JP2021121159A - Laminated core of electric machine, electric machine, manufacturing method of laminated core of electric machine and manufacturing method of electric machine - Google Patents

Abstract

To obtain a laminated core of an electric machine which can reduce eddy current loss in the laminated core of the electric machine.SOLUTION: A laminated core of an electric machine comprises a plurality of laminated core pieces, in which each of the core pieces has a first part and a second part, the plurality of core pieces comprise core pieces 70A and core pieces 70B, the first part 91 of the core piece 70A is oppositely arranged to the second part 94 of the core piece 70B, a recess is formed in the core piece 70B, the other surface of the second part 94 of the core piece 70B is arranged on the same plane to a plane including the other surface of the first part 93 of the core piece 70B, in each of the core piece 70A and the core piece 70B, the first part and the second part are arranged in parallel with each other in one direction, the first part 91 of the core piece 70A overlaps with the first part 93 of the core piece 70B adjacent to the second part 94 of the core piece 70B facing the first part 91 of the core piece 70A in a parallel direction in the parallel direction.SELECTED DRAWING: Figure 11

Description

The present disclosure relates to a laminated iron core of an electric machine, an electric machine, a method of manufacturing a laminated iron core of an electric machine, and a method of manufacturing an electric machine.

Conventionally, a rotary electric machine equipped with a stator core is known. The stator core has a plurality of divided laminated cores arranged in a ring shape in the circumferential direction. Each of the plurality of divided laminated iron cores has a back yoke portion and a teeth portion that protrudes inward in the radial direction from the back yoke portion. Each of the divided laminated iron cores has a configuration in which a plurality of iron core pieces are laminated in the axial direction (see, for example, Patent Document 1).

Japanese Unexamined Patent Publication No. 2017-163675

When the number of rotations is increased in the above-mentioned rotary electric machine, it is possible to increase the output and reduce the size of the rotary electric machine. However, when the rotation speed of the rotary electric machine increases, there is a problem that the iron loss in the stator core, particularly the eddy current loss, increases.

The present disclosure has been made to solve the above-mentioned problems, and an object thereof is to manufacture a laminated iron core of an electric machine, an electric machine, and a laminated iron core of an electric machine capable of reducing eddy current loss. And provides a method of manufacturing electrical machinery.

The laminated iron core of the electric machine according to the present disclosure includes a plurality of laminated iron core pieces, and each of the iron core pieces has a first portion and a second portion having a plate thickness thinner than that of the first portion. The plurality of iron core pieces include a first core piece and a second core piece adjacent to the first core piece in the stacking direction of the plurality of iron core pieces, and the first portion of the first core piece is , The second core piece is arranged to face the second portion of the second core piece, and the second core piece has one surface of the second portion with respect to a plane including one surface of the first portion of the second core piece. A concave portion is formed, and the other surface of the second portion of the second iron core piece is arranged on the same plane with respect to the plane including the other surface of the first portion of the second iron core piece. In each of the first iron core piece and the second iron core piece, the first part and the second part are arranged in parallel in one direction with each other, and the first part of the first iron core piece is the first iron core piece. It overlaps the first part of the second iron core piece adjacent to the second part of the second iron core piece facing the first part in the parallel direction.
The electric machine according to the present disclosure includes an armature having an armature core composed of laminated iron cores of the electric machine according to the present disclosure, and a field arranged so as to face the armature with a gap. I have.
The method for manufacturing a laminated iron core of an electric machine according to the present disclosure is a method for manufacturing a laminated iron core of an electric machine according to the present disclosure, in which a part of a steel plate sheet is crushed and a steel plate sheet having a first portion and a second portion is provided. It is provided with a crushing step for producing the above, and a punching step for producing a plurality of iron core pieces having a first portion and a second portion from the steel plate sheet after the crushing step.
The method for manufacturing an electric machine according to the present disclosure includes a method for manufacturing a laminated iron core of an electric machine according to the present disclosure.

According to the method for manufacturing the laminated iron core of the electric machine, the electric machine, the laminated iron core of the electric machine, and the manufacturing method of the electric machine according to the present disclosure, it is possible to reduce the eddy current loss in the laminated iron core of the electric machine.

It is sectional drawing which shows the schematic structure of the rotary electric machine which concerns on Embodiment 1. FIG. It is a perspective view which shows the structure of the stator core which concerns on Embodiment 1. FIG. It is a perspective view which shows the structure of one iron core piece in the comparative example of Embodiment 1. FIG. It is sectional drawing which shows the structure in which two iron core pieces in the comparative example of Embodiment 1 are laminated. It is a perspective view which shows the structure of the iron core piece of Embodiment 1. FIG. It is a perspective view which shows the structure of the iron core piece of Embodiment 1. FIG. It is sectional drawing which shows the structure in which the iron core piece and the iron core piece are laminated in Embodiment 1. FIG. It is a perspective view which shows the structure of the divided laminated iron core which concerns on Embodiment 1. FIG. It is a figure which shows the structure which looked at the tip part of the tooth part laminated body of the divided laminated iron core which concerns on Embodiment 1 along the radial direction. FIG. 5 is a cross-sectional view showing a configuration in which a part of the divided laminated iron core according to the first embodiment is cut by a plane perpendicular to the stretching direction of the first portion and the second portion. It is sectional drawing which shows the structure which cut | cut a part of the divided laminated iron core of the modification of Embodiment 1 in the plane perpendicular to the stretching direction of the 1st part and 2nd part. FIG. 5 is a cross-sectional view showing a configuration in which a stator winding is arranged on a divided laminated iron core of the first embodiment. It is a perspective view which shows the structure of the iron core piece of the divided laminated iron core of Embodiment 1. FIG. It is a flowchart which shows the flow of the manufacturing process of the divided laminated iron core which concerns on Embodiment 1. It is a conceptual diagram which shows the flow of the manufacturing process of the divided laminated iron core which concerns on Embodiment 1. FIG. It is sectional drawing which shows the structure of the steel plate sheet after the crushing process in the manufacturing process of the divided laminated iron core which concerns on Embodiment 1. FIG. It is a flowchart which shows the flow of the manufacturing process of the divided laminated iron core which concerns on Embodiment 2. It is a conceptual diagram which shows the flow of the manufacturing process of the divided laminated iron core which concerns on Embodiment 2. It is a conceptual diagram which shows the flow of the manufacturing process of the divided laminated iron core which concerns on Embodiment 2. It is a conceptual diagram which shows the annealing process in the manufacturing process of the divided laminated iron core which concerns on Embodiment 2. It is a conceptual diagram which shows the punching process in the manufacturing process of the divided laminated iron core which concerns on Embodiment 2. It is a conceptual diagram which shows the flow of the manufacturing process of the divided laminated iron core which concerns on Embodiment 3. It is a conceptual diagram which shows the flow of the manufacturing process of the divided laminated iron core which concerns on Embodiment 4. FIG. It is a conceptual diagram which shows the state which the lower roller of FIG. 23 is positioned with respect to a steel plate sheet. It is a conceptual diagram which shows the state which the tool part of FIG. 24 crushes a steel plate sheet. It is a perspective view which shows the structure of the iron core piece of the stator core which concerns on embodiment 5. FIG. 5 is a cross-sectional view showing a configuration in which a part of the divided laminated iron core according to the sixth embodiment is cut by a plane perpendicular to the stretching direction of the first portion and the second portion. FIG. 5 is a cross-sectional view showing a configuration in which a part of the divided laminated iron core according to the seventh embodiment is cut by a plane perpendicular to the stretching direction of the first portion and the second portion. FIG. 5 is a cross-sectional view showing a configuration in which a part of the divided laminated iron core according to the eighth embodiment is cut by a plane perpendicular to the stretching direction of the first portion and the second portion.

Embodiment 1.
A method for manufacturing a laminated iron core of an electric machine, an electric machine, a method for manufacturing a laminated iron core of an electric machine, and a method for manufacturing an electric machine according to the first embodiment will be described. First, the respective configurations of the laminated iron core of the electric machine and the electric machine according to the first embodiment will be described. In the first embodiment, a rotary electric machine including a stator and a rotor is illustrated as an electric machine. The rotary electric machine includes a motor, a generator, and the like. In this specification, the axial direction of the stator core, the radial direction of the stator core, and the circumferential direction of the stator core may be simply referred to as "axial direction", "diameter direction", and "circumferential direction", respectively. .. In addition, the inner peripheral side of the stator core, the outer peripheral side of the stator core, the inner side of the stator core and the outer side of the stator core are simply referred to as "inner peripheral side", "outer peripheral side", "inner side" and "inside", respectively. Sometimes referred to as "outside".

FIG. 1 is a cross-sectional view showing a schematic configuration of a rotary electric machine according to a first embodiment. As shown in FIG. 1, the rotary electric machine includes a housing 10, a stator 20, a rotor 30, and a shaft 40. The housing 10, the stator 20, the rotor 30, and the shaft 40 are arranged in this order from the outer peripheral side to the inner peripheral side. A gap 50 is formed between the inner peripheral surface of the stator 20 and the outer peripheral surface of the rotor 30.

The stator 20 is an armature of a rotating electric machine configured to generate a rotating magnetic field. The rotor 30 is a field of a rotating electric machine. The rotor 30 is rotatably provided on the inner peripheral side of the stator 20. The rotor 30 faces the stator 20 via the gap 50. The stator 20 and rotor 30 are held by the housing 10.

The stator 20 has a stator core 21 through which magnetic flux is passed, and a stator winding 22 which is formed by winding a conductor and generates a magnetic field by energization. The stator core 21 is an armature core of a rotary electric machine. The stator core 21 and the stator winding 22 are insulated from each other by an insulating paper (not shown). The winding method of the stator winding 22 may be distributed winding or centralized winding.

The rotor 30 is a permanent magnet type rotor including a rotor iron core 31 through which magnetic flux is passed and a permanent magnet 32. The rotor 30 is an IPM (Interior Permanent Magnet) type rotor in which a permanent magnet 32 is embedded inside the rotor core 31. The permanent magnet 32 is inserted into each of the plurality of through holes that penetrate the rotor core 31 in the axial direction. The rotor 30 may be an SPM (Surface Permanent Magnet) type rotor in which the permanent magnet 32 is arranged on the outer peripheral surface of the rotor core 31.

The shaft 40 penetrates the rotor core 31 along the central axis of the rotor 30, and is fixed to the rotor core 31 by shrink fitting, press fitting, or the like. The shaft 40 is rotatably supported by the housing 10 via a bearing 41 and a bearing 42. The torque of the rotary electric machine is transmitted to the outside via the shaft 40.

The housing 10 is made of a metal such as iron or aluminum. The housing 10 is formed in a cylindrical shape. The stator core 21 is fitted inside the housing 10.

FIG. 2 is a perspective view showing the configuration of the stator core 21 according to the first embodiment. As shown in FIG. 2, the shape of the stator core 21 is an annular shape as a whole. The stator core 21 has a plurality of divided laminated iron cores 60. The plurality of divided laminated iron cores 60 are fitted inside the housing 10 shown in FIG. 1 in a state of being arranged in an annular shape in the circumferential direction. As a result, the plurality of divided laminated iron cores 60 are joined to each other to form the annular stator core 21.

The stator core 21 according to the first embodiment has 48 magnetic pole pieces. Each of the divided laminated iron cores 60 constitutes, for example, one magnetic pole piece among the magnetic pole pieces of the stator core 21. As will be described later, each of the divided laminated iron cores 60 has a configuration in which a plurality of iron core pieces including the iron core piece 70A and the iron core piece 70B are laminated in the axial direction. That is, the stator core 21 is a laminated iron core having a structure in which a plurality of iron core pieces are laminated. Each of the iron core pieces is formed by using a thin plate which is an electromagnetic steel plate, for example, a steel plate sheet 130 which will be described later. Further, as will be described later, each of the divided laminated iron cores 60 is a back yoke portion laminated body 61 in which the back yoke portions of a plurality of iron core pieces are laminated, and a teeth portion laminated body in which the teeth portions of the plurality of iron core pieces are laminated. 62 and.

The configuration of the iron core piece of the first embodiment will be described in comparison with the configuration of the comparative example. FIG. 3 is a perspective view showing the configuration of one iron core piece 170 in the comparative example of the first embodiment. FIG. 4 is a cross-sectional view showing a configuration in which two iron core pieces 170 are laminated in the comparative example of the first embodiment. The iron core piece 170 of the comparative example has a back yoke portion 171 and a teeth portion 172, and is formed in a flat plate shape as a whole. In FIGS. 3 and 4, one surface of the iron core piece 170 facing upward and the other surface of the iron core piece 170 facing downward are both formed flat. The iron core piece 170 has a substantially uniform plate thickness t11 as a whole. The plate thickness t11 is, for example, 0.35 mm. In this case, the total thickness of the two laminated iron core pieces 170 is 0.70 mm. The plate thickness t11 is the same as the plate thickness at the time of purchasing the iron core piece 170 or the plate thickness at the time of purchasing the steel plate sheet 130 described later. In the comparative example, the divided laminated iron core 60 is formed by laminating a plurality of iron core pieces 170 having the same configuration in the plate thickness direction.

FIG. 5 is a perspective view showing the configuration of the iron core piece 70A of the first embodiment. FIG. 6 is a perspective view showing the configuration of the iron core piece 70B of the first embodiment. FIG. 7 is a cross-sectional view showing a configuration in which the iron core piece 70A and the iron core piece 70B in the first embodiment are laminated. FIG. 7 shows a cross section of the iron core piece 70A and the iron core piece 70B cut in a plane perpendicular to the radial direction. In the first embodiment, the iron core pieces 70A and the iron core pieces 70B are alternately laminated in the plate thickness direction to form a plurality of divided laminated iron cores 60 shown in FIG.

