JP2016165223A - Manufacturing method of laminated core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a laminated core capable of attaining further downsizing of a device and accelerating a press speed by laminating segment core pieces in an annular shape outside of a metal mold for manufacturing the segment core pieces.SOLUTION: A manufacturing method includes: a first step for separating from a belt-like core material 13 a segment core piece 14 which includes (n) pieces of magnetic pole parts 11 formed at a pitch angle of θ degrees, with which a caulking part 54 is formed at a specific position and which has an arcuate angle resulting from dividing a circumferential angle of 360 degrees into (m); a second step for caulking and laminating the separated segment core pieces 14 within a rotary lamination mechanism 35; a third step for rotating the rotary lamination mechanism 35 including the caulked and laminated segment core pieces 14 at 360 degrees/m; a fourth step for forming an annular coupled core piece 12 in which the segment core pieces 14 are arranged side by side in an annular shape, by repeating processing from the first step to the third step; and a fifth step for rotating the rotary lamination mechanism 35 on which the annular coupled core piece 12 is mounted, at θ r degrees. A caulked and laminated core 10 having a predetermined thickness is manufactured by repeating the fourth step and the fifth step.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method of manufacturing a laminated core (which may be a rotor laminated core and a stator laminated iron core) by a segmented iron core lamination method capable of reducing the size of a mold and increasing the pressing speed.

2. Description of the Related Art Conventionally, a motor core made of a laminated iron core in which several tens to several hundreds of annular thin plate members obtained by pressing an electromagnetic steel plate is known. The thickness of the thin plate member is about 0.15 to 0.5 mm, and the thinner the plate member, the better the energy efficiency.
Furthermore, in order to improve the yield of thin plate members, laminated iron cores manufactured by combining arcuate thin plate members obtained by dividing an annular thin plate member into a plurality of members are also known.

For example, Patent Document 1 discloses an apparatus for manufacturing a laminated iron core by forming a single annular thin plate member by a plurality of arc-shaped segment iron core pieces and laminating a large number thereof. In the present invention, the central angle of the arc-shaped segment core pieces is 360 degrees / p, and one annular thin plate member is constituted by p pieces of segment core pieces. The annular thin plate members of the adjacent layers are laminated so that the arc-shaped segment core pieces constituting them overlap with each other with the connecting positions shifted like brickwork.

In Patent Document 2, when manufacturing an annular laminated core consisting of a plurality of segment core pieces (arc-shaped members) in each layer, the segment core pieces are formed by half punching and flat pressing, and then pushed back. The core piece is pushed down and separated from the core material (thin plate material), and each time this separation is performed, the separated segment core piece is placed at the desired position of the laminated core, and the laminated iron core reaches the position where the next segment core piece is placed. Is a device that rotates a predetermined angle and repeats this to complete a laminated iron core.

Japanese Patent No. 3634801 JP 2012-95369 A JP-A-63-080741

However, according to the laminated core manufacturing apparatus described in Patent Document 1, in the final process, the segment core pieces are cut from the thin plate material into the mother die by cutting and simultaneously the positioning of the rotational position of the mother die is highly accurate. It is necessary to control with. Accordingly, the positioning control of the thin plate material and the mother die is complicated, the die is enlarged, and the press device is also enlarged accordingly, so that the device cost is increased, and accordingly, the product cost is also increased.

According to the manufacturing apparatus described in Patent Document 2, in the final process, the segment core piece formed by pushing back to the iron core material is pushed down to be separated from the iron core material and transferred to the laminated guide. Unlike the technology, it is not necessary to simultaneously control the feed pitch of the iron core and the positioning of the rotating die with high accuracy. Therefore, although the final process can be easily controlled, since the segment core piece continuous body forming process and the laminating process are performed in the same mold as in Patent Document 1, the mold becomes larger and the press device associated therewith The increase in size is inevitable, and the device cost and product cost also increase.

By the way, in patent document 3, outside the metal mold | die which formed the iron core material which has a tooth | gear part at one end and a base part at the other end, a core material is cut | disconnected for every volume, and the cutting | disconnection edge parts of an iron core material are couple | bonded and a ring A method of forming a stator laminated iron core by forming a laminated body and laminating and fixing a plurality of the ring-like bodies is described.

According to this manufacturing method, the step of forming the core material and the step of cutting the core material for each volume and laminating the ring-shaped combined body are performed in separate molds. Can be avoided. However, since the iron core material is cut every turn, there is only one cutting point, and the stress concentrates on that one point, so that there is a problem that the ring-shaped combined body cannot maintain its roundness.

The present invention has been made in view of such circumstances, and the segment core pieces are laminated in an annular shape outside the mold for manufacturing the segment core pieces, thereby further reducing the size of the apparatus and further improving the press speed. It aims at providing the manufacturing method of a laminated iron core.

The method for manufacturing a laminated core according to the first invention in accordance with the above object has n magnetic pole portions formed at a pitch angle of θ degrees, a caulking portion is formed at a specific position, and a circumferential angle of 360 degrees is m. A first step of separating a segment core piece having a divided arc angle from the belt-like core material and placing it on the mounting table;
A second step of transporting the segment core pieces placed on the mounting table to a stacking position of a rotary stacking mechanism with a pusher;
A third step of caulking and laminating the segment core pieces conveyed by the pusher in the rotary laminating mechanism;
A fourth step of rotating the rotary laminating mechanism including the caulked laminated segment core pieces by 360 degrees / m;
A fifth step of repeating the first step to the fourth step to form an annular connecting core piece in which the segment core pieces are arranged in a ring, and
A sixth step of rotating the rotating lamination mechanism on which the annular connecting core pieces are mounted by θ · r degrees;
By repeating the fifth step and the sixth step, an iron core having a predetermined thickness is formed.
However, r is an integer of 1 or more, m and n are integers of 2 or more, θ · n · m = 360 degrees, and r is not an integer multiple of n.

