JP2019076910A - Manufacturing apparatus of core for rotary electrical machine - Google Patents

Abstract

To provide a manufacturing apparatus of a core for a rotary electrical machine which secures a caulking depth when forming a caulking protrusion on a core thin plate in a range of allowable accuracy even when there is a variation on a plate thickness of a metallic plate work-piece.SOLUTION: A manufacturing apparatus 10 of a core for a rotary electrical machine includes a lower die 30 on which a metallic plate work-piece 8 is arranged and an upper die 50 having a caulking punch 40 which forms a caulking protrusion on the metallic plate work-piece 8. The manufacturing apparatus of the core for a rotary electrical machine further includes a caulking pressure detection part 60 for detecting a pressure applied to the caulking punch 40 and a driving mechanism 13 as a reciprocating mechanism for reciprocating the upper die 50 in a vertical direction. Therein, a control device 70 includes a die height adjustment part 74 which adjusts a die height DH in accordance with a detection result of the caulking pressure detection part 60 by setting a distance between a lower end position of the caulking punch 40 on a bottom dead center position LDP of the upper die 50 and a standard height position GL of the lower die 30 as a die height DH.SELECTED DRAWING: Figure 1

Description

  The present disclosure relates to an apparatus for manufacturing a core for a rotating electrical machine, and more particularly to an apparatus for manufacturing a core for a rotating electrical machine in which a plurality of thin core sheets are caulked and laminated to form a laminated core.

  As the core of the rotor of the rotary electric machine and the core of the stator, a laminated core in which thin core sheets formed by molding magnetic thin sheets in a predetermined shape are stacked is used. The core thin plate is formed by sequentially punching out a slit portion, a shaft hole portion, and the like with respect to a strip-like thin plate metal material using a progressive press forming apparatus, forming a caulking projection and performing an outer shape punching. The lamination of a plurality of core thin plates is performed by fitting and caulking the concave portions of the caulking projections in one core thin plate and the convex portions of the caulking projections in the core thin plate to be stacked next (Patent Document 1).

  In Patent Document 2, as a method of determining a touch point at which the upper mold comes in contact with a work placed in the lower mold in a press apparatus or the like, a visual inspection method by a manual operation or a method using detected values of drive current of the press apparatus A method is described using the load increase of a load cell mounted on the upper mold.

  In Patent Document 3, a scale is provided on the surface of the slide opposite to the support column of the press apparatus for detecting the bottom dead center position of the slide supporting the upper mold in the press apparatus, and the scale is provided by the read sensor provided on the support column. It is disclosed to read.

JP-A-8-228461 JP 11-300500 A JP, 2011-173140, A

  When laminating a plurality of core thin plates by providing a crimped projection on the core thin plate, the depth of the recess on the surface of the core thin plate of the crimped projection and the height of the convex on the back are substantially the same. The depth of the recess is called caulking depth. When the caulking depth is too deep, the recess is likely to break, and when the caulking depth is shallow, the fastening force of the lamination is insufficient. Therefore, it is necessary to keep the caulking depth within a predetermined tolerance. On the other hand, the metal plate work which is the material of the core thin plate has variation in plate thickness, and the variation in thickness of the metal plate work is added to the accuracy of the caulking depth. Therefore, it is necessary to keep the caulking depth within a predetermined allowable accuracy in consideration of the influence of the variation in the thickness of the metal plate work.

  Although detection and control of the bottom dead center have been conventionally performed in a progressive press forming apparatus and the like used for forming a crimped projection, the variation in thickness of a metal plate work is directly measured in the processing step. It is difficult. Therefore, there is a demand for a manufacturing apparatus of a core for a rotary electric machine which can secure the caulking depth in forming a caulking protrusion on the core thin plate within the allowable accuracy even if the thickness of the metal plate work of the material varies.

  An apparatus for manufacturing a core for a rotating electrical machine according to the present disclosure is an apparatus for manufacturing a core for a rotating electrical machine that forms a laminated core in which a plurality of thin core sheets are caulked and laminated, and a metal plate work that is a material of the core thin sheet is disposed. A lower die and a caulking punch for forming a caulking protrusion on a metal plate work, and an upper die disposed opposite to the upper side of the lower die, and a caulking punch for detecting a pressure applied to the caulking punch Between the lower end position of the caulking punch at the bottom dead center of the upper mold and the reference height position of the lower mold. And a die height adjustment unit for adjusting the die height according to the detection result of the caulking pressure detection unit as the die height of the caulking punch.

  For example, if the crimping depth is deeper between the crimping depth and the crimping pressure of the crimping punch when the crimping projection is formed on the metal plate work, the crimping pressure becomes higher and the crimping pressure becomes lower when the crimping depth is shallow, etc. There is a correlation of In other words, it is considered that the caulking depth is too deep if the caulking pressure is excessive, and the caulking depth is too shallow if the caulking pressure is too small. When the plate thickness of the metal plate work varies, if the plate thickness is dispersed in the thick direction with the die height at the height position of the crimping punch being the same, the crimping depth becomes too deep and the crimping pressure becomes excessive. On the other hand, when the thickness of the plate varies in the thinner direction, the caulking depth becomes too shallow and the caulking pressure becomes too small.