Each of the iron core piece 70A and the iron core piece 70B has a back yoke portion 71 and a teeth portion 72, and is formed in a flat plate shape as a whole, similarly to the iron core piece 170 of the comparative example. The back yoke portion 71 extends along a direction perpendicular to the stacking direction of the iron core piece 70A and the iron core piece 70B. The tooth portion 72 protrudes from the center of the back yoke portion 71 in the stretching direction of the back yoke portion 71 in a direction perpendicular to both the stacking direction of the iron core piece 70A and the iron core piece 70B and the stretching direction of the back yoke portion 71. .. The iron core piece 70A and the iron core piece 70B have the same planar shape.

In the stator core 21 shown in FIG. 2, the stretching direction of the back yoke portion 71 corresponds to the circumferential direction of the stator core 21 or the tangential direction in the circumferential direction. In the stator core 21 shown in FIG. 2, the protruding direction of the teeth portion 72 corresponds to the direction facing inward with respect to the radial direction of the stator core 21. The stacking direction of the iron core piece 70A and the iron core piece 70B corresponds to the axial direction of the stator core 21 in the stator core 21 shown in FIG.

The iron core piece 70A has a plurality of first portions 91 having a plate thickness t1 and a plurality of second portions 92 having a plate thickness t2 thinner than the plate thickness t1. For example, the plate thickness t1 is 0.35 mm, and the plate thickness t2 is 0.25 mm. The plate thickness t1 is, for example, the same as the plate thickness at the time of purchasing the iron core piece 70A or the plate thickness at the time of purchasing the steel plate sheet 130 described later. The second portion 92 is formed by crushing the steel plate sheet 130 in the plate thickness direction, as will be described later. The plate thickness t1 of the first portion 91 is the plate thickness of the thickest portion of the first portion 91, and the plate thickness t2 of the second portion 92 is the plate thickness of the thinnest portion of the second portion 92.

Each of the first portions 91 extends in a strip shape along the protruding direction of the tooth portion 72, that is, the radial direction of the stator core 21. Each of the first portions 91 is arranged in parallel with each other at intervals. Each of the second portions 92 is arranged between two adjacent first portions 91. Each of the second portions 92, like each of the first portions 91, extends in a band shape along the protruding direction of the teeth portion 72. Therefore, the first portion 91 and the second portion 92 are arranged in parallel in one direction. The parallel direction in which the first portion 91 and the second portion 92 are parallel is the extending direction of the back yoke portion 71, that is, the circumferential direction of the stator core 21. The plurality of first portions 91 and the plurality of second portions 92 are arranged alternately in the stretching direction of the back yoke portion 71.

On the upper surface of the iron core piece 70A facing upward in FIG. 7, each surface 92a of the second portion 92 is arranged on the same plane with respect to the plane 111 including each surface 91a of the first portion 91. There is. In other words, the one surface 92a of the second portion 92 of the iron core piece 70A is arranged on the same plane with respect to the plane 111 including one surface 91a of the first portion 91 of the iron core piece 70A.

On the lower surface of the iron core piece 70A facing downward in FIG. 7, each surface 92b of the second portion 92 is formed so as to be concave with respect to the plane 112 including each surface 91b of the first portion 91. ing. In other words, the other surface 92b of the second portion 92 of the iron core piece 70A is formed so as to be concave with respect to the plane 112 including the other surface 91b of the first portion 91 of the iron core piece 70A. As a result, a recess 104 is formed in the second portion 92 of the lower surface of the iron core piece 70A. A convex portion 103 that is convex with respect to the concave portion 104 is formed on the first portion 91 of the lower surface of the iron core piece 70A. Therefore, a convex portion is formed in the first portion 91 and a concave portion is formed in the second portion 92 only on the lower surface of the iron core piece 70A.

The iron core piece 70B has a plurality of first portions 93 having a plate thickness t3 and a plurality of second portions 94 having a plate thickness t4 thinner than the plate thickness t3. The plate thickness t3 of the first portion 93 is the plate thickness of the thickest portion of the first portion 93, and the plate thickness t4 of the second portion 94 is the plate thickness of the thinnest portion of the second portion 94. In the first embodiment, the difference between the plate thickness t3 and the plate thickness t4 is the same as the difference between the plate thickness t1 and the plate thickness t2. Further, in the first embodiment, the plate thickness t3 is the same as the plate thickness t1, and the plate thickness t4 is the same as the plate thickness t2. The plate thickness t3 is the same as the plate thickness at the time of purchasing the iron core piece 70B or the plate thickness at the time of purchasing the steel plate sheet 130 described later.

Here, the same in the specification includes not only the exact same but also the range that can be regarded as substantially the same in consideration of common general technical knowledge.

Each of the first portions 93 extends in a strip shape along the protruding direction of the tooth portion 72, that is, the radial direction of the stator core 21. Each of the first portions 93 is arranged in parallel with each other at intervals. Each of the second portions 94 is arranged between two adjacent first portions 93. Each of the second portions 94, like each of the first portions 93, extends in a band shape along the protruding direction of the teeth portion 72. Therefore, the first portion 93 and the second portion 94 are arranged in parallel in one direction. The parallel direction in which the first portion 93 and the second portion 94 are parallel is the extending direction of the back yoke portion 71, that is, the circumferential direction of the stator core 21. The plurality of first portions 93 and the plurality of second portions 94 are arranged alternately in the stretching direction of the back yoke portion 71.

On the upper surface of the iron core piece 70B facing upward in FIG. 7, each surface 94a of the second portion 94 is formed so as to be concave with respect to the plane 113 including each surface 93a of the first portion 93. ing. In other words, the one surface 94a of the second portion 94 of the iron core piece 70B is formed so as to be concave with respect to the plane 113 including one surface 93a of the first portion 93 of the iron core piece 70B. As a result, a recess 106 is formed in the second portion 94 of the upper surface of the iron core piece 70B. A convex portion 105 that is convex with respect to the concave portion 106 is formed on the first portion 93 of the upper surface of the iron core piece 70B.

On the lower surface of the iron core piece 70B facing downward in FIG. 7, each surface 94b of the second portion 94 is arranged on the same plane with respect to the plane 114 including each surface 93b of the first portion 93. There is. In other words, the other surface 94b of the second portion 94 of the iron core piece 70B is arranged on the same plane with respect to the plane 114 including the other surface 93b of the first portion 93 of the iron core piece 70B. Therefore, a convex portion is formed in the first portion 93 and a concave portion is formed in the second portion 94 only on the upper surface of the iron core piece 70B.

As will be described later with reference to FIG. 10, the width W1 of the first portion 91 of the iron core piece 70A is the same as the width W4 of the second portion 94 of the iron core piece 70B. Further, the width W2 of the second portion 92 of the iron core piece 70A is the same as the width W3 of the first portion 93 of the iron core piece 70B.

When a plurality of iron core pieces are laminated, the iron core pieces 70A and the iron core pieces 70B are arranged so as to overlap each other in the stacking direction. When the laminated iron core pieces 70A and the iron core pieces 70B are viewed along the stacking direction, the first portion 91 of the iron core piece 70A is arranged so as to overlap with the second portion 94 of the iron core piece 70B. Further, when viewed along the stacking direction, the first portion 91 of the iron core piece 70A is formed within the formation range of the second portion 94 of the iron core piece 70B. Therefore, the convex portion 103 formed in the first portion 91 of the iron core piece 70A is fitted into the concave portion 106 formed in the second portion 94 of the iron core piece 70B.

When viewed along the stacking direction, the first portion 93 of the iron core piece 70B is arranged so as to overlap with the second portion 92 of the iron core piece 70A. Further, when viewed along the stacking direction, the first portion 93 of the iron core piece 70B is formed within the formation range of the second portion 92 of the iron core piece 70A. Therefore, the convex portion 105 formed in the first portion 93 of the iron core piece 70B is fitted into the concave portion 104 formed in the second portion 92 of the iron core piece 70A.

The thickness of the laminated iron core pieces 70A and iron core pieces 70B is t1 + t4 or t2 + t3. When the plate thickness t1 and the plate thickness t3 are the same as the plate thickness t11 of the iron core piece 170 of the comparative example, the thickness of the laminated iron core pieces 70A and the iron core piece 70B is the thickness of the two iron core pieces laminated in the comparative example. It is thinner than 170. For example, the thickness of the laminated iron core pieces 70A and the iron core pieces 70B is 0.60 mm. In the first embodiment, the plate thickness t1 and the plate thickness t3 are both set to 0.35 mm, but the plate thickness t1 and the plate thickness t3 are 0.5 mm, 0.25 mm, 0.23 mm, etc., respectively. Other dimensions are possible. By matching each of the plate thickness t1 and the plate thickness t3 to the standard of the thin plate, a thin plate in which the iron core piece 70A and the iron core piece 70B are punched can be easily obtained at low cost.

FIG. 8 is a perspective view showing the configuration of the divided laminated iron core 60 according to the first embodiment. FIG. 9 is a diagram showing a configuration in which the tip portion 62a of the tooth portion laminated body 62 of the divided laminated iron core 60 according to the first embodiment is viewed along the radial direction.

As shown in FIGS. 8 and 9, the divided laminated iron core 60 has a configuration in which a plurality of iron core pieces 70A and a plurality of iron core pieces 70B are laminated. In FIG. 9, two iron core pieces 70A stacked on each other and two iron core pieces 70B stacked on each other are alternately arranged one by one, except for the iron core pieces at both ends in the stacking direction in the divided laminated iron core 60. It is laminated. Further, the two iron core pieces 70A stacked on each other have a shape inverted with respect to the stacking direction, and the two iron core pieces 70B stacked on each other have a shape inverted with respect to the stacking direction. There is. The plurality of laminated iron core pieces 70A and the plurality of iron core pieces 70B may be fixed by adhesion, by welding, or by mold fixing using a resin. Further, the plurality of laminated iron core pieces 70A and the plurality of iron core pieces 70B may be fixed by caulking using a half punched portion formed on each iron core piece, or may be fastened by fastening using a fastening member such as a rivet. It may be fixed.

The divided laminated iron core 60 has a back yoke portion laminated body 61 and a teeth portion laminated body 62. The back yoke portion laminated body 61 has a configuration in which the back yoke portions 71 of the plurality of iron core pieces 70A and the plurality of iron core pieces 70B are laminated. The tooth portion laminated body 62 has a configuration in which the tooth portions 72 of the plurality of iron core pieces 70A and the plurality of iron core pieces 70B are laminated. The back yoke portion laminated body 61 extends along the circumferential direction. The tooth portion laminated body 62 protrudes inward in the radial direction from the back yoke portion laminated body 61. A tip portion 62a facing the outer peripheral surface of the rotor 30 is formed at an end portion on the inner side in the radial direction of the tooth portion laminated body 62. The tip portion 62a is formed, for example, in a planar shape perpendicular to the radial direction or in a cylindrical surface shape along the outer peripheral surface of the rotor 30.

FIG. 10 is a cross-sectional view showing a configuration in which a part of the divided laminated iron core 60 according to the first embodiment is cut in a plane perpendicular to the stretching direction of the first portion 91 and the second portion 92. The left-right direction in FIG. 10 represents the parallel direction of the first portion 91 and the second portion 92. The vertical direction in FIG. 10 represents the stacking direction of the iron core piece 70A and the iron core piece 70B. FIG. 10 shows a cross section parallel to the cross section shown in FIG.

In the cross section of the divided laminated iron core 60 shown in FIG. 10, the recess 104 formed in the iron core piece 70A has a bay-shaped cross-sectional shape. The convex portion 103 formed on the iron core piece 70A has a bay-shaped cross-sectional shape. Further, the recess 106 formed in the iron core piece 70B has a bay-shaped cross-sectional shape. The convex portion 105 formed on the iron core piece 70B has a bay-shaped cross-sectional shape.

FIG. 11 is a cross-sectional view showing a configuration in which a part of the divided laminated iron core 60 of the modified example of the first embodiment is cut by a plane perpendicular to the stretching direction of the first portion 91 and the second portion 92. In FIG. 11, the recess 104 formed in the iron core piece 70A has a rectangular cross-sectional shape. The convex portion 103 formed on the iron core piece 70A has a rectangular cross-sectional shape. Further, the recess 106 formed in the iron core piece 70B has a rectangular cross-sectional shape. The convex portion 105 formed on the iron core piece 70B has a rectangular cross-sectional shape. In FIG. 11, the divided laminated iron core 60 has a configuration in which a plurality of iron core pieces 70A and a plurality of iron core pieces 70B are alternately laminated one by one.

Since both the convex portion and the concave portion have a rectangular cross-sectional shape, when the iron core piece 70A and the iron core piece 70B are laminated, the iron core piece 70A and the iron core piece 70B can be easily positioned. be able to. Further, since the iron core piece 70A and the iron core piece 70B are easily fitted into each other, the iron core piece 70A and the iron core piece 70B can be temporarily fixed until they are fixed by adhesion, welding, or the like. Further, since the iron core piece 70A and the iron core piece 70B are fitted at a plurality of places, it is possible to eliminate the need for fixing by adhesion, welding, or the like depending on the application. By reducing the width dimension of these convex portions and concave portions, it is possible to further increase the number of locations where fitting occurs between the iron core piece 70A and the iron core piece 70B.

In the cross section of the divided laminated iron core 60 shown in FIG. 10, the width W1 of the first portion 91 of the iron core piece 70A, that is, the width of the convex portion 103 is the width W2 of the second portion 92 of the iron core piece 70A, that is, the width of the concave portion 104. Is the same as. Further, the width W3 of the first portion 93 of the iron core piece 70B, that is, the width of the convex portion 105 is the same as the width W4 of the second portion 94 of the iron core piece 70B, that is, the width of the concave portion 106. Further, the width W1, the width W2, the width W3 and the width W4 are all the same. As a result, the width W1 of the first portion 91 of the iron core piece 70A and the width W4 of the second portion 94 of the iron core piece 70B become the same, and the width W2 of the second portion 92 of the iron core piece 70A and the first portion of the iron core piece 70B. The width W3 of 93 is the same. Therefore, when the iron core piece 70A and the iron core piece 70B are laminated, the gap formed between the iron core piece 70A and the iron core piece 70B can be reduced. Therefore, the occupancy rate of the iron core in the divided laminated iron core 60 can be increased.