A method for manufacturing a laminated core according to a second invention is the method for producing a laminated core according to the first invention, wherein the rotary lamination mechanism is provided with an inner diameter guide member, and the segment core piece is pushed by the pusher and It abuts on the inner diameter guide member and is conveyed to the stacking position of the segment core pieces.

The manufacturing method of the laminated core according to the third invention is the manufacturing method of the laminated core according to the first and second inventions, wherein the segment core piece in the first step has the longitudinal direction of the segment core piece as described above. In accordance with the width direction of the belt-shaped iron core material, the segment iron core piece is half-pulled and then pushed back, held by the outer frame of the belt-shaped iron core material, conveyed to the upper position of the mounting table, and separated from the belt-shaped iron core material. Then, remove (push) it down on the mounting table.

A method for manufacturing a laminated core according to a fourth aspect of the invention is the method for manufacturing a laminated core according to the third aspect of the invention, wherein the outer frame from which the segment core piece has been removed is broken down by a scrap cutter and discharged out of the system. Is done.

A method for manufacturing a laminated core according to a fifth invention is the method for producing a laminated core according to the first and second inventions, wherein the strip-like core material is formed by connecting a plurality of segment core pieces at a connecting portion, The segment core pieces separated from the strip-shaped core material by being transported to just above and separated by the connecting portion are independently arranged on the mounting table.

A method for manufacturing a laminated core according to a sixth invention is the method for producing a laminated core according to the fifth invention, wherein the feeding direction of the segment core pieces by the pusher intersects the feeding direction of the strip-like core material. Yes.

And the manufacturing method of the laminated iron core which concerns on 7th invention is a manufacturing method of the 5th, 6th laminated iron core, The said strip | belt-shaped iron core material is manufactured previously and wound by the reel.

The method for manufacturing a laminated core according to the present invention has the following effects.
(1) In the prior art, the mold for stacking the segment core pieces and the mold for forming the segment core pieces are performed in the same mold, but the mold has become larger and the equipment cost has increased. In the present invention, since the step of forming the segment core pieces (that is, the molding die) is performed outside the lamination die, the die can be miniaturized and the apparatus cost can be reduced.
(2) Moreover, it is possible to deal with a plurality of types of products (laminated cores) with one laminating apparatus (laminated core manufacturing apparatus), and it is not necessary to prepare a laminating apparatus individually.

(3) In the conventional apparatus, since the laminating step was performed with the same mold as the step of forming the segment core pieces, the press speed could not be increased, but in the present invention, the step of forming the segment core pieces was laminated. Since it is performed outside the mold, the press speed can be increased.
(4) And since the connection part of the adjacent segment core piece is isolate | separated compared with a wound core, since the lamination | stacking core manufactured by this manufacturing method of a laminated core has separated stress, the roundness of a core Will improve.

It is a top view which shows the main structures of the manufacturing apparatus of the laminated core to which the manufacturing method of the laminated core which concerns on the 1st Embodiment of this invention is applied. It is a side view which shows the main structures of the manufacturing apparatus of the same laminated iron core. It is a perspective view of the manufacturing apparatus of the same laminated iron core. It is explanatory drawing of the manufacturing method of the laminated core which concerns on the 2nd Embodiment of this invention.

Next, embodiments of the present invention will be described with reference to the accompanying drawings.
As shown in FIG. 1, a laminated core 10 to which the laminated core manufacturing method according to the first embodiment of the present invention is applied has a large number of magnetic pole portions 11 on the radially outer side. Adjacent magnetic pole portions 11 are formed with a pitch angle θ degrees, and the annular connecting core pieces 12 having a round (circular angle) of 360 degrees are equally divided into a plurality (m) of segment core pieces 14. That is, one segment core piece 14 has n magnetic pole portions 11 and θ · n · m = 360 degrees. In this embodiment, the magnetic pole portion 11 is provided on the outer side in the radial direction. However, a laminated iron core in which the magnetic pole portion is formed on the inner side in the radial direction may be used. M and n are integers of 2 or more. Each magnetic pole portion 11 is formed with a magnet insertion hole 11a.

In this laminated core 10, a segment core piece 14 is formed from a strip-like core 13 made of a thin magnetic steel plate, and one annular connecting core piece 12 using m (in this embodiment, five) segment core pieces 14. And a predetermined number of the annular connecting core pieces 12 are caulked and laminated to form a laminated core 10 having a predetermined thickness. In this case, if the connecting portions of the adjacent segment core pieces 14 are at the same circumferential angle position, they are easily disassembled after assembly. The positions are shifted by θ · r degrees. Here, r is an integer of 1 or more, and is not an integer multiple of n.

Next, the laminated iron core manufacturing apparatus 16 will be described with reference to FIGS. As shown in FIGS. 1 and 2, the laminated iron core manufacturing apparatus 16 has a base plate 18 and a lower plate 19 that are held around by four cylindrical support members 17, which are attached to a support frame (not shown). It is fixedly arranged. The four support members 17 are provided with an elevating plate 20 provided between a base plate 18 and a lower plate 19 so as to be movable up and down.

Upper parts of the right and left lifting rods 22 and 23 are fixed to both sides of the lifting plate 20, and lifting means 24 and 25 are provided below the lifting rods 22 and 23. The elevating means 24 and 25 have a drive motor inside, and by moving the drive motor in synchronization, the left and right elevating rods 22 and 23 are moved up and down synchronously, and the elevating plate 20 is moved up and down while maintaining a horizontal state. I am letting.

