutting the electromagnetic steel sheet M2 and the sensor 170 for detecting the joint WL formed on the electromagnetic steel sheet M2 is exemplified (see FIG. 4). If there is no particular restriction on the configuration, the punching device can individually cut the electromagnetic steel plates M1 and M2 and can detect the joint WL by welding of the electromagnetic steel plates M1 and M2 individually. Good. A punching apparatus 200 shown in FIG. 12 includes cutters 151 and 152 for individually cutting the electromagnetic steel sheets M1 and M2, and sensors 171 and 172 for individually detecting the joints WL formed on the electromagnetic steel sheets M1 and M2. With.

  In the said embodiment, although the case where the to-be-processed board W was comprised by the two electromagnetic steel plates M1 and M2 was illustrated, you may comprise the to-be-processed board W by three or more electromagnetic steel plates. In this case, when switching the other electromagnetic steel sheet to a new electromagnetic steel sheet, at least one of the two electromagnetic steel sheets forming the outermost layer of the work plate W so that the joining portion of the electromagnetic steel sheet can be easily detected. What is necessary is just to provide a cutting part each time and weld the cut parts, and to form a junction part. In addition, from the viewpoint of punching accuracy, the upper limit of the number of electromagnetic steel sheets constituting the workpiece plate may be about five.

  In the above-described embodiment, the case where only the workpiece WS is punched from one workpiece plate W has been exemplified, but both the workpiece WS and the workpiece for the laminated core R may be punched from one workpiece plate W. .

In the above embodiment, the laminated iron cores S and R having the crimps 2S and 2R are exemplified, but the laminated iron cores S and R are manufactured by fastening the electromagnetic steel plates laminated by welding, adhesion or resin material instead of the crimping. May be. Moreover, in the said embodiment, although the integral type laminated iron cores S and R and its manufacturing method were illustrated, this invention is not limited to integral type laminated iron cores S and R, It is applied to manufacture of a division type laminated iron core. May be. The laminated iron core _SD shown in FIG. 13 is configured by a total of twelve laminated bodies 30 arranged in a circumferential direction. Each laminated body 30 is provided with a dummy caulking portion 30a. The dummy caulking portion 30a is removed before or after the laminate 30 is fastened by welding, bonding, or a resin material. In addition, the number of the laminated bodies 30 and the dummy caulking portions 30a is not limited to twelve.

C1 ... first winding body, C2 ... second winding body, C1e, C2e ... end of winding body, C1s, C2s ... starting end of new winding body, L1e, L1s ... inclined line, L2a, L2b ... processed Lines extending in the width direction of the plate, M1, M2 ... electromagnetic steel plate, M2a ... cutting part, R ... laminated iron core for rotor, S ... laminated iron core for stator, _SD ... split laminated iron core, W ... processed plate, WL ... Joint part, WS ... Workpiece, 100,200 ... Punching device, 120 ... Feeding device, 130 ... Progressive die, 130a ... Outer peripheral punching tool (punching tool), 151,152 ... Cutter, 161,162 ... Welding machine , 170, 171, 172 ... sensors.

Claims (8)

(A) supplying a workpiece plate constituted by a plurality of electromagnetic steel plates drawn and superimposed respectively from at least two winding bodies including the first and second winding bodies to a progressive die;
(B) a step of continuously punching the workpiece plate in the progressive die;
(C) forming a melt mark with a welding machine at a position corresponding to the end of the first winding body in the longitudinal direction of the electromagnetic steel sheet of the second winding body;
(D) joining the end of the first roll and the start of the new roll by welding;
A punching method comprising: (A) supplying a workpiece plate constituted by a plurality of electromagnetic steel plates drawn and superimposed respectively from at least two winding bodies including the first and second winding bodies to a progressive die;
(B) a step of continuously punching the workpiece plate in the progressive die;
(C1) cutting the electrical steel sheet of the second winding body in accordance with the position and shape of the end of the first winding body to be joined to the starting end of a new winding body;
(C2) joining the cut portions of the electromagnetic steel sheet of the second wound body formed by the step (c1) by welding;
(D) joining the end of the first roll and the start of the new roll by welding;
A punching method comprising: (A) supplying a workpiece plate composed of a plurality of electromagnetic steel plates drawn and superimposed respectively from a plurality of winding bodies including the first and second winding bodies to a progressive die;
(B) a step of continuously punching the workpiece plate in the progressive die;
(C3) cutting the terminal end of the first winding body to be joined to the starting end of the new winding body;
(C4) cutting the electromagnetic steel sheet of the second winding body according to the cutting position and cutting shape of the first winding body;
(C5) cutting the starting end of the new winding body in accordance with the cutting shape of the first winding body;
(C6) The step of joining the cut portions of the electrical steel sheet of the second wound body formed by the step (c4) by welding;
(D) joining the terminal end of the first winding body formed by the step (c3) and the starting end of the new winding body formed by the step (c5) by welding;
A punching method comprising:   4. The punching method according to claim 3, wherein the cut shape in the step (c3), the step (c4), and the step (c5) has a line inclined with respect to the longitudinal direction of the processed plate. The punching process in the step (b) is a multi-row cutting process in which the pitch is shifted,
The cutting shapes in the step (c3), the step (c4) and the step (c5) have a plurality of lines respectively extending in the width direction of the processed plate at positions shifted from each other in the longitudinal direction of the processed plate. The punching method according to claim 3 or 4. (E) detecting a joining portion of the electromagnetic steel sheet of the second winding body;
(F) Step (e) so that the punching tool does not punch the workpiece when there is a welded joint at the position of the electromagnetic steel plate from the second roll to be punched. The step of shortening the protruding length of the punched blade based on the position data of the joint obtained in
The punching method according to claim 1, further comprising:   The punching method according to claim 6, wherein the punching cutter is for punching the outer periphery of a workpiece from the workpiece plate. A step of continuously producing a workpiece by the punching method according to claim 1;
A step of obtaining a laminated core by fastening a laminated body obtained by superimposing a plurality of the processed bodies with caulking, welding or resin;
A method for producing a laminated core comprising:

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