In the cross section of the divided laminated iron core 60 shown in FIG. 10, a plurality of repeating patterns 121 formed by the first portion 91 and the second portion 92 adjacent to each other are formed in the iron core piece 70A. The plurality of repeating patterns 121 of the iron core piece 70A are arranged at a pitch P1 along the parallel direction of the first portion 91 and the second portion 92. The pitch P1 is the same as the sum of the width W1 and the width W2 in the iron core piece 70A.

In the cross section of the divided laminated iron core 60 shown in FIG. 10, a plurality of repeating patterns 122 formed by the first portion 93 and the second portion 94 adjacent to each other are formed in the iron core piece 70B. The plurality of repeating patterns 122 of the iron core piece 70B are arranged at a pitch P2 along the parallel direction of the first portion 93 and the second portion 94. The pitch P2 is the same as the sum of the widths W3 and W4 in the iron core piece 70A, and is the same as the pitch P1.

The repeating pattern 121 of the iron core piece 70A and the repeating pattern 122 of the iron core piece 70B are arranged so as to be offset by a deviation width P3. The deviation width P3 corresponds to half of pitch P1 and pitch P2, that is, half pitch. That is, the first portion 91 of the iron core piece 70A and the first portion 93 of the iron core piece 70B are arranged so as to be offset by a half pitch. Similarly, the second portion 92 of the iron core piece 70A and the second portion 94 of the iron core piece 70B are arranged so as to be offset by a half pitch. As a result, it is possible to make it difficult for a gap to be formed between the iron core piece 70A and the iron core piece 70B. Further, in the manufacturing process of the split laminated iron core 60 described later, by matching the operation timings of the crusher 220 and the press machine 230, the split laminated iron core 60 is continuously manufactured without stopping the crusher 220 and the press machine 230. can do. Therefore, the productivity of the divided laminated iron core 60 can be increased.

Of the surfaces of the iron core piece 70A, the surface including the surface 91a and the surface 92a is designated as the first surface A1. The shape of the first surface A1 of the iron core piece 70A is a planar shape. Of the surfaces of the iron core piece 70A, the surface including the surface 91b and the surface 92b is referred to as the second surface A2. The shape of the second surface A2 of the iron core piece 70A is a wavy shape. Of the surfaces of the iron core piece 70B, the surface including the surface 93b and the surface 94b is designated as the first surface B1. The shape of the first surface B1 of the iron core piece 70B is a planar shape. Of the surfaces of the iron core piece 70B, the surface including the surface 93a and the surface 94a is referred to as the second surface B2. The shape of the second surface B2 of the iron core piece 70B is a wavy shape.

The recess 104 of the iron core piece 70A and the recess 106 of the iron core piece 70B are arranged so as to be offset by a deviation width P3 in the parallel direction. The center between the recess 104 of the iron core piece 70A and the recess 106 of the iron core piece 70B in the parallel direction, and the center of the recess 104 of the iron core piece 70A and the recess 106 of the iron core piece 70B are point-symmetrical in the depth direction. Let it be the center point. The shape of the recess 104 of the iron core piece 70A and the shape of the recess 106 of the iron core piece 70B are point-symmetrical with the center point of point symmetry as the center.

The second surface A2 of the iron core piece 70A and the second surface B2 of the iron core piece 70B are in contact with each other. The first surface A1 of the iron core piece 70A and the first surface B1 of the iron core piece 70B are arranged so as to be parallel to each other. Therefore, the shapes of both end faces in the stacking direction of the pair of iron core pieces 70A and the iron core pieces 70B laminated to each other are planar shapes. The divided laminated iron core 60 is configured by laminating a plurality of a set of iron core pieces 70A and iron core pieces 70B laminated to each other in the laminating direction. In other words, when the split laminated iron core 60 includes an iron core piece 70A and an iron core piece 70B having a first portion 93 adjacent to the first portion 91 of the iron core piece 70A in the parallel direction as a set of iron core pieces. It contains multiple sets of iron core pieces stacked in the stacking direction.

The shape of the second surface A2 of the iron core piece 70A and the shape of the second surface B2 of the iron core piece 70B are wavy. As a result, when aligning the pair of thin plates, even if the positions of the pair of thin plates are displaced in the parallel direction from each other, the other is in the parallel direction with respect to one of the pair of thin plates. Moving. In other words, there is an automatic adjustment function for alignment between the pair of thin plates. Further, the shape of the crusher forming the second portion 92 of the iron core piece 70A and the second portion 94 of the iron core piece 70B can be made round. As a result, the pressure applied by the crusher to the steel sheet sheet 130 can be increased. Further, by making the shape of the crusher round, it is possible to relax the stress concentration of the portion of the crusher that comes into contact with the steel plate sheet 130. Thereby, the durability of the steel plate sheet 130 in the crusher can be improved.

As shown in FIG. 10, the second surface B2 of the iron core piece 70B is overlapped with the second surface A2 of the iron core piece 70A. On the first surface B1 of the iron core piece 70B, the first surface B1 of the iron core piece 70B inverted in the stacking direction is overlapped. The second surface A2 of the iron core piece 70A inverted in the stacking direction is overlapped on the second surface B2 of the iron core piece 70B inverted in the stacking direction. Not limited to this configuration, for example, the first surface A1 of the iron core piece 70A may be overlapped with the first surface B1 of the iron core piece 70B.

FIG. 12 is a cross-sectional view showing a configuration in which the stator winding 22 is arranged on the divided laminated iron core 60 of the first embodiment. FIG. 12 shows a cross section of the divided laminated iron core 60 and the stator winding 22 cut in a plane perpendicular to the circumferential direction. An insulator 23 is attached to the axial end surface of the divided laminated iron core 60. The insulator 23 is made of an insulating material. The stator winding 22 is attached to the split laminated iron core 60 via the insulator 23.

The shape of both end faces in the axial direction of the divided laminated iron core 60 is a planar shape parallel to each other. As a result, the contact area between the divided laminated iron core 60 and the insulator 23 can be increased as compared with the case where the shape of the axial end surface of the divided laminated iron core 60 is an uneven shape. When the stator winding 22 is mounted on the split laminated iron core 60 via the insulator 23, a force is applied to the insulator 23 from the stator winding 22. However, by increasing the contact area between the split laminated iron core 60 and the insulator 23, the force applied to the insulator 23 is dispersed when the stator winding 22 is mounted on the split laminated iron core 60 via the insulator 23. be able to. When the shape of the axial end surface of the split laminated iron core 60 is uneven, the force applied to the insulator 23 when the stator winding 22 is mounted on the split laminated iron core 60 via the insulator 23 is one of the insulators 23. Focus on the club. As a result, the insulator 23 may be deformed or cracked.

FIG. 13 is a perspective view showing the configuration of the iron core piece 70B of the divided laminated iron core 60 of the first embodiment. The first portion 93 and the second portion 94 of the iron core piece 70B extend along the projecting direction of the teeth portion 72, that is, the radial direction. Although not shown, the first portion 91 and the second portion 92 of the iron core piece 70A extend along the projecting direction of the teeth portion 72, that is, the radial direction. The second portion 92 and the second portion 94 of the back yoke portion 71 and the second portion 92 and the second portion 94 of the teeth portion 72 extend in the same direction. Therefore, the second portion 92 and the second portion 94 can be formed by one crushing step. As a result, the productivity of the divided laminated iron core 60 can be increased.

The magnetic flux Φ flowing through the divided laminated iron core 60 flows mainly in the radial direction in the teeth portion 72, and mainly flows in the circumferential direction in the back yoke portion 71. As a result, the eddy current at the teeth portion 72 can be suppressed. When the magnetic flux density of the teeth portion 72 is higher than the magnetic flux density of the back yoke portion 71, the productivity of the split laminated iron core 60 can be increased and the eddy current of the split laminated iron core 60 can be suppressed.

Generally, the iron loss W _i generated in the rotary electric machine is expressed by the following equation (1).
_{W i = W h + W e} (1)
Here, W _h is the hysteresis loss, W _e is the eddy current loss.

Eddy current loss _{W e} is expressed by the following equation (2).
_{W e = k e / ρ ×} t 2 × f 2 × B 2 (2)
Here, k _e are coefficients, [rho is the resistivity of the thin plate, t is the thickness of the thin plate, f is the frequency, B is the magnetic flux density. In order to reduce the eddy current loss W _e is possible to increase the resistivity [rho, reducing the sheet thickness, it is effective such that an insulating treatment on the surface of the thin plate in order to block the path of the eddy current .. For example, when the thickness of the plate thickness t, the eddy current loss W _e is smaller in proportion to the square of the plate thickness t.

In the first embodiment, the plate thickness t2 of a part of the iron core piece 70A and the plate thickness t4 of a part of the iron core piece 70B are thinner than the plate thickness t11 of the iron core piece 170 of the comparative example shown in FIGS. 3 and 4. can do. Thereby, the eddy current generated in each part of the iron core piece 70A and the iron core piece 70B can be suppressed.

Next, a method for manufacturing a laminated iron core of an electric machine and a method for manufacturing an electric machine according to the first embodiment will be described. FIG. 14 is a flowchart showing the flow of the manufacturing process of the divided laminated iron core 60 according to the first embodiment. FIG. 15 is a conceptual diagram showing the flow of the manufacturing process of the divided laminated iron core 60 according to the first embodiment. FIG. 15 also shows a schematic configuration of a manufacturing apparatus 200 for manufacturing the divided laminated iron core 60 according to the first embodiment. Hereinafter, the flow of the manufacturing process of the divided laminated iron core 60 and the configuration of the manufacturing apparatus 200 will be described with reference to FIGS. 14 and 15.

As shown in FIG. 14, the manufacturing process of the divided laminated iron core 60 includes at least a crushing step, a punching step executed after the crushing step, and an annealing step executed after the punching step.

As shown in FIG. 15, the manufacturing apparatus 200 for manufacturing the divided laminated iron core 60 has a steel plate supply device 210, a crushing machine 220, a press machine 230, and a furnace 240 in this order in the flow of the manufacturing process. The steel plate supply device 210, the crusher 220, and the press 230 form a series of continuous production lines in this order. The crushing machine 220 executes the crushing process, the press machine 230 executes the punching process, and the furnace 240 executes the annealing process. The crushing and punching steps are performed by a series of production lines. Note that FIG. 15 shows a manufacturing apparatus 200 in which the convex portions and concave portions formed on the steel plate sheet 130 have a rectangular cross section.

The steel plate supply device 210 is configured to hold the steel plate sheet 130 wound in a hoop shape. The steel plate sheet 130 is formed by using a thin plate which is a non-oriented electrical steel plate. Further, the steel plate supply device 210 has a feeding device for feeding the strip-shaped steel plate sheet 130 to the right in FIG. As a result, the strip-shaped steel plate sheet 130 is supplied from the steel plate supply device 210 to the crusher 220. The plate thickness of the steel plate sheet 130 supplied to the crusher 220 is the same as the plate thickness of the steel plate sheet 130 in the initial state wound in a hoop shape.

In the crusher 220, the crushing step of step S101 of FIG. 14 is executed. The crushing step is a step of crushing a part of the steel sheet sheet 130. The crusher 220 is configured to press and crush a part of the steel plate sheet 130 supplied from the steel plate supply device 210 in the plate thickness direction. The crusher 220 has a plurality of rollers that sandwich the steel plate sheet 130 in the plate thickness direction. In the first embodiment, the crusher 220 has a pair of rollers that sandwich the steel plate sheet 130 in the plate thickness direction. Specifically, the crusher 220 has a lower roller 221 arranged below the steel plate sheet 130 and an upper roller 222 arranged above the steel plate sheet 130. Further, the lower roller 221 rotates about the central axis O1. The upper roller 222 rotates about the central axis O2. The positions of the central axis O1 and the central axis O2 with respect to the transport direction of the steel sheet sheet 130 are the same as each other. The crusher 220 has a drive mechanism (not shown) that drives the lower roller 221 in the vertical direction and a drive mechanism (not shown) that drives the upper roller 222 in the vertical direction.

A plurality of tool portions 223 are provided on the outer peripheral surface of the lower roller 221. The plurality of tool portions 223 are arranged side by side at equal intervals along the outer peripheral surface of the lower roller 221. A plurality of tool portions 224 are provided on the outer peripheral surface of the upper roller 222. The plurality of tool portions 224 are arranged side by side at equal intervals along the outer peripheral surface of the upper roller 222. The lower roller 221 and the upper roller 222 rotate in synchronization with each other. As the lower roller 221 and the upper roller 222 rotate, one of the plurality of tool portions 223 and one of the plurality of tool portions 224 face each other in order with the steel plate sheet 130 interposed therebetween. When the tool portion 223 and the tool portion 224 face each other, a part of the steel plate sheet 130 is pressed in the plate thickness direction and crushed. As a result, any position of the steel sheet sheet 130 can be accurately thinned.

FIG. 16 is a cross-sectional view showing the configuration of the steel plate sheet 130 after the crushing step in the manufacturing step of the divided laminated iron core 60 according to the first embodiment. As shown in FIG. 16, when a part of the steel plate sheet 130 is crushed by the crusher 220, the thin portion 131 having a plate thickness t6 thinner than the plate thickness t5 of the steel plate sheet 130 in the initial state in the part. Is formed. The thin portion 131 becomes the second portion 92 of the iron core piece 70A or the second portion 94 of the iron core piece 70B.

On the other hand, the portion of the steel plate sheet 130 other than the thin portion 131 is maintained at the initial plate thickness t5. This portion becomes a thick portion 132 having a plate thickness t5 thicker than the plate thickness t6 of the thin portion 131. The thick portion 132 becomes the first portion 91 of the iron core piece 70A or the first portion 93 of the iron core piece 70B.

Although not shown, each of the tool portions 223 has a protruding portion protruding outward in the radial direction of the lower roller 221. Similarly, each of the tool portions 224 has a protruding portion protruding outward in the radial direction of the upper roller 222. The protruding portion of the tool portion 223 and the protruding portion of the tool portion 224 facing each other via the steel plate sheet 130 have a planar shape symmetrical with respect to the steel plate sheet 130.