The elevating plate 20 is provided with a rotating plate 28 via a bearing 27, and a core mounting table 29 is mounted on the rotating plate 28 with its axis aligned, and the core mounting table 29 is provided with an inner diameter guide member 30. . The inner diameter guide member 30 determines the inner diameter of the laminated iron core 10. When the inner side of each segment core piece 14 is in contact with each other and becomes an annular connecting core piece 12, the inner diameter guide member 30 and the inner ring guide member 30 are annularly connected. A slight gap is formed between the iron core piece 12 and the laminated iron core 10. The inner diameter guide member 30 has a plurality of standing rod members 30a arranged side by side on the same circumference and a disc 30b connected to the upper end of the rod member 30a.

The rotary plate 28 is provided with a shaft 31, and is connected to the output shaft 34 of the lower rotation motor 33 by a coupling 32. The rotation motor 33 is fixed to the elevating plate 20 by a support plate 33a and a plurality of support rods 33b.
Accordingly, when the rotation motor 33 is driven, the rotation plate 28 is rotated, and when the elevating means 24 and 25 are driven, the elevating plate 20 is moved up and down, and a servo motor is used for each of these motors. The laminated iron core 10 (including during assembly) placed on the mounting table 29 is rotated by a predetermined angle and moved up and down to a predetermined height. A rotary laminating mechanism 35 that includes these and the above-described inner diameter guide member 30 and that sequentially rotates and laminates the segment core pieces 14 is formed.
The lower plate 19 is formed with a through hole (not shown) through which the rotation motor 33 can freely move up and down.

The core mounting table 29 is provided around the axis of the shaft 31, and an unillustrated loading means for sequentially loading the segment core pieces 14 formed on the strip core material 13 into a predetermined position on the outer position of the core mounting table 29. Is provided.
A large number of segment core pieces 14 are arranged in the band-shaped iron core material 13 with a slight gap by aligning the longitudinal direction of the segment iron core pieces 14 with the width direction of the band-shaped iron core material 13. The segment core piece 14 is half-cut by the first press with respect to the strip core member 13 and pushed back to the strip core member 13 by the second press so that the periphery of the segment core piece 14 can be easily separated. In the state, it is connected to the outer frame (skeleton) of the strip-shaped iron core material 13.

The strip-shaped iron core material 13 having the segment iron core pieces 14 so as to be separable is sent to the push-out jig 37 and the scrap cutter 38 by the above-mentioned carrying means using the pilot holes 36 provided on both sides.
The push-down jig 37 has a block 40 and pushes (drops) the segment core piece 14 on the mounting table 42.

The outer frame of the strip-shaped iron core material 13 from which the segment core pieces 14 have been pushed down is cut into short scraps 45 by a scrap cutter 38 having shearing blades 43 and 44, falls onto a discharge conveyor 46, and is connected to the system by a shooter 47 connected thereto. Discharged outside. Reference numeral 48 denotes a motor for driving the discharge conveyor 46. Further, after the segment core piece 14 is pushed down by the block 40, the outside of the belt-like core material 13 is conveyed by a predetermined distance and can be placed on the scrap cutter 38. In addition, since it is enough for the block 40 to drop the segment core piece 14, it may be smaller than the segment core piece 14 and may not be the same shape as the segment core piece 14.

A pusher 49 is provided for transporting the segment core piece 14 placed on the mounting table 42 to a predetermined position of the rotary stacking mechanism 35. The pusher 49 includes a reduction motor 50 that is driven to rotate, an arm 51 provided on the reduction motor 50, an advance / retreat member 52 provided on a front portion of the arm 51, and an iron core single pushing member 53 that is advanced / retreated by the advance / retreat member 52. A predetermined angular position of the laminated core 10 being assembled provided on the core mounting table 29 placed on the rotary plate 28 by pushing both longitudinal sides of the segment core piece 14 pushed down on the mounting table 42 from behind. It is transported to.

Here, the predetermined angular position of the laminated iron core 10 means that when one or a plurality of segment iron core pieces 14 do not form the annular connecting iron core piece 12, the laminated iron core pieces are laminated one before and rotated 360 degrees / m. When the end of the segment core piece 14 comes into contact with the starting end of the segment core piece 14 to be newly laminated, when the m segment core pieces 14 form the annular connecting core piece 12, The position is obtained by rotating the annular connecting core piece 12 by θ · r degrees. Here, the condition that θ · r degrees does not coincide with 360 / m.

The rotation angle of the laminated core 10 during the above assembly is controlled by controlling the rotation motor 33. In addition, the position of the upper surface of the laminated core 10 during assembly is such that when the m segment core pieces 14 form the annular connecting core pieces 12, the position of the annular core pieces 12 previously set in the lifting means 24 and 25 is set. A constant height is always maintained by lowering the thickness of the sheet.

The segment core pieces 14 that are pushed by the pusher 49 and arranged in contact with the inner diameter guide member 30 that functions as a positioning member are positioned at the positions of the magnetic pole portions 11 and the caulking portions 54 that are formed in advance. The caulking die 56 (independent of the rotary laminating mechanism 35) that moves up and down is caulked and laminated on the laminated iron core 10 being assembled. Here, the caulking portion 54 may be a well-known half-cut caulking or a V-shaped caulking, but is formed when the segment core piece 14 is formed. The caulking portions 54 are all at the same radial position, and are preferably formed at equal intervals according to the formation angle θ of the magnetic pole portion 11 or at an integral multiple of θ (specifically θ · r).