  According to the above configuration, the caulking punch is provided with a caulking pressure detection unit, and the pressure of the caulking punch at the time of forming the caulking projection can be detected. Therefore, it is possible to adjust the die height in real time according to the detected pressure of the crimping punch without measuring the thickness of the metal plate work. For example, the detected pressure is compared with a predetermined predetermined pressure tolerance, and the die height is reduced if the detected pressure is greater than the pressure tolerance, and the die height is detected if the detected pressure is less than the pressure tolerance. Increase the Thereby, even if there is variation in the thickness of the metal plate work of the material, the die height in the next step of forming the crimped projection becomes appropriate without measuring the thickness, and the caulking depth is determined to a predetermined allowable accuracy. Therefore, the lamination of a plurality of core sheets can be properly performed.

  According to the above-described apparatus for manufacturing a core for an electric rotating machine, the caulking depth in forming the caulking projections on the core thin plate is secured within the range of the allowable accuracy even if the thickness of the metal plate work of the material varies. it can.

It is a block diagram of the manufacturing apparatus of the core for rotary electric machines in embodiment. In the manufacturing apparatus of the core for rotary electric machines of FIG. 1, it is a figure which shows the process in which the metal plate work of a raw material is conveyed one by one, and is shape | molded. Fig.2 (a) is a figure which shows each forming station, (b) is a top view of the metal plate work in each forming station, (c) was along the C-C line of (b). FIG. It is a figure which shows the detailed process in the crimping and dropping-off station of FIG. Fig.3 (a) is a figure which shows the state in which the metal plate workpiece | work which finished axial drilling was conveyed to the crimping and cutting-off station was conveyed, and (b) performed crimping projection shaping | molding and crimping by a crimping punch. It is a figure which shows a state, and (c) is a figure which shows the state in which truncation was performed. (D) is a perspective view of a laminated core. In FIG. 1, it is a figure which shows the relationship between the part of a crimping punch, and a metal plate workpiece | work. Fig.4 (a) is sectional drawing of the part of a crimping punch and the crimping pressure detection part provided in it, (b) is a figure which shows a crimping projection about one metal plate work. It is a comparison figure of the dispersion | variation range of the plate | board thickness of a metal plate workpiece | work, and the tolerance | permissible precision of crimping depth. It is a figure which shows the example of the die height of the caulking punch for ensuring predetermined | prescribed caulking depth, when the plate | board thickness of metal plate workpiece | work varies. It is a flowchart which shows the procedure of the caulking * cut-out molding method used in the manufacturing apparatus of the core for rotary electric machines in embodiment. It is a figure which shows the other structural example about a crimping punch and a crimping pressure detection part. It is a figure which shows the example of lamination | stacking of the some core thin plate which has a crimping process in the prior art which does not use the caulking * cutting-off forming method of FIG. It is a comparison figure of the case where a prior art is used, and the case where the crimping and cutting method of FIG. 7 are used, about the lamination example of the some core thin plate which has a crimping process.

  Hereinafter, embodiments according to the present disclosure will be described in detail using the drawings. Hereinafter, the rotor core of the rotary electric machine will be described as the laminated core, but this is an example for explanation and may be a stator core. The number of core thin plates constituting the laminated core described below, the number of caulking projections, the shape, the material, and the like are merely examples for the purpose of description, and can be appropriately changed according to the specifications of the manufacturing apparatus of the core for the rotating electrical machine. is there. Further, in the following, the same reference numeral is given to the same element in all the drawings, and the overlapping description is omitted.

  FIG. 1 is a block diagram of a manufacturing apparatus 10 of a core for a rotating electrical machine. Hereinafter, unless otherwise specified, the manufacturing apparatus 10 for a core for a rotating electrical machine is referred to as a manufacturing apparatus 10 for a core. The core manufacturing apparatus 10 sequentially transports the metal plate work 8 as a material to a plurality of forming stations to form the core thin plate 90 having a predetermined shape, and caulking and laminating the plurality of core thin plates 90 to form a laminated core. 92 is a progressive press forming apparatus for forming 92 (see FIG. 3). FIG. 2 is a view showing a process in which the metal plate work 8 is sequentially conveyed and formed at each forming station of the manufacturing apparatus 10 of the core. FIG. 3 is a view showing a detailed process in the crimping and cutting-off station in which the process is performed using the crimping punch 40 among the forming stations.

  First, the basic configuration of the core manufacturing apparatus 10 will be described using FIG. 1, and then the contents of each molding station of the core manufacturing apparatus 10 will be described using FIG. 2, and using FIG. The details of the crimping and dropping station using the crimping punch 40 will be described. Then, returning to FIG. 1 again, control of the crimping depth in the core manufacturing apparatus 10 will be described.

  In FIG. 1, the core manufacturing apparatus 10 includes a lower mold 30 on which the metal plate work 8 is disposed, an upper mold 50 having a caulking punch 40 and disposed to face the lower mold 30, and a control device. And 70.

  The core manufacturing apparatus 10 is a base 12 as a base, a crown 14 provided on the upper side of the base 12 and including the drive mechanism 13 in the inside, and two pillars standing from the base 12 to support the crown 14 Includes column 16. Furthermore, it includes a slide portion 18 which is guided by the column 16 and can be moved in the vertical direction, and a slide drive portion 20 which transmits the driving force of the drive mechanism 13 provided on the crown 14 to the slide portion 18.

  FIG. 1 shows the vertical direction of the core manufacturing apparatus 10. The vertical direction is a direction parallel to the direction of gravity, with the base 12 side being the lower side and the crown 14 side being the upper side. The vertical direction is also the molding direction of the crimping projection 80, and is also the axial direction in which the crimping punch 40 used for molding the crimping projection 80 moves up and down. Hereinafter, the vertical direction of the core manufacturing apparatus 10 will be referred to as an axial direction unless otherwise specified.