The tool portion 223 provided on the lower roller 221 is radially movable with respect to the lower roller 221. The tool portion 224 provided on the upper roller 222 is radially movable with respect to the upper roller 222. When the thin-walled portion 131 is formed on the steel plate sheet 130 constituting the iron core piece 70A, the entire tool portion 224 is housed inside the upper roller 222. Therefore, the tool portion 224 does not project radially outward from the upper roller 222, and the tool portion 223 projects radially outward from the lower roller 221. As a result, the upper roller 222 comes into contact with one surface of the steel sheet sheet 130, and the tool portion 223 of the lower roller 221 comes into contact with the other surface of the steel sheet 130. In this state, the lower roller 221 and the upper roller 222 rotate to form the thin portion 131 on the steel plate sheet 130 constituting the iron core piece 70A.

On the other hand, when the thin-walled portion 131 is formed on the steel plate sheet 130 constituting the iron core piece 70B, the entire tool portion 223 is housed inside the lower roller 221. Therefore, the tool portion 223 does not project radially outward from the lower roller 221 and the tool portion 224 projects radially outward from the upper roller 222. As a result, the lower roller 221 comes into contact with one surface of the steel sheet sheet 130, and the tool portion 224 of the upper roller 222 comes into contact with the other surface of the steel sheet sheet 130. By rotating the lower roller 221 and the upper roller 222 in this state, the thin portion 131 is formed on the steel plate sheet 130 constituting the iron core piece 70B.

Therefore, both the steel plate sheet 130 constituting the iron core piece 70A and the steel plate sheet 130 forming the iron core piece 70B can be produced by the same crushing machine 220. This makes it possible to simplify the configuration of the manufacturing apparatus 200.

The thin-walled portion 131 is formed by crushing a part of the steel plate sheet 130 from above or below by the protruding portion of the tool portion 223 or the protruding portion of the tool portion 224. As a result, recesses are formed in the thin-walled portion 131 on both the upper surface and the lower surface of the steel plate sheet 130. Since each of the tool portion 223 and the tool portion 224 need only have a protruding portion protruding in one direction, the structure can be simplified as compared with a general mold.

As shown in FIG. 15, the thin portion 131 is formed on the steel plate sheet 130 by rotating each of the lower roller 221 and the upper roller 222. When the crusher 220 is composed of a lower table and an upper table that are driven in the vertical direction, the lower table and the upper table are driven in the vertical direction so that the lower table and the upper table are a part of the steel plate sheet 130. Is pressurized in the plate thickness direction. In this case, the upper table moves from the upper end position to the lower end position, and then moves from the lower end position to the upper end position. The lower table moves from the lower end position to the upper end position, and then moves from the upper end position to the lower end position. The steel sheet sheet 130 is pressurized by moving the upper table from the upper end position to the lower end position and the lower tail portion from the lower end position to the upper end position. When the crusher 220 is composed of a lower table and an upper table, it takes time for the upper table to move from the lower end position to the upper end position and the lower table to move from the upper end position to the lower end position. Therefore, when the crusher 220 is composed of a lower table and an upper table, it takes a long time to continuously form a plurality of recesses in the steel plate sheet 130.

On the other hand, in the first embodiment, the crusher 220 is composed of a lower roller 221 and an upper roller 222. By rotating each of the lower roller 221 and the upper roller 222, a plurality of thin-walled portions 131 are continuously formed on the steel sheet sheet 130. This reduces the time required to continuously form the plurality of recesses in the steel sheet sheet 130. Further, when the crusher 220 is composed of the lower table and the upper table, it is necessary to stop the feeding of the steel plate sheet 130 from the steel plate supply device 210. Therefore, when the crusher 220 is composed of a lower table and an upper table, it takes a long time to continuously form a plurality of recesses in the steel plate sheet 130. On the other hand, in the first embodiment, a plurality of thin-walled portions 131 are continuously formed on the steel plate sheet 130 by rotating each of the lower roller 221 and the upper roller 222. Therefore, the time required to continuously form the plurality of recesses in the steel sheet sheet 130 is reduced. As a result, the productivity of the laminated iron core of the rotary electric machine is improved.

In the first embodiment, the crusher 220 may have a configuration in which a recess is formed only on one of both surfaces of the steel plate sheet 130. In this case, of the lower roller 221 and the upper roller 222, the tool portion may be provided only on the roller facing the surface of the steel plate sheet 130 in which the recess is formed. This makes it possible to simplify the configuration of the manufacturing apparatus 200.

Each of the lower roller 221 and the upper roller 222 can be moved in the vertical direction, in other words, in the plate thickness direction of the steel plate sheet 130. As a result, the positions of the lower roller 221 and the upper roller 222 in the vertical direction are adjusted, so that the amount of crushing of the steel sheet sheet 130 can be easily adjusted.

Since each of the lower roller 221 and the upper roller 222 can be moved in the vertical direction, it is not necessary to move each of the plurality of tool portions 223 and the plurality of tool portions 224 in the vertical direction individually. Therefore, it is not necessary to individually adjust the positions of the plurality of tool units 223 and the plurality of tool units 224 in the vertical direction. As a result, the adjustment time of the crusher 220 can be shortened. As a result, the productivity of the laminated iron core of the rotary electric machine is improved.

When the crusher 220 pressurizes the steel plate sheet 130, a thin portion 131 is formed on the steel plate sheet 130. As a result, the steel sheet sheet 130 is formed with portions having different plate thicknesses.

When a plurality of thin-walled portions 131 are formed on the steel plate sheet 130, a plurality of protrusions may be provided on each of the tool portion 223 and the tool portion 224. Thereby, a plurality of thin-walled portions 131 can be formed on the steel plate sheet 130 by one pressurization by the crusher 220. For example, in the portion of the steel plate sheet 130 constituting one iron core piece, a plurality of thin-walled portions 131 can be formed at the same timing. In particular, in the portion of the steel plate sheet 130 constituting one iron core piece, all of the plurality of thin-walled portions 131 can be formed at the same timing. Therefore, when a plurality of thin-walled portions 131 are formed on the steel sheet sheet 130, it is possible to prevent the tact time of the crushing process from becoming long.

However, when forming a plurality of thin-walled portions 131 on the steel sheet sheet 130, it is also possible to form the thin-walled portions 131 one by one. For example, in the portion of the steel plate sheet 130 constituting one iron core piece, a plurality of thin-walled portions 131 can be formed at different timings from each other. In this case, regardless of the number of thin-walled portions 131 formed on the steel plate sheet 130, only one protruding portion needs to be provided for each of the tool portion 223 and the tool portion 224.

For example, when a plurality of thin-walled portions 131 are formed on the steel plate sheet 130 at a constant pitch, the thin-walled portions 131 at the first location are first formed, and then the steel plate sheet 130 is fed by one pitch to the second location. The thin-walled portion 131 is formed. After that, the feeding of the steel plate sheet 130 and the formation of the thin-walled portion 131 are repeated to form the required number of thin-walled portions 131 on the steel plate sheet 130. In this case, since the number of protrusions in each of the tool unit 223 and the tool unit 224 can be reduced, each of the tool unit 223 and the tool unit 224 can have a simpler structure, and the capital investment of the crusher 220 can be achieved. Can be suppressed. As a result, the manufacturing cost of the split laminated iron core 60 can be reduced.

In the first embodiment, the crusher 220 is composed of a lower roller 221 and an upper roller 222. As a result, the spacing between the plurality of tool portions is adjusted in response to the spacing between the plurality of thin-walled portions 131 formed on the steel sheet sheet 130. Therefore, the spacing between the plurality of recesses formed in the steel sheet sheet 130 can be easily changed. When switching between the iron core piece 70A and the iron core piece 70B, it can be handled by changing the positions of the tool portion of the lower roller 221 and the tool portion of the upper roller 222. By doing so, it is possible to continuously produce the laminated iron core without stopping the production. As a result, the productivity of the rotary electric machine can be increased.

In the crushing process, the steel sheet sheet 130 is not cut. Therefore, the steel plate sheet 130 on which the thin-walled portion 131 is formed is fed from the crushing machine 220 to the press machine 230 in the next process by using the above-mentioned feeding device. Instead of the above-mentioned feeding device, the steel sheet sheet 130 may be fed to the press machine 230 in the next step by using the lower roller 221 and the upper roller 222.

In FIG. 15, it seems that the thin-walled portion 131 is not formed on the steel plate sheet 130 at the stage after the crushing process is completed and before the punching process is started, but in reality, the steel plate sheet 130 has the thin-walled portion 131. It is formed. FIG. 15 shows an outline, and the recess of the thin-walled portion 131 is omitted.

In the press machine 230, the punching step of step S102 in FIG. 14 is executed. The punching step is a step of punching each of the iron core piece 70A and the iron core piece 70B from the steel plate sheet 130. As shown in FIG. 15, the press machine 230 moves the die 231 arranged below the steel plate sheet 130, the punch 232 arranged above the steel plate sheet 130, and the punch 232 in the vertical direction with respect to the die 231. It has a drive mechanism (not shown). The punch 232 has a planar shape similar to that of the iron core piece 70A and the iron core piece 70B, respectively. The punch 232 is driven by a drive mechanism so as to fit into the internal space 233 of the die 231. As a result, the press machine 230 can punch out the iron core piece 70A and the iron core piece 70B one by one from the steel plate sheet 130. The punched iron core piece 70A and the iron core piece 70B are pulled out into the internal space 233 of the die 231.

From the steel plate sheet 130, a plurality of iron core pieces 70A and a plurality of iron core pieces 70B are alternately punched one by one. That is, in the press machine 230, the step of punching one iron core piece 70A from the steel plate sheet 130 and the step of punching one iron core piece 70B from the steel plate sheet 130 are alternately and repeatedly executed. As a result, the plurality of iron core pieces 70A and the plurality of iron core pieces 70B are alternately stacked one by one in the internal space 233 of the die 231. In the manufacturing process shown in FIG. 15, since the steel plate sheet 130 is continuously sent to the press machine 230, a plurality of iron core pieces 70A and a plurality of iron core pieces 70B are stacked one after another in the internal space 233. Thereby, the productivity of the iron core piece 70A, the iron core piece 70B, and the divided laminated iron core 60 in which these are laminated can be improved.

Each of the crusher 220 and the press 230 may be configured to be movable in position along the transport direction of the steel sheet sheet 130. By adjusting the feed pitch of the steel plate sheet 130 while adjusting the positions of the crusher 220 and the press 230, continuous machining of the iron core piece 70A and the iron core piece 70B can be easily performed.

Although not shown, after the punching step, a stacking and fixing step of fixing the plurality of iron core pieces 70A and the plurality of iron core pieces 70B stacked alternately is executed. In the stacking and fixing step, for example, a plurality of alternately stacked iron core pieces 70A and a plurality of iron core pieces 70B are fixed by welding. Further, in the laminating and fixing step, for example, a plurality of alternately stacked iron core pieces 70A and a plurality of iron core pieces 70B are adhered by an adhesive. In this case, an adhesive layer is formed between the iron core pieces 70A and the iron core pieces 70B that overlap each other. As a result, the iron core pieces 70A and the iron core pieces 70B that overlap each other are fixed via the adhesive layer, and the divided laminated iron core 60 is produced. As a method of applying the adhesive, there is a method of immersing a plurality of alternately stacked iron core pieces 70A and iron core pieces 70B in a thermosetting adhesive placed in a tank, and then heating in a heating furnace. As a result, the adhesive is cured, and the plurality of iron core pieces 70A and the plurality of iron core pieces 70B are fixed. Further, as a method other than adhesion, there is a method in which a plurality of iron core pieces 70A and a plurality of iron core pieces 70B stacked alternately are put into a mold for resin molding, and the resin is poured into the mold. As a result, the plurality of iron core pieces 70A and the plurality of iron core pieces 70B are integrated together with the resin.

Next, the annealing step of step S103 of FIG. 14 is executed. The annealing step is a step of annealing the divided laminated iron core 60. In the annealing step, a plurality of alternately stacked iron core pieces 70A and a plurality of iron core pieces 70B obtained through a crushing step and a punching step are placed in a furnace 240 and heated. Generally, the thin plate formed by punching the steel plate sheet 130 is distorted. Iron loss increases in a thin plate in which distortion occurs. As a result, it is known that the energy efficiency of rotating electric machines and the like is reduced. In the first embodiment, a plurality of alternately stacked iron core pieces 70A and a plurality of iron core pieces 70B are annealed in order to remove the strain of the thin plate. The annealing conditions include, for example, first removing the punching oil at 300 (° C.) to 400 (° C.), and then mainly in a non-oxidizing or reducing atmosphere such as _{N 2} , CO _{2, CO.} Heat at 750 (° C.) for about 2 hours.

In this way, after the crushing step is executed, the punching step is executed, and then the annealing step is executed. As a result, the divided laminated iron core 60 is manufactured. By executing the annealing step, the strain generated when the iron core piece 70A and the iron core piece 70B are processed can be suppressed, and the iron loss increased in the crushing step and the punching step can be reduced. Thereby, the magnetic characteristics can be improved. An annealing step is performed after all steps that generate strain, such as a crushing step and a punching step. As a result, strain is suppressed, and the magnetic characteristics of the divided laminated iron core 60 can be improved.

By annealing the plurality of iron core pieces 70A and the plurality of iron core pieces 70B that are alternately laminated, it is not necessary to alternately laminate the plurality of iron core pieces 70A and the plurality of iron core pieces 70B after the annealing step. This facilitates the handling of the plurality of iron core pieces 70A and the plurality of iron core pieces 70B. In the annealing step, a plurality of iron core pieces 70A and a plurality of iron core pieces 70B can be annealed one by one. In this case, a plurality of iron core pieces 70A and a plurality of iron core pieces 70B are alternately alternated after the annealing step. A step of laminating is required.