A method for manufacturing a laminated core using the laminated core manufacturing apparatus 16 will be described. First, the segment core piece 14 having n magnetic pole portions 11 formed at a pitch angle θ degrees, a caulking portion 54 formed at a specific position, and having an arc angle obtained by dividing a circumferential angle 360 degrees into m is formed as a strip-shaped core. The material 13 is continuously formed by performing a half-punching process and a push-back process using a mold. In this case, the length direction of the segment core pieces 14 and the width direction of the belt-like core material 13 are matched.

The belt-shaped iron core material 13 is conveyed to the lower position of the dropping jig 37 by the conveying means for accurately positioning and utilizing the pilot hole 36, and the segment core piece 14 is separated by the dropping jig 37 (block 40). Then, it is placed on a predetermined position of the mounting table 42. Then, the segment core pieces 14 placed on the mounting table 42 are transported by the pusher 49 to the stacking position of the rotary stacking mechanism 35, that is, the position of the caulking die 56. In this case, the segment core pieces 14 are in close contact with or in contact with the inner diameter guide member 30.

Next, the caulking die 56 is lowered, and the segment core pieces 14 are caulked and stacked on the segment core pieces 14 at the lower position and shifted in phase by θ · r degrees. Then, the rotary laminating mechanism 35 including the caulking laminated segment core pieces 14 is rotated 360 degrees / m, and this operation (loading of the segment iron core pieces 14, caulking lamination, and rotation of the laminated iron core 10 during lamination) is repeated. The segment core pieces 14 are arranged in a ring shape to form an annular connecting core piece 12.

Next, the rotating laminated mechanism 35 on which the annular connecting core piece 12 is mounted is rotated by θ · r degrees so that the connecting portions (contact portions) in the circumferential direction of the segment core pieces 14 do not overlap vertically. 10 is formed. The strip-shaped iron core material 13 (outer frame) from which the segment core pieces 14 have been removed is conveyed to the scrap cutter 38 as it is, and is cut into small pieces and carried outside by the carry-out conveyor 46 and the shooter 47.
The above steps are repeated until the number of annular connecting core pieces 12 reaches a predetermined number, that is, until the laminated core 10 reaches a predetermined thickness.

Then, the manufacturing method of the laminated core which concerns on the 2nd Embodiment of this invention is demonstrated, referring FIG.
In the first embodiment, a wide strip-shaped iron core material 13 is used, and a plurality of segment iron core pieces 14 are formed by aligning the longitudinal direction of the segment iron core pieces 14 with the width direction of the band-shaped iron core material 13. In the manufacturing method of the laminated core in the second embodiment, a strip-shaped strip 61 made of a magnetic material slightly wider than the radial width of the arc-shaped segment core piece 60 is used, and the pressing device 62 The segment core pieces 60 are connected to each other by a connecting portion 63 to form a strip-like core material 65.

The strip-shaped iron core material 65 is made in advance by a press device 62, and is wound around a reel and stored. When this strip-shaped iron core material 65 is used, the reel core is unwound and, if necessary, each segment core piece 60 is flattened with a correction roller or the like, and then placed on the conveyance table 67 to move the pusher conveyance position (of the loading table). The connecting portion 63 is cut by a cutting die 64 to form a single segment core piece 60. In this case, the feeding direction of the strip-shaped iron core material 65 and the direction in which each segment iron core piece 60 is fed to the caulking die 69 by the pusher 68 are orthogonal to each other.
In FIG. 4, reference numeral 70 denotes a laminated iron core, and 71 denotes a rotary table. Alternatively, the sheet may be sent directly from the press device 62 to the transport table 67 and sent to the pusher 68 without being reeled.

The present invention is not limited to the above-described embodiment, and the configuration thereof can be changed without changing the gist of the present invention. For example, in the above-described embodiment, a motor is used as a drive source, but an actuator that operates with a hydraulic source or a pneumatic source may be used.
The inner diameter guide member is mainly composed of a plurality of rod members, but may be formed by arranging annular or plural arc-shaped materials.
In the above-described embodiment, the method for manufacturing the rotor laminated core has been described. However, the present invention can be applied to a stator laminated core having magnetic poles on the outer side or the inner side in the radial direction.

10: laminated iron core, 11: magnetic pole part, 11a: magnet insertion hole, 12: annular connecting iron core piece, 13: strip-shaped iron core material, 14: segment iron core piece, 16: manufacturing apparatus for laminated iron core, 17: support member, 18: Base plate, 19: lower plate, 20: elevating plate, 22, 23: elevating rod, 24, 25: elevating means, 27: bearing, 28: rotating plate, 29: core mounting table, 30: inner diameter guide member, 30a: rod 30b: disc, 31: shaft, 32: coupling, 33: motor for rotation, 33a: support plate, 33b: support rod, 34: output shaft, 35: rotary stacking mechanism, 36: pilot hole, 37: Sticking jig, 38: scrap cutter, 40: block, 42: mounting table, 43, 44: shear blade, 45: scrap, 46: discharge conveyor, 47: shooter, 8: Motor, 49: Pusher, 50: Deceleration motor, 51: Arm, 52: Advance / retract member, 53: Iron core piece pushing member, 54: Caulking part, 56: Caulking die, 60: Segment iron piece, 61: Thin strip Material: 62: Pressing device, 63: Connecting part, 64: Cutting die, 65: Strip-shaped iron core material, 67: Transport base, 68: Pusher, 69: Caulking die, 70: Stacked iron core, 71: Rotary table

The present invention relates to a method of manufacturing a laminated core (which may be a rotor laminated core and a stator laminated iron core) by a segmented iron core lamination method capable of reducing the size of a mold and increasing the pressing speed.