  The drive mechanism 13 provided in the crown 14 is a reciprocating motion mechanism that drives the slide portion 18 vertically along the column 16 with a predetermined stroke via the slide drive portion 20. As a reciprocating motion mechanism, a crank motion mechanism configured of a motor whose output shaft rotates and a crankshaft connected to the output shaft of the motor is used. Instead of the crank movement mechanism, a hydraulic lift mechanism having a predetermined reciprocating stroke may be used.

  When the drive mechanism 13 is performed by a reciprocating motion mechanism such as a crank motion mechanism, the highest lowering point of the upper mold 50 corresponds to the lower dead point of the reciprocating motion mechanism. Therefore, the highest lowering point of the upper mold 50 is the upper mold Called 50 bottom dead center. Therefore, the lower limit position of the predetermined stroke of the reciprocating motion mechanism is measured from the reference height position GL of the lower mold 30, and this is referred to as a lower dead center position LDP of the upper mold 50. The reference height position GL of the lower mold 30 is set to the height position of the upper surface of the lower mold 30. This is an example, and the height position other than this may be used as the reference height position GL of the lower mold 30 in the core manufacturing apparatus 10.

  The slide portion 18 is a member which is guided by the column 16 and moves up and down along the axial direction. The slide drive unit 20 is a mechanical component that is provided on the upper side of the slide unit 18 and transmits the driving force of the drive mechanism 13 contained in the crown 14 to the slide unit 18 and is configured by, for example, an elevating shaft and a bearing. .

  The lower mold 30 is a work holding mold which is provided on the upper surface of the base 12 and arranges and holds the metal plate work 8 at a predetermined position. The metal plate work 8 is a sheet of a magnetic thin plate as a material used for a core for a rotating electrical machine mounted on a vehicle, wound in a coil, and sequentially from the winding start end side of the coil by a transport mechanism not shown. It is transported onto the lower mold 30.

  The upper mold 50 is fixedly attached to the lower surface of the slide portion 18. The upper mold 50 is disposed to face the lower mold 30 and forms a pair of the lower mold 30 to form a plurality of forming stations along the conveying direction of the metal plate work 8.

  The above is the basic configuration of the core manufacturing apparatus 10. FIG. 2 is a view showing the contents of a plurality of forming stations for forming a rotor core used for a rotor of a rotating electrical machine from a sheet of magnetic thin sheet in the core manufacturing apparatus 10. As shown in FIG. 2 (a), the plurality of forming stations are, from the upstream side to the downstream side of the forming process, a loading station, a pilot hole station, a slitting station, a shaft punching station, a crimping / cutting station, Arranged in order of unloading station. 2 (b) and 2 (c) are diagrams showing the state of the metal plate work 8 at each forming station, (b) is a top view of the metal plate work 8, and (c) is a C- of (b). It is sectional drawing along C line.

  At the loading station, the sheet of the magnetic thin sheet wound in a coil shape is drawn out as the long metal plate work 8 and disposed at the pilot hole station of the lower mold 30. A sheet of a magnetic steel sheet can be used as the thin sheet of the magnetic material.

  At the pilot hole station, the long metal plate work 8 is punched and formed into a plurality of pilot holes 32 which are a plurality of feed holes at a predetermined pitch along the longitudinal direction. The metal plate work 8 is transported using the pilot holes 32, and at each downstream station, the pilot holes 32 position the forming area of the metal plate work 8. In the example of FIG. 2 (b), the area surrounded by the four pilot holes 32 is the forming area at each forming station.

  When the formation of the pilot holes 32 is completed, the long metal plate work 8 is sent downstream by one pitch of the pilot holes 32 and positioned in the forming area of the slitting station. At the slitting station, molding is performed to punch a plurality of magnet insertion holes 34 of the rotor. When the formation of the magnet insertion holes 34 is finished, the metal plate work 8 is sent downstream by one pitch of the pilot holes 32 and positioned in the forming area of the axial hole drilling station. At the axial drilling station, the axial hole 36, which is the central hole of the rotor, is punched and formed. When the formation of the shaft hole 36 is completed, the metal plate work 8 is sent to the downstream side of one pitch of the pilot hole 32 and positioned in the forming area of the crimping and cutting station.

  At the crimping / cutting-down station, a plurality of crimped projections 80 are formed, and then an outer shape is cut out in an annular shape to be an outer shape of the rotor core, and an annular core thin plate 90 is formed. The lower die 30 of the caulking and dropping station portion is provided with a pedestal 31 for receiving the core thin plate 90 that has been cut off. On the receiving table 31, the core thin plate 90 which has been formed, cut out, and cut out of the crimping projection 80 in the preceding forming process is placed. In the crimping / cutting-off station, when the crimped projection 80 is formed on the conveyed metal plate work 8, the convex portion on the lower surface thereof is the crimped projection 80 of the core thin plate 90 already mounted on the pedestal 31. It is fitted in the concave part of and caulked. Thereafter, outline removal is performed.

  In the example of FIG. 2C, four core thin plates 90 which are crimped and stacked on each other are placed on the pedestal 31. The metal plate work 8 is conveyed thereon, and the caulking projection 80 is formed, and the convex portion of the lower surface thereof is the core thin plate placed on the uppermost side among the four core thin plates 90 on the pedestal 31 It is fitted into the recess on the upper surface of 90 and crimped. FIG. 2 shows the state immediately before the crimping is performed and the outline removal is performed.