A required number of the divided laminated iron cores 60 produced in this manner, for example, 48 are prepared. By connecting these divided laminated iron cores 60 in parallel in an annular shape, the stator core 21 of a rotary electric machine is manufactured. When connecting the plurality of divided laminated iron cores 60, welding or adhesion may be used, or fixing by resin molding may be used. The stator 20 is manufactured by mounting the stator winding 22 on the stator core 21. The stator windings 22 may be attached to each of the plurality of divided laminated iron cores 60, and then the divided laminated iron cores 60 may be connected in parallel in an annular shape.

Further, the rotary electric machine shown in FIG. 1 is obtained through a step of inserting the rotor 30 and the shaft 40 into the inner peripheral side of the stator 20.

In the first embodiment, the punching step is executed after the crushing step. As a result, even if the steel sheet sheet 130 is deformed or dimensionally changed in the crushing process, the iron core piece 70A and the iron core piece 70B can be punched out with an accuracy corresponding to the processing accuracy of the press machine 230 in the punching process. .. Therefore, the iron core piece 70A and the iron core piece 70B having high dimensional accuracy and geometric accuracy can be easily obtained. As a result, the dimensional accuracy and the geometric accuracy of the divided laminated iron core 60 manufactured by using the iron core piece 70A and the iron core piece 70B can be improved.

If the punching step is executed before the crushing step, even if the dimensional accuracy and the geometric accuracy of the iron core piece 70A and the iron core piece 70B are secured in the punching step, the dimensional accuracy and the geometrical accuracy are secured in the subsequent crushing step. Geometric accuracy is reduced. Therefore, after the crushing step, a step of improving the dimensional accuracy and the geometrical accuracy of each of the iron core piece 70A and the iron core piece 70B may be further required. Further, since it is necessary to send the iron core pieces 70A and the iron core pieces 70B punched out in the punching process one by one to the crushing process, it takes time to transport the iron core pieces 70A and the iron core pieces 70B from the punching process to the crushing process. It ends up.

Each of the iron core piece 70A and the iron core piece 70B of the first embodiment has a first portion and a second portion as two portions having different plate thicknesses. However, each of the iron core piece 70A and the iron core piece 70B may have three or more portions having different plate thicknesses from each other. That is, each of the iron core piece 70A and the iron core piece 70B has a first portion, a second portion having a plate thickness thinner than the plate thickness of the first portion, and a second portion having a plate thickness thinner than the plate thickness of the second portion. It may have three parts and.

As described above, the divided laminated iron core 60 according to the first embodiment includes an iron core piece 70A and an iron core piece 70B as a plurality of laminated iron core pieces. The iron core piece 70A has a first portion 91 and a second portion 92 having a plate thickness t2 thinner than the plate thickness t1 of the first portion 91. The iron core piece 70B has a first portion 93 and a second portion 94 having a plate thickness t4 thinner than the plate thickness t3 of the first portion 93. Here, the divided laminated iron core 60 is an example of the laminated iron core of an electric machine.

According to the above configuration, the plate thickness t2 of the second portion 92 can be made thinner than the plate thickness t1 of the first portion 91. Since the eddy current loss is proportional to the square of the plate thickness of the iron core piece, according to the above configuration, the eddy current loss in the second portion 92 of the iron core piece 70A can be reduced. Similarly, according to the above configuration, the eddy current loss in the second portion 94 of the iron core piece 70B can be reduced. Therefore, according to the above configuration, the eddy current loss of the divided laminated iron core 60 can be reduced. As a result, the iron loss generated in the rotary electric machine can be reduced, so that the efficiency of the rotary electric machine can be improved.

In the first embodiment, the plate thickness t1 of the first portion 91 is the same as the plate thickness at the time of purchase of the steel plate sheet 130. Further, the second portion 92 having a plate thickness t2 thinner than the plate thickness t1 is formed by crushing the steel plate sheet 130. Therefore, the iron core piece 70A can be manufactured by using the steel plate sheet 130 which can be easily obtained at low cost. Similarly, the iron core piece 70B can be manufactured using a steel plate sheet 130 that is easily available at low cost. Therefore, according to the first embodiment, it is possible to reduce the eddy current loss of the divided laminated iron core 60 while suppressing the material cost.

In the divided laminated iron core 60 according to the first embodiment, the plurality of iron core pieces include an iron core piece 70A and an iron core piece 70B that overlaps the iron core piece 70A in the stacking direction of the plurality of iron core pieces. The first portion 91 of the iron core piece 70A is arranged so as to face the second portion 94 of the iron core piece 70B. The second portion 92 of the iron core piece 70A is arranged so as to face the first portion 93 of the iron core piece 70B. Here, the iron core piece 70A is an example of the first iron core piece, and the iron core piece 70B is an example of the second iron core piece.

According to this configuration, the gap formed between the iron core piece 70A and the iron core piece 70B can be reduced. Therefore, the occupancy rate of the iron core in the divided laminated iron core 60 can be increased. Further, since the iron core piece 70A and the iron core piece 70B can be manufactured by using the same manufacturing apparatus 200, the manufacturing cost of the split laminated iron core 60 can be reduced, and a cheaper electric machine can be realized.

In the divided laminated iron core 60 according to the first embodiment, in the iron core piece 70A, the first portion 91 and the second portion 92 are arranged in parallel in one direction with each other. In the iron core piece 70B, the first portion 93 and the second portion 94 are arranged in parallel in the direction of each other. The width W2 of the second portion 92 of the iron core piece 70A in the parallel direction of the first portion and the second portion is the same as the width W4 of the second portion 94 of the iron core piece 70B in the parallel direction. In the parallel direction of the first portion and the second portion, the first portion 91 of the iron core piece 70A overlaps with the first portion 93 of the iron core piece 70B.

In the divided laminated iron core 60 according to the first embodiment, the iron core piece 70A is formed with a plurality of repeating patterns 121 composed of a first portion 91 and a second portion 92 adjacent to each other. The iron core piece 70B is formed with a plurality of repeating patterns 122 composed of a first portion 93 and a second portion 94 adjacent to each other. The plurality of repeating patterns 121 of the iron core piece 70A and the repeating pattern 122 of the iron core piece 70B are arranged at the same pitch P1 or P2 along the parallel direction, and are offset by a half pitch.

According to this configuration, it is possible to make it difficult for a gap to be formed between the iron core piece 70A and the iron core piece 70B. Further, in the manufacturing process of the split laminated iron core 60, by matching the operation timings of the crusher 220 and the press machine 230, the split laminated iron core 60 is continuously manufactured without stopping the crusher 220 and the press machine 230. Can be done.

In the divided laminated iron core 60 according to the first embodiment, the iron core piece 70A is formed with a recess 104 in which the surface 92b of the second portion 92 is concave with respect to the plane 112 including the surface 91b of the first portion 91. There is. Similarly, the iron core piece 70B is formed with a recess 106 in which the surface 94a of the second portion 94 is concave with respect to the plane 113 including the surface 93a of the first portion 93.

According to this configuration, the iron core piece 70A and the iron core piece 70B can be easily aligned. Further, according to this configuration, by fitting the convex portion formed on one of the iron core piece 70A and the iron core piece 70B and the concave portion formed on the other side of the iron core piece 70A and the iron core piece 70B, adhesion, welding, etc. It may not be necessary to fix the iron core piece 70A and the iron core piece 70B by the above method.

In the divided laminated iron core 60 according to the first embodiment, each of the iron core piece 70A and the iron core piece 70B has a back yoke portion 71 and a teeth portion 72 protruding from the back yoke portion 71. The second portion 92 and the second portion 94 of the teeth portion 72 extend along the projecting direction of the teeth portion 72.

In the rotary electric machine, the magnetic flux Φ entering the stator core 21 from the rotor 30 flows in the radial direction of the teeth portion 72, that is, in the protruding direction of the teeth portion 72. Therefore, according to the above configuration, the second portion 92 and the second portion 94 in the tooth portion 72 can be formed long along the direction in which the magnetic flux flows. Therefore, since the eddy current in the teeth portion 72 can be suppressed more effectively, the eddy current loss in the teeth portion 72 can be reduced. When the first embodiment is applied to a rotary electric machine in which the magnetic flux density of the teeth portion 72 is larger than the magnetic flux density of the back yoke portion 71, a higher effect can be obtained.

In the divided laminated iron core 60 according to the first embodiment, the second portion 92 and the second portion 94 in the back yoke portion 71 and the second portion 92 and the second portion 94 in the teeth portion 72 are stretched in the same direction. There is. According to this configuration, the second portion 92 and the second portion 94 can be easily formed.

In the divided laminated iron core 60 according to the first embodiment, all the second portions 92 of the iron core piece 70A are extended in the same direction, and all the second portions 94 of the iron core piece 70B are extended in the same direction. There is. According to this configuration, the second portion 92 and the second portion 94 can be easily formed.

In the divided laminated iron core 60 according to the first embodiment, the plate thickness t1 of the first portion 91 and the plate thickness t3 of the first portion 93 are 0.35 mm or 0.5 mm. Generally, a thin plate having a plate thickness of 0.35 mm and a thin plate having a plate thickness of 0.5 mm are easily available. Therefore, according to the above configuration, the materials of the iron core piece 70A and the iron core piece 70B can be easily obtained at low cost. The plate thickness t2 of the second portion 92 and the plate thickness t4 of the second portion 94 may be 0.25 mm or less.

In the divided laminated iron core 60 according to the first embodiment, on one surface of the iron core piece 70A, one surface 92a of the second portion 92 is on the same plane with respect to the plane 111 including one surface 91a of the first portion 91. Is located in. On the other surface of the iron core piece 70A, a recess 104 is formed in which the other surface 92b of the second portion 92 is concave with respect to the plane 112 including the other surface 91b of the first portion 91. Similarly, on one surface of the iron core piece 70B, one surface 94b of the second portion 94 is arranged on the same plane with respect to the plane 114 including the one surface 93b of the first portion 93. On the other surface of the iron core piece 70B, a recess 106 is formed in which the other surface 94a of the second portion 94 is concave with respect to the plane 113 including the other surface 93a of the first portion 93. Here, the recess 106 is an example of the first recess. The recess 104 is an example of the second recess. According to this configuration, the shape of one surface of each iron core piece is a planar shape. The flat surface has a high surface roughness. Therefore, by laminating the planes of the iron core pieces, the gap between the laminated iron core pieces can be suppressed. As a result, the space factor of the thin plate of the laminated iron core can be increased.

The recess 104 is formed by pressing a thin plate from one surface by a protruding portion of the tool portion 223 in the crushing machine 220 used in the crushing step. The recess 106 is formed by pressing the thin plate from the other surface by the protruding portion of the tool portion 224 in the crushing machine 220 used in the crushing step. Each of the tool portion 223 and the tool portion 224 may have a protruding portion protruding in one direction. Therefore, the tool unit 223 and the tool unit 224 of the crusher 220 can have a simple structure.

The rotary electric machine according to the first embodiment includes a stator 20 having a split laminated iron core 60, and a rotor 30 arranged so as to face the stator 20 through a gap 50. Here, the rotary electric machine is an example of an electric machine. The stator 20 is an example of an armature. The rotor 30 is an example of a field magnet. According to this configuration, the above effect can be obtained in the rotary electric machine.

The method for manufacturing the divided laminated iron core 60 according to the first embodiment includes a crushing step, a punching step executed after the crushing step, and an annealing step executed after the crushing step. The crushing step is a step of crushing a part of the steel plate sheet 130 by sandwiching the steel plate sheet 130 in the plate thickness direction by a plurality of rollers to form a thin-walled portion 131 to be the second portion 92 or the second portion 94. The punching step is a step of punching each of the iron core piece 70A and the iron core piece 70B from the steel plate sheet 130. The annealing step is a step of annealing the steel sheet sheet 130 produced by the crushing step. Here, the method for manufacturing the divided laminated iron core 60 is an example of the method for manufacturing the laminated iron core of an electric machine.

According to this manufacturing method, even if the steel sheet sheet 130 is deformed or dimensionally changed in the crushing process, in the punching process, each of the iron core pieces 70A and the iron core pieces 70B is subjected to the processing accuracy of the press 230. It can be punched out with precision. Therefore, the iron core piece 70A and the iron core piece 70B having high dimensional accuracy and geometric accuracy can be easily obtained.

In the method for manufacturing the divided laminated iron core 60 according to the first embodiment, in the crushing step, a plurality of thin-walled portions 131 may be formed one by one. According to this manufacturing method, the pressurizing load required in the crushing process is reduced, so that the capital investment of the crushing machine 220 can be suppressed. Further, when the thin-walled portions 131 at a plurality of locations are formed at one time, it becomes difficult to provide a relief that allows the steel sheet sheet 130 to stretch, which occurs in the crushing step, so that the thin-walled portions 131 may not be formed. On the other hand, according to the above manufacturing method, it becomes easy to provide a relief that allows the steel sheet sheet 130 to stretch.

In the method for manufacturing the divided laminated iron core 60 according to the first embodiment, in the crushing step, a plurality of thin-walled portions 131 may be formed at one time. In the crushing step, all the thin-walled portions 131, for example, all the thin-walled portions 131 contained in one iron core piece may be formed at one time. According to these manufacturing methods, even when a plurality of thin-walled portions 131 are provided, it is possible to prevent the tact time of the crushing process from becoming long. Therefore, it is possible to suppress a decrease in the productivity of the divided laminated iron core 60, and it is possible to obtain an inexpensive divided laminated iron core 60 and a stator core 21.

In the method for manufacturing the divided laminated iron core 60 according to the first embodiment, the annealing step is executed after the crushing step and the punching step. Thereby, the iron loss increased by the crushing step and the punching step can be reduced. As a result, the magnetic characteristics of the stator core 21 can be improved.

In the method for manufacturing the divided laminated iron core 60 according to the first embodiment, the laminated iron core pieces 70A and the iron core pieces 70B are annealed. As a result, it is not necessary to stack the iron core piece 70A and the iron core piece 70B after the annealing step. As a result, the iron core piece 70A and the iron core piece 70B after the annealing step can be easily handled.

The method for manufacturing an electric machine according to the first embodiment includes the method for manufacturing the divided laminated iron core 60 according to the first embodiment. According to this configuration, the same effect as described above can be obtained in the method of manufacturing an electric machine.