2. Description of the Related Art Conventionally, a motor core made of a laminated iron core in which several tens to several hundreds of annular thin plate members obtained by pressing an electromagnetic steel plate is known. The thickness of the thin plate member is about 0.15 to 0.5 mm, and the thinner the plate member, the better the energy efficiency.
Furthermore, in order to improve the yield of thin plate members, laminated iron cores manufactured by combining arcuate thin plate members obtained by dividing an annular thin plate member into a plurality of members are also known.

For example, Patent Document 1 discloses an apparatus for manufacturing a laminated iron core by forming a single annular thin plate member by a plurality of arc-shaped segment iron core pieces and laminating a large number thereof. In the present invention, the central angle of the arc-shaped segment core pieces is 360 degrees / p, and one annular thin plate member is constituted by p pieces of segment core pieces. The annular thin plate members of the adjacent layers are laminated so that the arc-shaped segment core pieces constituting them overlap with each other with the connecting positions shifted like brickwork.

In Patent Document 2, when manufacturing an annular laminated core consisting of a plurality of segment core pieces (arc-shaped members) in each layer, the segment core pieces are formed by half punching and flat pressing, and then pushed back. The core piece is pushed down and separated from the core material (thin plate material), and each time this separation is performed, the separated segment core piece is placed at the desired position of the laminated core, and the laminated iron core reaches the position where the next segment core piece is placed. Is a device that rotates a predetermined angle and repeats this to complete a laminated iron core.

Japanese Patent No. 3634801 JP 2012-95369 A JP-A-63-080741

However, according to the laminated core manufacturing apparatus described in Patent Document 1, in the final process, the segment core pieces are cut from the thin plate material into the mother die by cutting and simultaneously the positioning of the rotational position of the mother die is highly accurate. It is necessary to control with. Accordingly, the positioning control of the thin plate material and the mother die is complicated, the die is enlarged, and the press device is also enlarged accordingly, so that the device cost is increased, and accordingly, the product cost is also increased.

According to the manufacturing apparatus described in Patent Document 2, in the final process, the segment core piece formed by pushing back to the iron core material is pushed down to be separated from the iron core material and transferred to the laminated guide. Unlike the technology, it is not necessary to simultaneously control the feed pitch of the iron core and the positioning of the rotating die with high accuracy. Therefore, although the final process can be easily controlled, since the segment core piece continuous body forming process and the laminating process are performed in the same mold as in Patent Document 1, the mold becomes larger and the press device associated therewith The increase in size is inevitable, and the device cost and product cost also increase.

By the way, in patent document 3, outside the metal mold | die which formed the iron core material which has a tooth | gear part at one end and a base part at the other end, a core material is cut | disconnected for every volume, and the cutting | disconnection edge parts of an iron core material are couple | bonded and a ring A method of forming a stator laminated iron core by forming a laminated body and laminating and fixing a plurality of the ring-like bodies is described.

According to this manufacturing method, the step of forming the core material and the step of cutting the core material for each volume and laminating the ring-shaped combined body are performed in separate molds. Can be avoided. However, since the iron core material is cut every turn, there is only one cutting point, and the stress concentrates on that one point, so that there is a problem that the ring-shaped combined body cannot maintain its roundness.

The present invention has been made in view of such circumstances, and the segment core pieces are laminated in an annular shape outside the mold for manufacturing the segment core pieces, thereby further reducing the size of the apparatus and further improving the press speed. It aims at providing the manufacturing method of a laminated iron core.

The method for manufacturing a laminated core according to the first invention in accordance with the above object has n magnetic pole portions formed at a pitch angle of θ degrees, a caulking portion is formed at a specific position, and a circumferential angle of 360 degrees is m. the segment core piece having a divided arc angle, a first step causes separation from the strip core material,
A second step of caulking laminated prior Symbol isolated segment core pieces in a rotary laminating mechanism,
A third step of rotating the rotary laminating mechanism including the caulked laminated segment core pieces by 360 degrees / m;
Repeat the first step to the third step, a fourth step of forming an annular connecting core pieces in which the segment core pieces are arranged in an annular,
A fifth step of rotating the rotary lamination mechanism on which the annular connecting core pieces are mounted by θ · r degrees;
By repeating the fourth step and the fifth step, an iron core having a predetermined thickness is formed.
However, r is an integer of 1 or more, m and n are integers of 2 or more, θ · n · m = 360 degrees, and r is not an integer multiple of n.

Method of manufacturing a laminated core according to a second aspect is the method of manufacturing a laminated core according to the first invention, the the rotary lamination mechanism provided inside diameter guide member, the divided segment core pieces before Symbol inner diameter It abuts on the guide member and is positioned at the laminated position of the segment core pieces.

The manufacturing method of the laminated core according to the third invention is the manufacturing method of the laminated core according to the first and second inventions, wherein the segment core piece in the first step has the longitudinal direction of the segment core piece as described above. to the width direction of the belt-shaped core material, the segment core pieces pushed back after half die, held in the outer frame of the band-shaped core material, dropping unplug separated before Symbol strip core material (butt).

A method for manufacturing a laminated core according to a fourth aspect of the invention is the method for manufacturing a laminated core according to the third aspect of the invention, wherein the outer frame from which the segment core piece has been removed is broken down by a scrap cutter and discharged out of the system. Is done.

Method of manufacturing a laminated core according to the fifth invention, in the first method for manufacturing a laminated core according to the second invention, the band-shaped core material plurality of the segment core pieces are connected by a connecting portion, before Symbol coupling It is separated min from the strip core material is cut in parts.