  FIG. 3 is a cross-sectional view sequentially illustrating a plurality of forming steps performed in the crimping and dropping station. Each figure of FIG. 3 is sectional drawing in alignment with the CC line | wire of FIG.2 (b) similarly to FIG.2 (c). In each drawing of FIG. 3, illustration of the lower mold 30 and the pedestal 31 is omitted, and instead, the crimping punch 40 of the upper mold 50 and the crimping pressure detection unit 60 provided thereon are shown. Moreover, it conveys to a crimping * cutting-off station, the shaping | molding of the crimping protrusion 80 and an outline extraction is performed, and the part used as the 5th core thin plate 90 is shown by oblique lines.

  FIG. 3A is a view showing a state in which the metal plate work 8 is conveyed on the four core thin plates 90 which are formed and stacked in advance. Although the magnet insertion hole 34 and the axial hole 36 have been formed in the metal plate work 8, the magnet insertion hole 34 is not shown because it is not on the line C-C. The caulking punch 40 is above the bottom dead center position LDP.

  In FIG. 3B, the upper mold 50 is lowered to the bottom dead center position LDP from the state of FIG. 3A, the crimping punch 40 presses the metal plate work 8 downward with the pressing force F, and the crimped projection 80 by plastic deformation. Shows the molded state. At this time, the convex portion on the lower surface side of the formed crimped projection 80 is fitted into the concave portion on the upper surface side of the core thin plate 90 placed on the uppermost side among the four core thin plates 90 already laminated. It is crimped. The caulking pressure P received by the caulking punch 40 from the metal plate work 8 and the lower mold 30 is detected by the caulking pressure detection unit 60 and transmitted to the control device 70 by the signal line 71.

  In FIG. 3 (c), the portion of the metal plate work 8 on which the caulking projection 80 is formed is subjected to outline removal using a notched punch not shown, and cut off from the metal plate work 8 and five core thin plates 90 It is a figure which shows the state isolate | separated from the laminated core 92 laminated | stacked. Illustration of the caulking punch 40 is omitted.

  FIG. 3D is a perspective view showing a laminated core 92 in which five core thin plates 90 are crimped together by caulking projections 80 and integrated. The above steps are repeated to laminate a predetermined number of core thin plates 90 to obtain a laminated rotor core. Further, permanent magnets are respectively disposed in the magnet insertion holes 34 of the laminated body, and the rotor shaft is fixed to the shaft hole 36, whereby the rotor of the rotary electric machine is formed.

  The above is the contents of each forming station of the manufacturing apparatus 10 of the core, and the explanation of the crimping and cutting-off station using the crimping punch 40. Returning to FIG. 1 again, the configuration of the core manufacturing apparatus 10 with respect to the control of the crimping depth of the crimping projection 80 will be described. In FIG. 1, a part of the upper mold 50 is broken, and a caulking punch 40 at a caulking / cutting-off station and a caulking pressure detection unit 60 provided on the caulking punch 40 are shown. In the example of FIG. 1, four caulking punches 40 and four caulking pressure detection units 60 are provided, but three caulking punches 40 on the front side of the paper surface and three caulking pressure detection units 60 respectively provided thereon are illustrated. The remaining one caulking punch 40 and one caulking pressure detection unit 60 provided thereon are not illustrated because they are disposed on the other side of the paper surface with respect to the caulking punch 40 and the caulking pressure detection unit 60 illustrated. Since the number of crimping punches 40 is four, there are four crimping projections 80 formed for the core thin plate 90. This is an illustrative example, and the number of crimping projections 80 formed for the core thin plate 90 may be other than four, for example, one, two, three, five or more.

  The crimping pressure detection unit 60 is a pressure sensor that detects a crimping pressure P that the crimping punch 40 receives when the crimping projection 80 is formed on the metal plate work 8. The detected crimping pressure P is transmitted to the control device 70 by a signal line 71. In FIG. 1, four signal lines 71 are shown corresponding to the four crimping pressure detection units 60. As the caulking pressure detection unit 60, a small and lightweight piezo element is used. Instead of the piezoelectric element, a semiconductor strain gauge type diaphragm pressure sensor may be used.

  What is shown as DH in FIG. 1 is the die height of the caulking punch 40. The die height DH of the caulking punch 40 is the distance between the lower end position of the caulking punch 40 at the lower dead center position LDP of the upper mold 50 and the reference height position GL of the lower mold 30. Hereinafter, the die height DH of the caulking punch 40 is referred to as die height DH unless otherwise specified. The large die height DH indicates that the lower end position of the caulking punch 40 is located on the upper side in the axial direction with reference to the reference height position GL of the lower mold 30. When the die height DH is excessive, the caulking depth is shallow. If the die height DH is too small, the caulking depth is deep. In FIG. 1, the die height DH is shown on the upper side not in contact with the metal plate work 8. However, in order to show the relationship between the reference height position GL of the lower mold 30 and the bottom dead center position LDP of the upper mold 50 and the die height DH. It is. In practice, the die height DH is located below the upper surface of the metal plate work 8.

  The core manufacturing apparatus 10 has a function of adjusting the die height DH in accordance with the detection value of the crimping pressure detection unit 60.

  For adjustment of the die height DH, the drive mechanism 13 of the crown 14 includes a collective die height adjustment mechanism 15. Under control of the control device 70, the collective die height adjustment mechanism 15 changes the stroke of the drive mechanism 13 which is a reciprocating motion mechanism from the standard stroke, and adjusts the bottom dead center position LDP of the upper mold 50. By this, adjustment of the die height DH of the plurality of caulking punches 40 provided on the upper mold 50 is collectively performed. The collective die height adjustment mechanism 15 can use a known bottom dead center adjustment mechanism.