Embodiment 2.
FIG. 17 is a flowchart showing the flow of the manufacturing process of the divided laminated iron core 60 according to the second embodiment. FIG. 18 is a conceptual diagram showing the flow of the manufacturing process of the divided laminated iron core 60 according to the second embodiment. FIG. 19 is a conceptual diagram showing the flow of the manufacturing process of the divided laminated iron core 60 according to the second embodiment. In the second embodiment, the manufacturing process of the divided laminated iron core 60 is different from that in the first embodiment. In the first embodiment, in the manufacturing process of the divided laminated iron core 60, the step of crushing the steel plate sheet 130 is executed by one crushing step. On the other hand, in the second embodiment, the step of crushing the steel sheet sheet 130 is composed of a plurality of partial crushing steps. Specifically, the crushing step of crushing the steel sheet sheet 130 includes at least a first partial crushing step and a second partial crushing step. That is, the second embodiment is different from the first embodiment in that the step of crushing the steel sheet sheet 130 is executed by two partial crushing steps.

Further, the first embodiment has at least a punching step and an annealing step after the punching step. On the other hand, the second embodiment has at least an annealing step and a punching step executed after the annealing step. That is, the second embodiment is different from the first embodiment in that the annealing step is executed before the punching step.

As shown in FIG. 18, the manufacturing apparatus 200 for manufacturing the divided laminated iron core 60 has a steel plate supply device 210, a first crusher 250, and a steel plate winding device 260 in this order in the flow of the manufacturing process. The steel plate supply device 210 has the same configuration as that of the steel plate supply device 210 of the first embodiment.

The steel plate supply device 210 is configured to hold the steel plate sheet 130 wound in a hoop shape. The steel sheet winding device 260 is configured to wind the steel sheet sheet 130 in a hoop shape. The steel plate sheet 130 is formed by using a thin plate which is a non-oriented electrical steel plate. Further, the steel plate supply device 210 has a feeding device for feeding the strip-shaped steel plate sheet 130 to the right in FIG. As a result, the strip-shaped steel plate sheet 130 is supplied from the steel plate supply device 210 to the first crusher 250. The plate thickness of the steel plate sheet 130 supplied to the first crusher 250 is the same as the plate thickness of the steel plate sheet 130 in the initial state wound in a hoop shape.

In the first crusher 250, the first partial crushing step of step S201 of FIG. 17 is executed. The first partial crushing step is a step of crushing a part of the steel sheet sheet 130. The first crusher 250 is configured to press and crush a part of the steel plate sheet 130 supplied from the steel plate supply device 210 in the plate thickness direction. The first crusher 250 forms a thin-walled portion 131 on a portion of the steel plate sheet 130 constituting the iron core piece 70A. The first crusher 250 has a lower roller 251 arranged below the steel plate sheet 130 and an upper roller 252 arranged above the steel plate sheet 130. Further, the first crusher 250 has a drive mechanism (not shown) for driving the lower roller 251 in the vertical direction and a drive mechanism (not shown) for driving the upper roller 252 in the vertical direction.

A plurality of tool portions 253 are provided on the outer peripheral surface of the lower roller 251. The plurality of tool portions 253 are arranged side by side at equal intervals along the outer peripheral surface of the lower roller 251. A tool portion is not provided on the outer peripheral surface of the upper roller 252. The lower roller 251 and the upper roller 252 are controlled to rotate in synchronization with each other. By rotating each of the lower roller 221 and the upper roller 222, one of the plurality of tool portions 253 and the upper roller 252 face each other in order with the steel plate sheet 130 interposed therebetween. When the tool portion 253 and the upper roller 252 face each other, a part of the steel plate sheet 130 is pressed in the plate thickness direction and crushed. As a result, any position of the steel sheet sheet 130 can be accurately thinned.

The first crusher 250 forms the thin-walled portion 131 on the steel plate sheet 130 at the same pitch as the pitch P1 in the first embodiment. In other words, the first crushing machine 250 is formed on the steel sheet sheet 130 at intervals of the same length as compared with the intervals of the thin-walled portions 131 formed on the steel plate sheet 130 by the crushing machine 220 in the first embodiment. To form. On the right side of FIG. 18, a part of the steel plate sheet 130 on which the thin-walled portion 131 is formed by the first crusher 250 is enlarged and shown. In the first partial crushing step, the thin-walled portion 131 is formed only in the portion of the steel plate sheet 130 constituting the iron core piece 70A. Therefore, in the first crusher 250, the upper roller 252 does not need a tool portion, and the lower roller 251 does not need a drive mechanism for moving the tool portion 253 in the radial direction. Thereby, the configuration of the first crusher 250 can be simplified. In the first embodiment, the tool unit must be moved at high speed in accordance with the rotation of each of the lower roller 221 and the upper roller 222. On the other hand, in the second embodiment, it is not necessary to move the tool portion 253 with respect to the lower roller 251. As a result, the steel sheet sheet 130 can be crushed at high speed by the first crushing machine 250.

In the first partial crushing step, the steel sheet sheet 130 is not cut. Therefore, the steel plate sheet 130 on which the thin-walled portion 131 is formed is fed from the first crushing machine 250 to the steel plate winding device 260 by using the above-mentioned feeding device.

In the steel sheet winding device 260, the steel sheet sheet 130 crushed by the first crushing machine 250 is wound in a hoop shape. The winding step by the steel sheet winding device 260 is included in the first partial crushing step. By winding up the steel sheet sheet 130, the first partial crushing step is completed.

The steel sheet sheet 130 crushed by the first crushing machine 250 is wound in a hoop shape by the steel sheet winding device 260 before the second partial crushing step is executed. As a result, the first crusher 250 continuously crushes the steel sheet 130 while winding the steel sheet 130. By continuously winding the steel sheet sheet 130, the first partial crushing step can be performed at high speed.

As shown in FIG. 19, the manufacturing apparatus 200 for manufacturing the divided laminated iron core 60 has a steel plate supply device 210, a second crusher 270, and a steel plate winding device 260 in this order in the flow of the manufacturing process. The steel plate supply device 210 has the same configuration as the steel plate supply device 210 used in the first partial crushing step. The steel sheet winding device 260 has the same configuration as the steel sheet winding device 260 used in the first partial crushing step. The steel plate supply device 210 is configured such that the thin-walled portion 131 is formed by the first partial crushing step and is held by the steel plate sheet 130 wound in a hoop shape. The steel sheet winding device 260 is configured to wind the steel sheet sheet 130 in a hoop shape. The steel plate supply device 210 has a feed device for feeding the strip-shaped steel plate sheet 130 to the right in FIG. As a result, the strip-shaped steel plate sheet 130 is supplied from the steel plate supply device 210 to the second crusher 270.

In the second crusher 270, the second partial crushing step of step S202 of FIG. 17 is executed. The second partial crushing step is a step of crushing a part of the steel sheet sheet 130. The second crusher 270 is configured to press and crush a part of the steel plate sheet 130 supplied from the steel plate supply device 210 in the plate thickness direction. The second crusher 270 forms a thin-walled portion 131 on the portion of the steel plate sheet 130 constituting the iron core piece 70B. The second crusher 270 has a lower roller 271 arranged below the steel plate sheet 130 and an upper roller 272 arranged above the steel plate sheet 130. Further, the second crusher 270 has a drive mechanism (not shown) for driving the lower roller 271 in the vertical direction and a drive mechanism (not shown) for driving the upper roller 272 in the vertical direction.

A tool portion is not provided on the outer peripheral surface of the lower roller 271. A plurality of tool portions 274 are provided on the outer peripheral surface of the upper roller 272. The plurality of tool portions 274 are arranged side by side at equal intervals along the outer peripheral surface of the upper roller 272. The lower roller 271 and the upper roller 272 are controlled to rotate in synchronization with each other. By rotating each of the lower roller 271 and the upper roller 272, the lower roller 271 and one of the plurality of tool portions 274, in order, face each other with the steel plate sheet 130 interposed therebetween. When the lower roller 271 and the tool portion 274 face each other, a part of the steel plate sheet 130 is pressed in the plate thickness direction and crushed. As a result, any position of the steel sheet sheet 130 can be accurately thinned.

The second crusher 270 forms a thin portion 131 on the steel plate sheet 130 at the same pitch as the pitch P1 in the first embodiment. In other words, the second crusher 270 is formed on the steel sheet sheet 130 at intervals of the same length as compared with the intervals of the thin portions 131 formed on the steel sheet sheet 130 by the crusher 220 in the first embodiment. To form. On the right side of FIG. 19, a part of the steel plate sheet 130 on which the thin-walled portion 131 is formed by the first crusher 250 and the second crusher 270 is enlarged and shown. In the second partial crushing step, the thin-walled portion 131 is formed only in the portion of the steel plate sheet 130 constituting the iron core piece 70B. Therefore, in the second crusher 270, the lower roller 271 does not need a tool portion, and the upper roller 272 does not need a drive mechanism for moving the tool portion 274 in the radial direction. This makes it possible to simplify the configuration of the second crusher 270. In the first embodiment, the tool unit must be moved at high speed in accordance with the rotation of each of the lower roller 221 and the upper roller 222. On the other hand, in the second embodiment, it is not necessary to move the tool portion 274 with respect to the upper roller 272. As a result, the steel sheet sheet 130 can be crushed at high speed by the second crusher 270.

In the second partial crushing step, the thin-walled portion 131 is formed only in the portion of the steel plate sheet 130 constituting the iron core piece 70B. Therefore, the second crusher 270 does not come into contact with the portion of the steel plate sheet 130 constituting the iron core piece 70A in the first partial crushing step in the second partial crushing step.

Further, each of the first crushing machine 250 and the second crushing machine 270 may be configured so that the positions can be moved along the conveying direction of the steel plate sheet 130. By adjusting the feed pitch of the steel sheet sheet 130 while adjusting the positions of the first crusher 250 and the second crusher 270, continuous processing of the steel sheet sheet 130 can be easily performed.

In the second partial crushing step, the steel sheet sheet 130 is not cut. Therefore, the steel plate sheet 130 on which the thin-walled portion 131 is formed is fed from the second crusher 270 to the steel plate winding device 260 by using the above-mentioned feeding device.

In the steel sheet winding device 260, the steel sheet sheet 130 crushed by the second crusher 270 is wound in a hoop shape. The winding step by the steel sheet winding device 260 is included in the second partial crushing step. By winding up the steel sheet sheet 130, the second partial crushing step is completed.

The steel sheet sheet 130 crushed by the second crusher 270 is wound in a hoop shape by the steel sheet winding device 260 before the annealing step is executed. As a result, the second crusher 270 continuously crushes the steel sheet 130 while winding the steel sheet 130. By continuously winding the steel sheet sheet 130, the second partial crushing step can be performed at high speed.

FIG. 20 is a conceptual diagram showing an annealing process in the manufacturing process of the divided laminated iron core 60 according to the second embodiment. The manufacturing apparatus 200 includes a furnace 240. The furnace 240 has the same configuration as the furnace 240 of the first embodiment. In the furnace 240, the annealing step of step S203 of FIG. 17 is executed. The annealing step is a step of annealing the divided laminated iron core 60. In the annealing step, the steel sheet sheet 130 wound by the steel sheet winding device 260 is annealed. The annealing step is the same as the annealing step of the first embodiment. By annealing the steel sheet sheet 130, distortion in the steel sheet sheet 130 is suppressed.

FIG. 21 is a conceptual diagram showing a punching process in the manufacturing process of the divided laminated iron core 60 according to the second embodiment. The manufacturing apparatus 200 includes a press machine 230. The press machine 230 has the same configuration as the press machine 230 of the first embodiment. In the press machine 230, the punching step of step S204 of FIG. 17 is executed. The punching step is a step of punching each of the iron core piece 70A and the iron core piece 70B from the steel plate sheet 130. As shown in FIG. 21, the press machine 230 moves the die 231 arranged below the steel plate sheet 130, the punch 232 arranged above the steel plate sheet 130, and the punch 232 in the vertical direction with respect to the die 231. It has a drive mechanism (not shown). The punch 232 has a planar shape similar to that of the iron core piece 70A and the iron core piece 70B, respectively. The punch 232 is driven by a drive mechanism so as to fit into the internal space 233 of the die 231. As a result, the press machine 230 can punch out the iron core piece 70A and the iron core piece 70B one by one from the steel plate sheet 130. The punched iron core piece 70A and the iron core piece 70B are pulled out into the internal space 233 of the die 231.

In the punching process, the annealed steel sheet sheet 130 is sent to the press 230. The manufacturing apparatus 200 includes a steel plate supply device 210 that is an annealed steel sheet sheet 130 and holds the steel sheet sheet 130 wound in a hoop shape. The steel plate supply device 210 has the same configuration as the steel plate supply device 210 used in the first partial crushing step. The steel plate supply device 210 has a feed device for feeding the strip-shaped steel plate sheet 130 to the right in FIG. 21.

From the steel plate sheet 130, a plurality of iron core pieces 70A and a plurality of iron core pieces 70B are alternately punched one by one. That is, in the press machine 230, the step of punching one iron core piece 70A from the steel plate sheet 130 and the step of punching one iron core piece 70B from the steel plate sheet 130 are alternately and repeatedly executed. As a result, the plurality of iron core pieces 70A and the plurality of iron core pieces 70B are alternately stacked one by one in the internal space 233 of the die 231. In the manufacturing process shown in FIG. 21, since the steel plate sheet 130 is continuously sent to the press machine 230, a plurality of iron core pieces 70A and a plurality of iron core pieces 70B are stacked one after another in the internal space 233. Thereby, the productivity of the iron core piece 70A, the iron core piece 70B, and the divided laminated iron core 60 in which these are laminated can be improved.

Further, the press machine 230 may be configured so that the position can be moved along the feeding direction of the steel plate sheet 130. By adjusting the feed pitch of the steel plate sheet 130 while adjusting the position of the press machine 230, continuous machining of the iron core piece 70A and the iron core piece 70B can be easily performed.