And the manufacturing method of the laminated iron core which concerns on 6th invention is a manufacturing method of the laminated iron core which concerns on 5th invention , The said strip | belt-shaped iron core material is manufactured previously and wound by the reel.

The method for manufacturing a laminated core according to the present invention has the following effects.
(1) In the prior art, the mold for stacking the segment core pieces and the mold for forming the segment core pieces are performed in the same mold, but the mold has become larger and the equipment cost has increased. In the present invention, since the step of forming the segment core pieces (that is, the molding die) is performed outside the lamination die, the die can be miniaturized and the apparatus cost can be reduced.
(2) Moreover, it is possible to deal with a plurality of types of products (laminated cores) with one laminating apparatus (laminated core manufacturing apparatus), and it is not necessary to prepare a laminating apparatus individually.

(3) In the conventional apparatus, since the laminating step was performed with the same mold as the step of forming the segment core pieces, the press speed could not be increased, but in the present invention, the step of forming the segment core pieces was laminated. Since it is performed outside the mold, the press speed can be increased.
(4) And since the connection part of the adjacent segment core piece is isolate | separated compared with a wound core, since the lamination | stacking core manufactured by this manufacturing method of a laminated core has separated stress, the roundness of a core Will improve.

It is a top view which shows the main structures of the manufacturing apparatus of the laminated core to which the manufacturing method of the laminated core which concerns on the 1st Embodiment of this invention is applied. It is a side view which shows the main structures of the manufacturing apparatus of the same laminated iron core. It is a perspective view of the manufacturing apparatus of the same laminated iron core. It is explanatory drawing of the manufacturing method of the laminated core which concerns on the 2nd Embodiment of this invention.

Next, embodiments of the present invention will be described with reference to the accompanying drawings.
As shown in FIG. 1, a laminated core 10 to which the laminated core manufacturing method according to the first embodiment of the present invention is applied has a large number of magnetic pole portions 11 on the radially outer side. Adjacent magnetic pole portions 11 are formed with a pitch angle θ degrees, and the annular connecting core pieces 12 having a round (circular angle) of 360 degrees are equally divided into a plurality (m) of segment core pieces 14. That is, one segment core piece 14 has n magnetic pole portions 11 and θ · n · m = 360 degrees. In this embodiment, the magnetic pole portion 11 is provided on the outer side in the radial direction. However, a laminated iron core in which the magnetic pole portion is formed on the inner side in the radial direction may be used. M and n are integers of 2 or more. Each magnetic pole portion 11 is formed with a magnet insertion hole 11a.

In this laminated core 10, a segment core piece 14 is formed from a strip-like core 13 made of a thin magnetic steel plate, and one annular connecting core piece 12 using m (in this embodiment, five) segment core pieces 14. And a predetermined number of the annular connecting core pieces 12 are caulked and laminated to form a laminated core 10 having a predetermined thickness. In this case, if the connecting portions of the adjacent segment core pieces 14 are at the same circumferential angle position, they are easily disassembled after assembly. The positions are shifted by θ · r degrees. Here, r is an integer of 1 or more, and is not an integer multiple of n.

Next, the laminated iron core manufacturing apparatus 16 will be described with reference to FIGS. As shown in FIGS. 1 and 2, the laminated iron core manufacturing apparatus 16 has a base plate 18 and a lower plate 19 that are held around by four cylindrical support members 17, which are attached to a support frame (not shown). It is fixedly arranged. The four support members 17 are provided with an elevating plate 20 provided between a base plate 18 and a lower plate 19 so as to be movable up and down.

Upper parts of the right and left lifting rods 22 and 23 are fixed to both sides of the lifting plate 20, and lifting means 24 and 25 are provided below the lifting rods 22 and 23. The elevating means 24 and 25 have a drive motor inside, and by moving the drive motor in synchronization, the left and right elevating rods 22 and 23 are moved up and down synchronously, and the elevating plate 20 is moved up and down while maintaining a horizontal state. I am letting.

The elevating plate 20 is provided with a rotating plate 28 via a bearing 27, and a core mounting table 29 is mounted on the rotating plate 28 with its axis aligned, and the core mounting table 29 is provided with an inner diameter guide member 30. . The inner diameter guide member 30 determines the inner diameter of the laminated iron core 10. When the inner side of each segment core piece 14 is in contact with each other and becomes an annular connecting core piece 12, the inner diameter guide member 30 and the inner ring guide member 30 are annularly connected. A slight gap is formed between the iron core piece 12 and the laminated iron core 10. The inner diameter guide member 30 has a plurality of standing rod members 30a arranged side by side on the same circumference and a disc 30b connected to the upper end of the rod member 30a.

The rotary plate 28 is provided with a shaft 31, and is connected to the output shaft 34 of the lower rotation motor 33 by a coupling 32. The rotation motor 33 is fixed to the elevating plate 20 by a support plate 33a and a plurality of support rods 33b.
Accordingly, when the rotation motor 33 is driven, the rotation plate 28 is rotated, and when the elevating means 24 and 25 are driven, the elevating plate 20 is moved up and down, and a servo motor is used for each of these motors. The laminated iron core 10 (including during assembly) placed on the mounting table 29 is rotated by a predetermined angle and moved up and down to a predetermined height. A rotary laminating mechanism 35 that includes these and the above-described inner diameter guide member 30 and that sequentially rotates and laminates the segment core pieces 14 is formed.
The lower plate 19 is formed with a through hole (not shown) through which the rotation motor 33 can freely move up and down.