  In FIG. 1, the upper die 50 includes the individual die height adjustment mechanism 51 with a two-dot chain line, but the individual die height adjustment mechanism 51 is used when adjusting the die height DH of each of the four swage punches 40 independently. The details will be described later.

  The controller 70 generally controls the operation of other elements in the core manufacturing apparatus 10. The control device 70 includes a movement control unit 72 for the sequential feeding process as the sequential feeding press forming device. The movement control unit 72 controls the operation of the drive mechanism 13 to move the upper mold 50 up and down within a predetermined stroke range. Control device 70 further includes a die height adjustment unit 74.

  The die height adjustment unit 74 of the control device 70 adjusts the die height DH of the caulking punch 40 in accordance with the detection result of the caulking pressure detection unit 60. The adjustment of the die height DH is to keep the caulking depth of the caulking projection 80 formed on the metal plate work 8 within a predetermined allowable range. Specifically, the caulking pressure P detected by the caulking pressure detection unit 60 is compared with a predetermined pressure allowable range, and if the detected caulking pressure P is larger than the pressure allowable range, the die height DH Increase the Conversely, when the detected crimping pressure P is smaller than the pressure allowable range, the die height DH is reduced.

  FIG. 4 is a view showing the relationship between the portion of the caulking punch 40 and the metal plate work 8. FIG. 4A is a cross-sectional view showing a part of the four crimping punches 40 in FIG. 1 and a portion of the crimping pressure detection unit 60 provided thereon, and FIG. 4B shows that the crimping projections 80 are formed. It is a figure which shows the metal plate workpiece | work 8. FIG.

  In FIG. 4A, the upper die holder 52 is disposed in a guiding space provided inside the upper die 50, and the retainer 54 is fixed to the upper die 50. The retainer 54 is a block member that fixes and holds the four caulking punches 40 and the four caulking pressure detection units 60 integrally. Accordingly, the four swaging punches 40 move in the axial direction integrally with the upper die 50.

  In FIG. 4A, the metal plate work 8 is indicated by a two-dot chain line. FIG. 4A is an example in the case where the thickness t of the metal plate work 8 is a standard value t0 and the crimping pressure P detected by the crimping pressure detection unit 60 is within a predetermined pressure tolerance range. is there. In this case, the adjustment of the die height DH is not performed, and the die height DH is at a standard value DH0 for the plate thickness t = t0 of the metal plate work 8. The metal plate work 8 is supported by the upper surface of the lower mold 30 at the reference height position GL, and the lower end position of the caulking punch 40 protrudes to the height position of the die height DH0, whereby the caulking projection 80 is formed.

  FIG. 4 (b) is a view showing a crimping projection 80 formed in the metal plate work 8 under the standard thickness t0 of (a) and the standard die height DH0. The caulking projection 80 has a recess recessed from the upper surface 9 of the metal plate work 8 and a protrusion protruding from the lower surface 7. The depth of the recess from the upper surface 9 of the metal plate work 8 is a standard caulking depth d0. The value of the height d0 'of the convex portion from the lower surface 7 of the metal plate work 8 is almost the same as the value of the caulking depth d0 and is somewhat smaller. In the following, the crimping depth d0 is used as a representative of the size of the crimping projection 80.

  The thickness t of the long metal plate work 8 is not uniform along the transport direction and the direction orthogonal to the transport direction, and varies from the standard thickness t0. FIG. 5 is a comparison diagram of the variation range of the plate thickness t of the metal plate work 8 and the allowable accuracy of the caulking depth d. In FIG. 5, the thickness t of the metal plate work 8 is taken on the right vertical axis, and the caulking depth d is taken on the left vertical axis. Then, with the standard thickness t0 of the thickness t and the standard value d0 of the crimping depth d at the same level, the variation range of the thickness t of the metal plate work 8 and the tolerance of the crimping depth d , Respectively indicated by the arrow range. As shown in FIG. 5, the allowable accuracy of the crimping depth d is considerably narrower than the variation range of the plate thickness t of the metal plate workpiece 8 and requires accurate control. This is because the variation range of the plate thickness t of the metal plate work 8 is determined by the mechanical variation dimension such as rolling of the magnetic thin plate which is the material, while the allowable accuracy of the caulking depth d is a plurality of core thin plates It is because it becomes settled by the specification of the height dimension and parallelism of the laminated body which laminated | stacked 90. FIG. For example, when the specification of the tolerance of the height dimension of the laminate is ± ΔH and the number of the core thin plates 90 to be stacked is N, the tolerance of the caulking depth d of one core thin plate 90 is In simple calculations, {(. +-.. DELTA.H) / N} is obtained, and the more N increases, the tighter the tolerance accuracy becomes.

  FIG. 6 is a view showing an example of the die height DH of the crimping punch 40 for securing a standard crimping depth d0 when the thickness t of the metal plate work 8 varies. FIG. 6 (b) shows the case of the board thickness t = t0, FIG. 6 (a) shows the case of the board thickness t = t1 (<t0), and FIG. 6 (c) shows the board thickness t = t2 (> t0). In the case of Each drawing is a cross-sectional view corresponding to FIG. In the case of (b), since the board thickness t = t0, the same die height DH = DH0 as in FIG. 4 and the caulking depth is standard d0.