A required number of the divided laminated iron cores 60 produced in this manner, for example, 48 are prepared. By connecting these divided laminated iron cores 60 in parallel in an annular shape, the stator core 21 of a rotary electric machine is manufactured. When connecting the plurality of divided laminated iron cores 60, welding or adhesion may be used, or fixing by resin molding may be used. The stator 20 is manufactured by mounting the stator winding 22 on the stator core 21. The stator windings 22 may be attached to each of the plurality of divided laminated iron cores 60, and then the divided laminated iron cores 60 may be connected in parallel in an annular shape.

Further, a rotary electric machine is obtained through a step of inserting the rotor 30 and the shaft 40 on the inner peripheral side of the stator 20. Other configurations are the same as those of the first embodiment or the second embodiment.

As described above, the method for manufacturing the divided laminated iron core 60 according to the second embodiment includes a crushing step, an annealing step executed after the crushing step, and a punching step executed after the annealing step. ing. The crushing step is a step of crushing a part or all of the steel plate sheet 130 to form a thin-walled portion 131 to be an iron core piece 70A and an iron core piece 70B. The annealing step is a step of annealing the steel sheet sheet 130 crushed by the crushing step. The punching step is a step of punching each of the iron core piece 70A and the iron core piece 70B from the annealed steel plate sheet 130.

Generally, the adhesive cannot withstand the temperature of the annealing process. However, when an adhesive is used as a method for fixing the plurality of laminated iron core pieces, in the method for manufacturing the divided laminated iron core 60 according to the second embodiment, the plurality of laminated iron core pieces are laminated after the annealing step. The iron core piece is fixed. Therefore, fixing with an adhesive can be used.

Further, in the method for manufacturing the divided laminated iron core 60 according to the second embodiment, the punching step is executed after the annealing step. Since the steel sheet sheet 130 on which the punching process is executed has already been annealed, the punching accuracy in the punching process is improved. As a result, the split laminated iron core 60 can be manufactured with press punching accuracy. When the annealing step is executed after the punching step, the iron core pieces punched with the press punching accuracy are deformed in the annealing step, and reworking is required after the annealing step. In the second embodiment, since this reworking is unnecessary, the productivity can be improved.

Further, in the method for manufacturing the divided laminated iron core 60 according to the second embodiment, the crushed steel plate sheet 130 is wound in a hoop shape by the steel plate winding device 260. As a result, the first crushing machine 250 and the second crushing machine 270 can continuously crush the steel sheet sheet 130. As a result, productivity can be improved.

Further, in the method for manufacturing the divided laminated iron core 60 according to the second embodiment, the steel plate sheet 130 wound in a hoop shape is sent out to the press machine 230. As a result, the press machine 230 can continuously punch out the steel sheet sheet 130. As a result, productivity can be improved.

Further, in the method for manufacturing the divided laminated iron core 60 according to the second embodiment, the thin portion 131 is formed on the steel plate sheet 130 by using each of the first crushing machine 250 and the second crushing machine 270. If the dimension between the tool portions 253 adjacent to each other is small and the dimension between the tool portions 274 adjacent to each other is small, it may not be possible to form a recess having a desired shape in the steel plate sheet 130. In the second embodiment, even when the dimension between the plurality of recesses finally formed is small, the dimension between the tool portions 253 adjacent to each other is increased, and the dimension between the tool portions 274 adjacent to each other is increased. The dimensions can be increased. Therefore, it is possible to more reliably form a recess having a desired shape in the steel sheet sheet 130.

In the second embodiment, the crushing process composed of the first partial crushing step and the second partial crushing step has been described. However, any natural number of 2 or more may be n, and any crushing step may be composed of steps from the first partial crushing step to the nth partial crushing step. As a result, the interference between the tool portions 253 adjacent to each other is suppressed, and the interference between the tool portions 274 adjacent to each other is suppressed. For example, the step of forming the thin-walled portion 131 on the steel plate sheet 130 constituting the iron core piece 70A may be composed of a plurality of partial crushing steps. Thereby, even when the dimension between the tool portions 253 adjacent to each other is small, the concave portion having a desired shape can be formed in the steel plate sheet 130. When the number of partial crushing steps is n, the pitch at which the thin-walled portion 131 is formed in each partial crushing step is n times the pitch at which the thin-walled portion 131 is formed in the entire crushing step. Further, for example, the step of forming the thin-walled portion 131 on the steel plate sheet 130 constituting the iron core piece 70B may be composed of a plurality of partial crushing steps. Thereby, even when the dimension between the tool portions 274 adjacent to each other is small, the recess of the desired shape can be formed in the steel plate sheet 130. When the number of partial crushing steps is n, the pitch at which the thin-walled portion 131 is formed in each partial crushing step is n times the pitch at which the thin-walled portion 131 is formed in the entire crushing step. Even if the dimension between the plurality of recesses finally formed is small, the dimension between the tool portions 253 adjacent to each other can be increased, and the dimension between the tool portions 274 adjacent to each other can be increased. can. This makes it possible to more reliably form a recess having a desired shape in the steel sheet sheet 130. Further, in the second and subsequent partial crushing steps, the already formed thin-walled portion 131 can be used as the positioning portion.

Further, in the second embodiment, the configuration in which the convex portion and the concave portion formed on the steel plate sheet 130 have a rectangular cross section has been described. However, the convex portion and the concave portion formed on the steel plate sheet 130 may have a bay shape.

Embodiment 3.
FIG. 22 is a conceptual diagram showing the flow of the manufacturing process of the divided laminated iron core 60 according to the third embodiment. In the third embodiment, the manufacturing process of the divided laminated iron core 60 is different from that in the second embodiment. In the second embodiment, the first partial crushing step is executed, and after the steel sheet sheet 130 is wound up, the second partial crushing step is executed. In the third embodiment, the manufacturing apparatus 200 for manufacturing the divided laminated iron core 60 has a steel plate supply device 210, a first crushing machine 250, a second crushing machine 270, and a pressing machine 230 in this order in the flow of the manufacturing process. There is. The steel plate supply device 210, the first crusher 250, the second crusher 270, and the press machine 230 constitute a series of continuous production lines in this order. A plurality of sets of rollers are arranged side by side in the transport direction of the steel sheet sheet 130. The first crushing machine 250 executes the first partial crushing process, the second crushing machine 270 executes the second partial crushing process, and the press machine 230 executes the punching process. The first partial crushing step, the second partial crushing step and the punching step are carried out by a series of production lines.

After the thin-walled portion 131 is formed on the steel plate sheet 130 constituting the iron core piece 70A in the first partial crushing step, the steel plate sheet 130 forming the iron core piece 70B in the second partial crushing step without cutting the steel plate sheet 130. A thin-walled portion 131 is formed on the surface. After the thin portion 131 is formed on the steel plate sheet 130 in the second partial crushing step, the iron core piece 70A and the iron core piece 70B are punched out in the punching step without cutting the steel plate sheet 130.

Each of the first crusher 250 and the second crusher 270 is controlled to rotate synchronously. In other words, the plurality of sets of rollers are controlled to be synchronized with each other. Thereby, the positions of the thin-walled portion 131 and the thick-walled portion 132 can be easily controlled. As a method of synchronizing each of the first crusher 250 and the second crusher 270, for example, a method of synchronizing using a plurality of servomotors and a method of synchronizing the rollers of the first crusher 250 and the second crusher 270 using gears. There is a method of synchronizing with the roller of. Other configurations are the same as those in the second embodiment.

As described above, the method for manufacturing the split laminated iron core 60 according to the third embodiment uses the first crusher 250 and the second crusher 270, respectively, to form the steel sheet sheet 130, as in the second embodiment. A thin-walled portion 131 is formed. After the thin-walled portion 131 is formed on the steel plate sheet 130 by the first crushing machine 250, the thin-walled portion 131 is formed on the steel plate sheet 130 by the second crushing machine 270 without winding the steel plate sheet 130. As a result, the step of forming the thin-walled portion 131 on the steel plate sheet 130 by the first crusher 250 and the step of forming the thin-walled portion 131 on the steel plate sheet 130 by the second crusher 270 can be continuously executed. can. As a result, the productivity of the divided laminated iron core 60 can be increased.

In the third embodiment, the crushing process composed of the first partial crushing step and the second partial crushing step has been described. However, any natural number of 2 or more may be n, and any crushing step may be composed of steps from the first partial crushing step to the nth partial crushing step. As a result, the interference between the tool portions 253 adjacent to each other is suppressed, and the interference between the tool portions 274 adjacent to each other is suppressed. Further, in the second and subsequent partial crushing steps, the already formed thin-walled portion 131 can be used as the positioning portion.

Further, in the third embodiment, the configuration in which the convex portion and the concave portion formed on the steel plate sheet 130 have a rectangular cross section has been described. However, the convex portion and the concave portion formed on the steel plate sheet 130 may have a bay shape.

Embodiment 4.
FIG. 23 is a conceptual diagram showing the flow of the manufacturing process of the divided laminated iron core 60 according to the fourth embodiment. In the fourth embodiment, the second partial crushing step is different from that in the second embodiment. In the fourth embodiment, the second crusher 270 has a lower roller 271 arranged below the steel sheet 130 and an upper roller 272 arranged above the steel sheet 130. A plurality of positioning portions 275 are provided on the outer peripheral surface of the lower roller 271. The plurality of positioning portions 275 are arranged at equal intervals along the outer peripheral surface of the lower roller 271. A plurality of tool portions 274 are provided on the outer peripheral surface of the upper roller 272. The plurality of tool portions 274 are arranged side by side at equal intervals along the outer peripheral surface of the upper roller 272. In the fourth embodiment, the lower roller 271 is provided with four positioning portions 275, and the upper roller 272 is provided with four tool portions 274. The lower roller 271 and the upper roller 272 are controlled to rotate in synchronization with each other.

The positioning portion 275 provided on the lower roller 271 is inserted into the recess formed in the steel plate sheet 130 by the tool portion 253 provided on the lower roller 251 of the first crusher 250. Therefore, in the second partial crushing step, the positioning portion 275 uses the thin-walled portion 131 formed on the steel plate sheet 130 as the positioning portion. As a result, the lower roller 271 is positioned with respect to the steel plate sheet 130.

FIG. 24 is a conceptual diagram showing a state in which the lower roller 271 of FIG. 23 is positioned with respect to the steel plate sheet 130. FIG. 25 is a conceptual diagram showing a state in which the tool portion 274 of FIG. 24 crushes the steel plate sheet 130. The positioning portion 275 is inserted into the recess formed in the steel plate sheet 130 by the tool portion 253 provided on the lower roller 251 of the first crusher 250.

The positioning portion 275 is movable in the radial direction with respect to the lower roller 271. With the steel plate sheet 130 stopped, the positioning portion 275 moves inward in the radial direction with respect to the lower roller 271, and the positioning portion 275 is pulled out from the recess formed in the steel plate sheet 130. In this state, the tool portion 274 forms the thin-walled portion 131 on the steel plate sheet 130 by moving the steel plate sheet 130 and rotating the lower roller 271 and the upper roller 272. Other configurations are the same as those in the second embodiment.

As described above, in the method for manufacturing the divided laminated iron core 60 according to the fourth embodiment, the thin-walled portion 131 formed on the steel plate sheet 130 in the first partial crushing step is used as a positioning portion with respect to the steel plate sheet 130. The second crusher 270 is positioned. In the first partial crushing step, when a hole is formed in a portion of the thin plate that does not become a magnetic pole piece and the hole is used as a positioning portion, the material yield is deteriorated and press working is increased. On the other hand, in the fourth embodiment, the material yield can be improved and the man-hours can be reduced by using the thin-walled portion 131 formed on the steel plate sheet 130 as the positioning portion in the first partial crushing step.

In the fourth embodiment, the crushing process composed of the first partial crushing step and the second partial crushing step has been described. However, any natural number of 2 or more may be set to n, and any crushing step composed of steps from the first partial crushing step to the nth crushing step may be used. In the second and subsequent partial crushing steps, the already formed thin-walled portion 131 is used as the positioning portion.

Further, in the fourth embodiment, the configuration in which the convex portion and the concave portion formed on the steel plate sheet 130 have a rectangular cross section has been described. However, the convex portion and the concave portion formed on the steel plate sheet 130 may have a bay shape.

Embodiment 5.
FIG. 26 is a perspective view showing the configuration of the iron core piece 80A of the stator core 21 according to the fifth embodiment. The description of the same configuration as that of any of the first to fifth embodiments will be omitted.

As shown in FIG. 26, the iron core piece 80A of the fifth embodiment is a unit core having a plurality of sub iron core pieces 81. The iron core piece 80A has a plurality of sub-core pieces 81 arranged in parallel with each other, and a connecting portion 82 for connecting two sub-core pieces 81 adjacent to each other. The iron core piece 80A shown in FIG. 26 has four sub-core pieces 81 and three connecting portions 82. The number of sub-core pieces 81 included in one iron core piece 80A may be 2, 3, or 5 or more.

Each of the sub-core pieces 81 has a back yoke portion 71 and a teeth portion 72. The connecting portion 82 connects the end portions of the back yoke portions 71 of the two sub-core pieces 81 adjacent to each other in the extending direction. The back yoke portions 71 of the plurality of sub iron core pieces 81 are linearly arranged in parallel via the connecting portion 82. The connecting portion 82 has a structure that can be bent in a plane parallel to the iron core piece 80A. For example, the connecting portion 82 has a plate thickness thinner than that of the first portion 91, similarly to the second portion 92.

Each of the plurality of second portions 92 in the iron core piece 80A is stretched in a band shape along the stretching direction of the back yoke portion 71. Similarly, each of the plurality of first portions 91 in the iron core piece 80A is stretched in a strip shape along the stretching direction of the back yoke portion 71.

Although not shown, another iron core piece laminated with the iron core piece 80A includes a first portion formed at a position corresponding to the second portion 92 of the iron core piece 80A and a first portion 91 of the iron core piece 80A. It has a second portion formed at a position corresponding to the above. In the other iron core piece as described above, each of the plurality of second portions and each of the plurality of first portions are elongated in a strip shape along the stretching direction of the back yoke portion 71.