The core mounting table 29 is provided around the axis of the shaft 31, and an unillustrated loading means for sequentially loading the segment core pieces 14 formed on the strip core material 13 into a predetermined position on the outer position of the core mounting table 29. Is provided.
A large number of segment core pieces 14 are arranged in the band-shaped iron core material 13 with a slight gap by aligning the longitudinal direction of the segment iron core pieces 14 with the width direction of the band-shaped iron core material 13. The segment core piece 14 is half-cut by the first press with respect to the strip core member 13 and pushed back to the strip core member 13 by the second press so that the periphery of the segment core piece 14 can be easily separated. In the state, it is connected to the outer frame (skeleton) of the strip-shaped iron core material 13.

The strip-shaped iron core material 13 having the segment iron core pieces 14 so as to be separable is sent to the push-out jig 37 and the scrap cutter 38 by the above-mentioned carrying means using the pilot holes 36 provided on both sides.
The push-down jig 37 has a block 40 and pushes (drops) the segment core piece 14 on the mounting table 42.

The outer frame of the strip-shaped iron core material 13 from which the segment core pieces 14 are pushed down is cut short by a scrap cutter 38 having shearing blades 43 and 44 to become scrap 45, falls on a discharge conveyor 46, and is connected to the system by a shooter 47 connected thereto. Discharged outside. Reference numeral 48 denotes a motor for driving the discharge conveyor 46. Further, after the segment core piece 14 is pushed down by the block 40, the outside of the belt-like core material 13 is conveyed by a predetermined distance and can be placed on the scrap cutter 38. In addition, since it is enough for the block 40 to drop the segment core piece 14, it may be smaller than the segment core piece 14 and may not be the same shape as the segment core piece 14.

A pusher 49 is provided for transporting the segment core piece 14 placed on the mounting table 42 to a predetermined position of the rotary stacking mechanism 35. The pusher 49 includes a reduction motor 50 that is driven to rotate, an arm 51 provided on the reduction motor 50, an advance / retreat member 52 provided on a front portion of the arm 51, and an iron core single pushing member 53 that is advanced / retreated by the advance / retreat member 52. A predetermined angular position of the laminated core 10 being assembled provided on the core mounting table 29 placed on the rotary plate 28 by pushing both longitudinal sides of the segment core piece 14 pushed down on the mounting table 42 from behind. It is transported to.

Here, the predetermined angular position of the laminated iron core 10 means that when one or a plurality of segment iron core pieces 14 do not form the annular connecting iron core piece 12, the laminated iron core pieces are laminated one before and rotated 360 degrees / m. When the end of the segment core piece 14 comes into contact with the starting end of the segment core piece 14 to be newly laminated, when the m segment core pieces 14 form the annular connecting core piece 12, The position is obtained by rotating the annular connecting core piece 12 by θ · r degrees. Here, the condition that θ · r degrees does not coincide with 360 / m.

The rotation angle of the laminated core 10 during the above assembly is controlled by controlling the rotation motor 33. In addition, the position of the upper surface of the laminated core 10 during assembly is such that when the m segment core pieces 14 form the annular connecting core pieces 12, the position of the annular core pieces 12 previously set in the lifting means 24 and 25 is set. A constant height is always maintained by lowering the thickness of the sheet.

The segment core pieces 14 that are pushed by the pusher 49 and arranged in contact with the inner diameter guide member 30 that functions as a positioning member are positioned at the positions of the magnetic pole portions 11 and the caulking portions 54 that are formed in advance. The caulking die 56 (independent of the rotary laminating mechanism 35) that moves up and down is caulked and laminated on the laminated iron core 10 being assembled. Here, the caulking portion 54 may be a well-known half-cut caulking or a V-shaped caulking, but is formed when the segment core piece 14 is formed. The caulking portions 54 are all at the same radial position, and are preferably formed at equal intervals according to the formation angle θ of the magnetic pole portion 11 or at an integral multiple of θ (specifically θ · r).

A method for manufacturing a laminated core using the laminated core manufacturing apparatus 16 will be described. First, the segment core piece 14 having n magnetic pole portions 11 formed at a pitch angle θ degrees, a caulking portion 54 formed at a specific position, and having an arc angle obtained by dividing a circumferential angle 360 degrees into m is formed as a strip-shaped core. The material 13 is continuously formed by performing a half-punching process and a push-back process using a mold. In this case, the length direction of the segment core pieces 14 and the width direction of the belt-like core material 13 are matched.

The belt-shaped iron core material 13 is conveyed to the lower position of the dropping jig 37 by the conveying means for accurately positioning and utilizing the pilot hole 36, and the segment core piece 14 is separated by the dropping jig 37 (block 40). Then, it is placed on a predetermined position of the mounting table 42. Then, the segment core pieces 14 placed on the mounting table 42 are transported by the pusher 49 to the stacking position of the rotary stacking mechanism 35, that is, the position of the caulking die 56. In this case, the segment core pieces 14 are in close contact with or in contact with the inner diameter guide member 30.

Next, the caulking die 56 is lowered, and the segment core pieces 14 are caulked and stacked on the segment core pieces 14 at the lower position and shifted in phase by θ · r degrees. Then, the rotary laminating mechanism 35 including the caulking laminated segment core pieces 14 is rotated 360 degrees / m, and this operation (loading of the segment iron core pieces 14, caulking lamination, and rotation of the laminated iron core 10 during lamination) is repeated. The segment core pieces 14 are arranged in a ring shape to form an annular connecting core piece 12.

Next, the rotating laminated mechanism 35 on which the annular connecting core piece 12 is mounted is rotated by θ · r degrees so that the connecting portions (contact portions) in the circumferential direction of the segment core pieces 14 do not overlap vertically. 10 is formed. The strip-shaped iron core material 13 (outer frame) from which the segment core pieces 14 have been removed is conveyed to the scrap cutter 38 as it is, and is cut into small pieces and carried outside by the carry-out conveyor 46 and the shooter 47.
The above steps are repeated until the number of annular connecting core pieces 12 reaches a predetermined number, that is, until the laminated core 10 reaches a predetermined thickness.