  In the case of the board thickness t = t1 (<t0), assuming the same die height DH = DH0 as (b), since the board thickness t is thinner than t0, breakage easily occurs at the crimped projection 80. Further, the caulking depth d from the upper surface 9 becomes shallower than d = d0, the protrusion height of the convex portion from the lower surface 7 becomes high, and the caulking strength at the time of lamination becomes insufficient. Then, it is set as di height DH = DH1 (<DH0) which can secure caulking depth d = d0.

  In the case of the board thickness t = t2 (> t0), assuming the same die height DH = DH0 as (b), there is no fear of breakage since the board thickness t is thicker than t0. However, the caulking depth d from the upper surface 9 becomes deeper than d = d0, the protrusion height of the convex portion from the lower surface 7 becomes lower, and the caulking strength during lamination becomes insufficient. Then, it is set as die height DH = DH2 (> DH0) which can secure caulking depth d = d0.

  As described above, when the thickness t of the metal plate work 8 varies, the die height DH needs to be adjusted accordingly. When laminating a plurality of core thin plates 90, it is necessary to adjust the die height DH each time the caulking projections 80 of each core thin plate 90 are formed. In order to adjust the die height DH, the thickness t of the metal plate work 8 may be measured each time the caulking projections 80 of the core thin plate 90 one by one are formed, but the plate of the metal plate work 8 in the sequential feeding process It is difficult to measure thickness in real time.

  Here, there is a certain correlation between the caulking depth d and the caulking pressure P of the caulking punch 40 when the caulking projections 80 are formed on the metal plate workpiece 8. For example, if the crimping depth d is increased, the crimping pressure P is increased, and if the crimping depth d is shallow, the crimping pressure P is decreased. In other words, it is considered that the caulking depth d is too deep if the caulking pressure P is excessive, and too shallow if the caulking pressure P is too small. When the thickness t of the metal plate work 8 varies, assuming that the die height DH at the height position of the caulking punch 40 is the same, if the board thickness t disperses in the thick direction, the caulking depth d becomes too deep and the caulking pressure P becomes excessive. become. On the other hand, when the thickness t varies in the thin direction, the crimping depth d becomes too shallow and the crimping pressure P becomes too small. The correlation between the caulking depth d and the caulking pressure P under the conditions where the thickness t of the metal plate work 8 is given is determined in advance experimentally or by simulation.

  Therefore, the core manufacturing apparatus 10 does not measure the thickness t of the metal plate work 8 in real time, and uses the caulking pressure detection unit 60 for the caulking pressure P that the caulking punch 40 receives when the caulking projection 80 is formed. Detect in real time.

  FIG. 7 is a flow chart showing the procedure of a caulking / cut-out method used in the control device 70 of the core manufacturing apparatus 10. Each procedure is realized by the control device 70 executing a laminated core forming program. When the core manufacturing apparatus 10 starts up, initialization is performed. The die height DH of the caulking punch 40 is set to the standard value DH = DH0. After that, the laminated core forming program is started up, and while the metal plate work 8 is held by the lower mold 30, it is sequentially transported to each forming station described in FIG.

  After being transported (S10) to the crimping / cutting-off station, the metal plate work 8 is positioned immediately below the four crimping punches 40 using the pilot holes 32. Then, the upper mold 50 is lowered downward in the axial direction by the function of the movement control unit 72 of the control device 70. Then, under the setting of DH = DH0, the four caulking punches 40 form four caulking projections 80 on the metal plate workpiece 8. At the same time, in the case where the preceding core thin plate 90 is already laminated on the pedestal 31 of the lower mold 30, crimping is performed between the uppermost core thin plates 90 (S12). When forming and caulking the four caulking projections 80, the four caulking pressure detectors 60 respectively detect the caulking pressure P (S14), and are transmitted to the control device 70 via the signal line 71. The control device 70 calculates an average value P0 of the four detected crimping pressures P (S16).

  Next, it is determined whether the average value P0 of the four crimping pressures P is within a predetermined pressure tolerance (S18). The predetermined pressure allowable range is defined by the allowable upper limit pressure PH and the allowable lower limit pressure PL. S18 is a determination as to whether PL ≦ P0 ≦ PH. The allowable upper limit pressure PH and the allowable lower limit pressure PL are based on the specification of the allowable accuracy of the caulking depth d in the manufacturing apparatus 10 of the core, and the relationship between the caulking depth d and the caulking pressure P previously obtained by experiment or simulation It is set using. Since the allowable pressure range determined based on the relation between the caulking depth d and the caulking pressure P determined in advance and the allowable accuracy specification of the caulking depth d is stored in the memory of the control device 70 in advance, The relationship is read out, and the determination of S18 is performed.

  If the determination in S18 is affirmative, the die height DH is not changed for any of the four caulking punches 40 because the caulking depth d is within the allowable accuracy and the die height DH is appropriate. If the determination in S18 is negative, it is a case where the die height DH of the crimping punch 40 is inappropriate, and it is next determined whether the average value P0 of the crimping pressure P exceeds PH (S20). S20 is a determination as to whether P0> PH. When S20 is affirmed, the average value P0 of the crimping pressure P is high, and the die height DH of the four crimping punches 40 is too small in a state where the crimping depth d is too deep beyond the allowable accuracy. Therefore, the die heights DH of the four crimping punches 40 are increased (S22). The increase amount of the die height DH is set such that the average value P0 of the crimping pressure P falls within the pressure tolerance range. The relationship between the average value P0 of the caulking pressure P and die height DH where the caulking depth d = d0 under the conditions where the thickness t of the metal plate work 8 is given can be obtained in advance experimentally or by simulation etc. . Since the determined relationship is stored in the memory of the control device 70, the increase amount of the die height DH can be determined using the relationship.

  When S18 and S20 are both negative, the average value P0 of the crimping pressure P is less than PL, and the die height DH of the crimping punch 40 is in an excessive state in a state where the crimping depth d is too shallow to exceed the allowable accuracy range. is there. Therefore, the die height DH of the crimping punch 40 is reduced (S24). The reduction amount of DH is set using the relationship between the average value P0 of the crimping pressure P stored in the memory of the control device 70 and the die height DH.

  Thereafter, the die height set value in the control device 70 is updated (S26). The update is performed based on the results of S22 and S24, and when S18 is positive, only the update time is updated without changing the die height setting value. The update result is overwritten on the die height setting value of the memory of the control device 70.

  Thereafter, the metal plate work 8 is subjected to outline removal, and the portion of the core thin plate 90 is cut off (S28). The laminated core 92 is separated from the metal plate work 8 when caulking is performed with the core thin plate 90 which has already been laminated on the pedestal 31 of the lower die 30. When the process of S28 is completed, the process returns to S10, and the metal plate workpiece 8 is fed by one pitch in the transport direction, and the next crimping and cutting process is performed. In the process, the value of DH updated at S26 is used to adjust the DH. Adjustment of the die height DH is performed by a collective die height adjustment mechanism 15 provided in the drive mechanism 13 of the crown 14 under the control of the die height adjustment unit 74 of the control device 70. The collective die height adjustment mechanism 15 changes the stroke of the drive mechanism 13 which is a reciprocating motion mechanism from the standard stroke according to the updated value of the die height DH, and adjusts the bottom dead center position LDP of the upper die 50. By this, adjustment of the die height DH of the four caulking punches 40 provided in the upper mold 50 is performed collectively.

  In the above, the caulking pressure detection unit 60 is provided at the rear side end opposite to the lower end position of the caulking punch 40. This is to ensure sufficient rigidity such that no deformation or the like occurs even if the caulking punch 40 receives the caulking pressure P. In the metal plate work 8, when the crimping depth d0 is not too deep, the crimping pressure detection portion 61 is disposed at a position near the lower end position of the crimping punch 41 inside the crimping punch 41 as in the crimping punch 41 shown in FIG. You may By arranging the crimping pressure detection unit 61 close to the lower end position of the crimping punch 41, the accuracy of the crimping pressure P to be detected is improved.

  In the above, as described in FIG. 4, four caulking punches 40 are held by one retainer 54, and the die heights DH of the four caulking punches 40 are collectively adjusted by the collective die height adjusting mechanism 15. In this case, since the average value P0 of the crimping pressure P detected by the four crimping pressure detecting portions 60 is used, the plate thickness t of the metal plate work 8 at the portion corresponding to the four crimping projections 80 is different. For example, the four crimping depths d have different values.

  In order to equalize the four caulking depths d, the four retainers 54 are used such that only one caulking punch 40 is disposed in one retainer 54. The outer peripheral surface of each retainer 54 is axially slidably held along the inner wall surface of the upper mold holder 52 so that the axial position of each retainer 54 can be changed independently with respect to the upper mold 50, Make each die height DH adjustable.

  In FIG. 1, the individual die height adjustment mechanism 51 provided in the upper mold 50 has four die height adjustment mechanisms, and is used when adjusting the die height DH of four caulking punches 40 independently. That is, a dedicated die height adjustment mechanism is connected to each of the retainers 54 on which the four crimping punches 40 are disposed. Each die height adjustment mechanism adjusts the axial height position in accordance with the caulking pressure P detected by the caulking pressure detection unit 60 provided in the caulking punch 40 disposed in the corresponding retainer 54. As a result, the die height DH of each of the four swaging punches 40 can be adjusted individually, and the four swaging depths d can be made uniform. As such a die height adjustment mechanism, a combination of a precision motor and a mechanism such as a screw and a nut for converting the rotational movement of the precision motor into the axial movement of the retainer 54 can be used. In the case of using this method, since the individual die height adjusting mechanism 51 including the four retainers 54 and the four die height adjusting mechanisms is required, the mass of the upper mold 50 is increased and the size thereof is increased.

  According to the core manufacturing apparatus 10 configured as described above, adjustment of the die height DH is performed based on the caulking pressure P that the caulking punch 40 receives, each time the caulking / dropping station performs shaping and caulking of the caulking projections 80. The adjustment of the die height DH is not reflected in the formation of the caulking projections 80 at which the caulking pressure P is detected, but the metal plate work 8 is fed by one pitch for conveyance, and the next caulking projections 80 are formed and caulked Applies to When the thickness t of the metal plate work 8 varies from the standard thickness t0, the caulking depth d of the first core thin plate 90 is directly affected by the variation of the thickness d. When the thickness t of the metal plate work 8 is loosely dispersed in a long cycle as compared to the length of one pitch of conveyance, the caulking depth d of the core thin plate 90 next is standard by adjusting the die height DH. Close to caulking depth d0.

  The metal plate work 8 is a long material wound in a coil shape for progressive press forming, and has a length capable of forming, for example, several thousand or more core thin plates 90. Since the range of the thickness variation of the metal plate work 8 is the variation in thickness over the entire length of the long length, the thickness t along the transport direction changes gently. Further, although the number of laminations of the core thin plate 90 in the laminated core 92 depends on the specifications of the rotary electric machine, in many cases, it is several tens or more. Therefore, the length of the metal plate work 8 required to form the dozens of core thin plates 90 used for one laminated core 92 is considerably shorter than the total length of the metal plate work 8 wound in a coil shape. . From these facts, by performing die height DH feedback for each conveyance pitch, the caulking depth d of the number of core thin plates 90 required for the laminated core 92 is an average to the standard caulking depth d0 as a whole. Turn Thereby, in the laminated core 92, lamination of a plurality of thin core sheets 90 can be appropriately performed.