Then, the manufacturing method of the laminated core which concerns on the 2nd Embodiment of this invention is demonstrated, referring FIG.
In the first embodiment, a wide strip-shaped iron core material 13 is used, and a plurality of segment iron core pieces 14 are formed by aligning the longitudinal direction of the segment iron core pieces 14 with the width direction of the band-shaped iron core material 13. In the manufacturing method of the laminated core in the second embodiment, a strip-shaped strip 61 made of a magnetic material slightly wider than the radial width of the arc-shaped segment core piece 60 is used, and the pressing device 62 The segment core pieces 60 are connected to each other by a connecting portion 63 to form a strip-like core material 65.

The strip-shaped iron core material 65 is made in advance by a press device 62, and is wound around a reel and stored. When this strip-shaped iron core material 65 is used, the reel core is unwound and, if necessary, each segment core piece 60 is flattened with a correction roller or the like, and then placed on the conveyance table 67 to move the pusher conveyance position (of the loading table). The connecting portion 63 is cut by a cutting die 64 to form a single segment core piece 60. In this case, the feeding direction of the strip-shaped iron core material 65 and the direction in which each segment iron core piece 60 is fed to the caulking die 69 by the pusher 68 are orthogonal to each other.
In FIG. 4, reference numeral 70 denotes a laminated iron core, and 71 denotes a rotary table. Alternatively, the sheet may be sent directly from the press device 62 to the transport table 67 and sent to the pusher 68 without being reeled.

The present invention is not limited to the above-described embodiment, and the configuration thereof can be changed without changing the gist of the present invention. For example, in the above-described embodiment, a motor is used as a drive source, but an actuator that operates with a hydraulic source or a pneumatic source may be used.
The inner diameter guide member is mainly composed of a plurality of rod members, but may be formed by arranging annular or plural arc-shaped materials.
In the above-described embodiment, the method for manufacturing the rotor laminated core has been described. However, the present invention can be applied to a stator laminated core having magnetic poles on the outer side or the inner side in the radial direction.

10: laminated iron core, 11: magnetic pole part, 11a: magnet insertion hole, 12: annular connecting iron core piece, 13: strip-shaped iron core material, 14: segment iron core piece, 16: manufacturing apparatus for laminated iron core, 17: support member, 18: Base plate, 19: lower plate, 20: elevating plate, 22, 23: elevating rod, 24, 25: elevating means, 27: bearing, 28: rotating plate, 29: core mounting table, 30: inner diameter guide member, 30a: rod 30b: disc, 31: shaft, 32: coupling, 33: motor for rotation, 33a: support plate, 33b: support rod, 34: output shaft, 35: rotary stacking mechanism, 36: pilot hole, 37: Sticking jig, 38: scrap cutter, 40: block, 42: mounting table, 43, 44: shear blade, 45: scrap, 46: discharge conveyor, 47: shooter, 8: Motor, 49: Pusher, 50: Deceleration motor, 51: Arm, 52: Advance / retract member, 53: Iron core piece pushing member, 54: Caulking part, 56: Caulking die, 60: Segment iron piece, 61: Thin strip Material: 62: Pressing device, 63: Connecting part, 64: Cutting die, 65: Strip-shaped iron core material, 67: Transport base, 68: Pusher, 69: Caulking die, 70: Stacked iron core, 71: Rotary table

Claims (6)

A segment core piece having n magnetic pole portions formed at a pitch angle of θ degrees, a caulking portion formed at a specific position, and an arc angle obtained by dividing a circumferential angle of 360 degrees into m is separated from the strip-shaped core material. The first step;
A second step of caulking and laminating the separated segment core pieces in a rotary laminating mechanism;
A third step of rotating the rotary laminating mechanism including the caulked laminated segment core pieces by 360 degrees / m;
A fourth step of repeating the first step to the third step to form an annular connecting core piece in which the segment core pieces are arranged in a ring; and
A fifth step of rotating the rotary lamination mechanism on which the annular connecting core pieces are mounted by θ · r degrees;
A method of manufacturing a laminated core, wherein the fourth and fifth steps are repeated to produce a caulked laminated core having a predetermined thickness.
However, r is an integer of 1 or more, m and n are integers of 2 or more, θ · n · m = 360 degrees, and r is not an integer multiple of n. 2. The method of manufacturing a laminated core according to claim 1, wherein the rotary lamination mechanism is provided with an inner diameter guide member, and the separated segment core pieces abut against the inner diameter guide member and are positioned at a lamination position of the segment core pieces. A method for producing a laminated iron core, characterized in that: 3. The method of manufacturing a laminated core according to claim 1, wherein the segment core piece in the first step is configured such that a longitudinal direction of the segment core piece is aligned with a width direction of the belt-like core material, and the segment core piece is A method of manufacturing a laminated core, wherein the laminated core is pulled out after being half-pulled, held by an outer frame of the strip-shaped core material, and separated and removed from the strip-shaped core material. 4. The method of manufacturing a laminated core according to claim 3, wherein the outer frame from which the segment core pieces have been removed is fragmented by a scrap cutter and discharged out of the system. 3. The method for manufacturing a laminated core according to claim 1, wherein a plurality of the segment core pieces are connected by a connecting portion and separated from the strip-shaped core material by being cut at the connecting portion. A method for manufacturing a laminated iron core. 6. The method of manufacturing a laminated core according to claim 5, wherein the belt-like core material is manufactured in advance and wound in a reel.

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