  Next, with respect to the operation and effect of the core manufacturing apparatus 10 using the crimping pressure detection unit 60, a comparison between the allowable accuracy of the crimping depth d and the prior art that does not use the crimping pressure detection unit 60 will be described. FIG. 9 is a view showing an example of lamination of a plurality of core thin plates 91 having caulking projections 81 in the prior art which does not use the caulking / cut-out molding method of FIG. For example, when the plate thickness t of the long metal plate work 8 is not uniform along the width direction and the plate thickness of one end is thicker than the plate thickness of the other end, the prior art The core thin plate 91 having the caulking projection 81 which can not cope with the variation of the thickness t of the metal plate work 8 is formed. In each molded core thin plate 91, the caulking depth d of the caulking projection 81 becomes shallower than the standard projection depth d0 at the other end of the thin plate thickness t, and one side of the thick plate thickness t At the end, the crimping depth d of the crimping projection 81 becomes deeper than the standard crimping depth d0. As a result, the laminated core 93 formed by crimping the plurality of core thin plates 91 has an outer shape inclined in the height direction, and the parallelism in the height direction is reduced.

  FIG. 10 shows the case where the plate thickness t of the long metal plate work 8 is irregularly uneven along the longitudinal direction or the width direction. FIG. 10 (a) shows a laminated core 93 according to the prior art, and FIG. 10 (b) is a view showing a laminated core 92 molded using the crimping / cutting-off method of FIG. In the laminated core 93 according to the prior art, since the caulking depth d varies among the core thin plates 91, the dimension in the height direction is not determined, and the parallelism in the height direction is reduced. On the other hand, the laminated core 92 formed by using the caulking method of FIG. 7 is formed to have a caulking depth d substantially equal to the standard caulking depth d0 with each core thin plate 90. The dimensions are fixed and the parallelism in the height direction is good.

  Although the rotor core of the rotary electric machine has been described above as the laminated core, the above contents can be applied similarly to the case of the stator core of the rotary electric machine as the laminated core. The difference between the rotor core and the stator core is the shape of the core. Even if the shape of the core is different, the lamination of a plurality of core thin plates is the same. And for that purpose, at the crimping / cutting-off station, the formation of the crimping projection, the crimping and the cutting off of the outer diameter are performed, and the crimping pressure is detected and the die height DH is adjusted accordingly. is there. Therefore, in the manufacturing apparatus 10 of the above-described rotary electric machine core, the stator core of the rotary electric machine can be manufactured in the same manner by appropriately changing the above contents regarding the shape of the rotor core to the contents regarding the shape of the stator core.

  According to the manufacturing apparatus 10 for a core for a rotating electrical machine having the above configuration, the caulking pressure detection unit 60 is provided on the caulking punch 40, and the caulking pressure P received by the caulking punch 40 can be detected when the caulking projection 80 is formed. Therefore, the die height DH can be adjusted in real time according to the detected crimping pressure P of the crimping punch 40 without measuring the plate thickness t of the metal plate work 8. For example, the detected pressure is compared with a predetermined predetermined pressure tolerance, and the die height DH is decreased if the detected pressure is greater than the pressure tolerance, and the die height is detected if the detected pressure is less than the pressure tolerance. Increase DH. Thereby, even if there is variation in the thickness t of the metal plate work 8, the die height DH in the next step of forming the crimped projection becomes appropriate without measuring the thickness t, and the crimping depth d is set to a predetermined value. Therefore, the lamination of the core thin plate 90 can be properly performed.

  7 lower surface, 8 metal plate work, 9 upper surface, 10 (rotary electric machine) core manufacturing apparatus, 12 base, 13 drive mechanism (reciprocation mechanism), 14 crown, 15 batch die height adjustment mechanism, 16 column, 18 slide portion, 20 Slide drive part, 22 bolster part, 30 lower mold, 31 pedestal, 32 pilot hole, 34 magnet insertion hole, 36 axial hole, 40, 41 caulking punch, 50 upper mold, 51 individual die height adjustment mechanism, 52 upper mold Holder, 54 retainer, 60, 61 caulking pressure detector, 70 controller, 71 signal line, 72 movement controller, 74 die height adjusting part, 80, 81 caulking projection, 90, 91 core thin plate, 92, 93 laminated core.

Claims (1)

A manufacturing apparatus for a core for a rotating electrical machine, which forms a laminated core in which a plurality of thin core sheets are laminated by caulking.
A lower mold on which a metal plate work which is a material of the core thin plate is disposed;
An upper mold having a caulking punch for forming a caulking projection on the metal plate work and disposed to face the upper side of the lower mold;
A caulking pressure detector provided on the caulking punch for detecting a pressure exerted on the caulking punch;
A reciprocating motion mechanism for reciprocating the upper mold in a vertical direction at a predetermined stroke;
The distance between the lower end position of the crimping punch at the bottom dead center of the upper mold and the reference height position of the lower mold is taken as the die height of the crimping punch according to the detection result of the crimping pressure detection unit Die height adjustment unit to adjust,
An apparatus for manufacturing a core for a rotating electrical machine, comprising:

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