A laminated unit core is formed by alternately laminating the iron core piece 80A and the other iron core piece described above. The connecting portion 82 is bent in a plane parallel to the iron core piece 80A so that the protruding directions of the teeth portions 72 face the center of the annulus. As a result, each stretching direction of the second portion 92 becomes the circumferential direction of the stator core 21. The bending of the connecting portion 82 may be performed before the plurality of iron core pieces are laminated, or may be performed after the plurality of iron core pieces are laminated. By connecting the plurality of laminated unit cores in an annular shape, the stator core 21 which is a laminated iron core is produced.

In the fifth embodiment, since the plurality of sub-core pieces 81 are connected, it is possible to reduce the labor of transportation between the processes. Further, since a plurality of sub iron core pieces 81 are connected, continuous winding can be easily realized and the connection processing time can be shortened.

The plurality of laminated iron core pieces may be fixed by adhesion, by welding, or by mold fixing using a resin. Further, the plurality of laminated iron core pieces may be fixed by caulking using a half punched portion formed on each iron core piece, or may be fixed by fastening using a fastening member such as a rivet.

In the iron core piece 80A of the fifth embodiment, the second portion 92 is stretched along the stretching direction of the back yoke portion 71, but the present invention is not limited to this. For example, the second portion 92 may be stretched along the protruding direction of the teeth portion 72. Further, the second portion 92 of the back yoke portion 71 may be stretched in the stretching direction of the back yoke portion 71, and the second portion 92 of the teeth portion 72 may be stretched along the protruding direction of the teeth portion 72. Further, the second portion 92 may be stretched along a direction that is inclined with respect to both the stretching direction of the back yoke portion 71 and the protruding direction of the teeth portion 72.

As described above, in the stator core 21 according to the fifth embodiment, each of the plurality of core pieces includes a plurality of sub core pieces 81 arranged in parallel and two sub core pieces 81 adjacent to each other. It has a connecting portion 82 for connecting. The connecting portion 82 is bent in a plane parallel to each of the plurality of iron core pieces. According to this configuration, it is possible to reduce the labor of transportation between processes, and it is possible to shorten the wiring processing time. As a result, the manufacturing cost of the stator winding 22 can be reduced.

In the fifth embodiment, the configuration in which the convex portion and the concave portion formed on the steel plate sheet 130 have a rectangular cross section has been described. However, the recess formed in the steel sheet sheet 130 may have a bay shape.

Embodiment 6.
FIG. 27 is a cross-sectional view showing a configuration in which a part of the divided laminated iron core 60 according to the sixth embodiment is cut in a plane perpendicular to the stretching direction of the first portion 91 and the second portion 92. In the divided laminated iron core 60 of the modified example of the first embodiment, the convex portion 103 and the concave portion 104 formed in the iron core piece 70A have a rectangular cross section, and the convex portion 105 and the concave portion 106 formed in the iron core piece 70B. The shape of is a rectangular cross section. In other words, in the split laminated iron core 60 of the modified example of the first embodiment, the bottom surface and the side surface of the recess 104 of the iron core piece 70A are arranged perpendicular to each other, and the bottom surface and the side surface of the recess 106 of the iron core piece 70B are mutually arranged. It is arranged vertically. On the other hand, in the divided laminated iron core 60 of the sixth embodiment, the cross-sectional shape of the recess 104 of the iron core piece 70A is tapered, and the cross-sectional shape of the recess 106 of the iron core piece 70B is tapered. In the iron core piece 70A, the angle between the surface 92b and the side surface of the recess 104 is larger than 90 degrees, and the angle between the side surface of the recess 104 and the surface 91b is larger than 90 degrees. .. In the iron core piece 70B, the angle between the surface 94a and the side surface of the recess 106 is larger than 90 degrees, and the angle between the side surface of the recess 106 and the surface 93a is larger than 90 degrees. .. Since the cross-sectional shape of the recess 104 of the iron core piece 70A and the cross-sectional shape of the recess 106 of the iron core piece 70B are tapered, even if the positions of the iron core piece 70A and the iron core piece 70B are displaced, the position is automatically set. The misalignment is corrected. As a result, the laminating work is made more efficient. Other configurations are the same as those of the first to fifth embodiments.

As described above, according to the divided laminated iron core 60 according to the sixth embodiment, the cross-sectional shapes of the recesses 104 and the recesses 106 are tapered. Thereby, the iron core piece 70A and the iron core piece 70B can be easily laminated.

Embodiment 7.
FIG. 28 is a cross-sectional view showing a configuration in which a part of the divided laminated iron core 60 according to the seventh embodiment is cut in a plane perpendicular to the stretching direction of the first portion 91 and the second portion 92. In the divided laminated iron core 60 of the modified example of the first embodiment, the convex portion 103 and the concave portion 104 formed in the iron core piece 70A have a rectangular cross section, and the convex portion 105 and the concave portion 106 formed in the iron core piece 70B. The shape of is a rectangular cross section. In other words, in the split laminated iron core 60 of the modified example of the first embodiment, the bottom surface and the side surface of the recess 104 of the iron core piece 70A are arranged perpendicular to each other, and the bottom surface and the side surface of the recess 106 of the iron core piece 70B are mutually arranged. It is arranged vertically. On the other hand, in the divided laminated iron core 60 of the seventh embodiment, a relief portion 73 is formed between the first portion 91 of the iron core piece 70A and the first portion 93 of the iron core piece 70B in the parallel direction.

Let Lα1 be the dimension of the first portion 91 of the iron core piece 70A in the parallel direction. Let Lα2 be the dimension of the second portion 92 of the iron core piece 70A in the parallel direction. Let Lβ1 be the dimension of the first portion 93 of the iron core piece 70B in the parallel direction. Let Lβ2 be the dimension of the second portion 94 of the iron core piece 70B in the parallel direction. In this case, Lα1 <Lα2, Lβ1 <Lβ2, Lα1 <Lβ2, Lα2> Lβ1 are satisfied. Other configurations are the same as those of the first to fifth embodiments.

As described above, in the divided laminated iron core 60 according to the seventh embodiment, a relief portion 73 is formed between the first portion 91 of the iron core piece 70A and the first portion 93 of the iron core piece 70B in the parallel direction. Has been done. As a result, when the iron core piece 70A and the iron core piece 70B are laminated, it is possible to prevent the first portion 91 of the iron core piece 70A and the first portion 93 of the iron core piece 70B from interfering with each other. Further, even if the dimensions of the iron core piece 70A and the iron core piece 70B vary due to the crushing process, it is possible to prevent the first portion 91 of the iron core piece 70A and the first portion 93 of the iron core piece 70B from interfering with each other. Will be done.

Embodiment 8.
FIG. 29 is a cross-sectional view showing a configuration in which a part of the divided laminated iron core 60 according to the eighth embodiment is cut by a plane perpendicular to the stretching direction of the first portion 91 and the second portion 92. In the divided laminated iron core 60 of the modified example of the first embodiment, the convex portion 103 and the concave portion 104 formed in the iron core piece 70A have a rectangular cross section, and the convex portion 105 and the concave portion 106 formed in the iron core piece 70B. The shape of is a rectangular cross section. In other words, in the split laminated iron core 60 of the modified example of the first embodiment, the bottom surface and the side surface of the recess 104 of the iron core piece 70A are arranged perpendicular to each other, and the bottom surface and the side surface of the recess 106 of the iron core piece 70B are mutually arranged. It is arranged vertically. On the other hand, in the eighth embodiment, the cross-sectional shape of the recess 104 of the iron core piece 70A has a curved surface formed between the surface 92b, which is the bottom surface of the recess 104, and the side surface of the recess 104. The shape of the recess 106 of the iron core piece 70B is such that a curved surface is formed between the surface 93a of the first portion 93 and the side surface of the recess 106.

The method for manufacturing the iron core piece 70A and the iron core piece 70B is performed by arranging two types of crushers in a row. One of the two types of crushers is used to form the recess 104 in the iron core piece 70A, and the other is used to form the recess 106 in the iron core piece 70B. By arranging the two types of crushers in a row in this way, different recesses can be formed in each of the iron core piece 70A and the iron core piece 70B. Other configurations are the same as those of the first to fifth embodiments.

As described above, in the divided laminated iron core 60 according to the eighth embodiment, the cross-sectional shape of the recess 104 of the iron core piece 70A is such that a curved surface is formed between the bottom surface and the side surface of the recess 104. The shape of the recess 106 of the iron core piece 70B is such that a curved surface is formed between the surface 93a of the first portion 93 and the side surface of the recess 106. As a result, the tool portion of the crusher that forms the recess 104 of the iron core piece 70A can be rounded. Therefore, the concentration of stress on a part of the tool portion is alleviated. As a result, the durability of the tool portion can be improved.

Although the steel plate sheets 130 and the iron core pieces of the first to eighth embodiments are formed by using non-oriented electrical steel sheets, they may be formed by using grain-oriented electrical steel sheets, SPCC, SS400, etc. It may be formed by using the iron-based magnetic material of.

Further, in the first to eighth embodiments, the rotary electric machine is taken as an example as the electric machine, but the present invention is not limited to this. Embodiments 1 to 3 are also applicable to various electric machines in which a laminated iron core is used, for example, a linear motor, a transformer, and the like.

Each embodiment and modification can be implemented in combination with each other.

10 housing, 20 stator, 21 stator core, 22 stator windings, 23 insulators, 30 rotors, 31 rotor cores, 32 permanent magnets, 40 shafts, 41 bearings, 42 bearings, 50 voids, 60 split laminated cores , 61 back yoke part laminate, 62 teeth part laminate, 70A, 70B iron core piece, 71 back yoke part, 72 teeth part, 73 relief part, 91 first part, 91a surface, 91b surface, 92 second part, 92a Surface, 92b surface, 93 1st part, 93a surface, 93b surface, 94 2nd part, 94a surface, 94b surface, 101 convex part, 102 concave part, 103 convex part, 104 concave part, 105 convex part, 106 concave part, 107 convex Part, 108 recess, 111 plane, 112 plane, 113 plane, 114 plane, 121 repeat pattern, 122 repeat pattern, 130 steel plate sheet, 131 thin part, 132 thick part, 170 iron core piece, 171 back yoke part, 172 teeth part , 200 Manufacturing equipment, 210 Steel plate feeder, 220 Crusher, 221 Lower roller, 222 Upper roller, 223 Tool part, 224 Tool part, 230 Press machine, 231 die, 232 punch, 233 Internal space, 240 furnace, 250th 1 crusher, 251 lower roller, 252 upper roller, 253 tool part, 260 steel plate winding device, 270 second crusher, 271 lower roller, 272 upper roller, 274 tool part, 275 positioning part.

Claims (32)

Equipped with multiple stacked iron core pieces,
Each of the iron core pieces has a first portion and a second portion having a plate thickness thinner than the plate thickness of the first portion.
The plurality of iron core pieces include a first iron core piece and a second iron core piece adjacent to the first iron core piece in the stacking direction of the plurality of iron core pieces.
The first portion of the first iron core piece is arranged so as to face the second portion of the second iron core piece.
The second iron core piece is formed with a recess in which one surface of the second portion is concave with respect to a plane including one surface of the first portion of the second iron core piece.
The other surface of the second portion of the second iron core piece is arranged on the same plane with respect to the plane including the other surface of the first portion of the second iron core piece.
In each of the first iron core piece and the second iron core piece, the first portion and the second portion are arranged in parallel in one direction with each other.
The first portion of the first core piece is the second core piece adjacent to the second portion of the second core piece facing the first portion of the first core piece in a parallel direction. A laminated iron core of an electric machine that overlaps the first part in the parallel direction. The second portion adjacent to the first portion in the parallel direction in the first iron core piece is arranged so as to face the first portion in the second iron core piece.
The laminated iron core of an electric machine according to claim 1, wherein the first portion of the first iron core piece is fitted in the recess of the second iron core piece. The plurality of iron core pieces include a set of the first core piece and the second core piece having the first portion adjacent to the first portion of the first core piece in the parallel direction. The laminated iron core of the electric machine according to claim 1 or 2, wherein a plurality of sets of iron core pieces stacked in the stacking direction are included. On the outer surface of the iron core pieces arranged at the ends in the stacking direction of the plurality of iron core pieces, the surface of the first portion and the surface of the second portion are arranged on the same plane as each other. The laminated iron core of the electric machine according to any one of claims 1 to 3. Each of the iron core pieces has a back yoke portion and a teeth portion protruding from the back yoke portion.
The laminated iron core of an electric machine according to any one of claims 1 to 4, wherein the second portion of the teeth portion extends along a protruding direction of the teeth portion. Each of the iron core pieces has a back yoke portion and a teeth portion protruding from the back yoke portion.
The laminated iron core of an electric machine according to any one of claims 1 to 4, wherein the second portion of the teeth portion is stretched along the stretching direction of the back yoke portion. The laminated iron core of the electric machine according to claim 5 or 6, wherein the second portion in the back yoke portion is stretched along the stretching direction of the second portion in the teeth portion. Claims 1 to 7 each of the iron core pieces having a plurality of sub-core pieces arranged in parallel and a connecting portion for connecting two sub-core pieces adjacent to each other. The laminated iron core of the electric machine according to any one item. Any of claims 1 to 8, wherein the width of the second portion of the second iron core piece in the parallel direction is the same as the width of the first portion of the first iron core piece in the parallel direction. The laminated iron core of the electric machine according to the first paragraph. The laminated iron core of an electric machine according to any one of claims 1 to 9, wherein the cross-sectional shape of the second portion is rectangular. The laminated iron core of an electric machine according to any one of claims 1 to 9, wherein the cross-sectional shape of the second portion is a bay shape. The laminated iron core of an electric machine according to any one of claims 1 to 9, wherein the cross-sectional shape of the second portion is a tapered shape. Any of claims 1 to 12, wherein a relief portion is formed between the first portion of the first iron core piece and the first portion of the second iron core piece in the parallel direction. The laminated iron core of the electric machine according to the first paragraph. The first iron core piece is formed with a recess in which one surface of the second portion is concave with respect to a plane including one surface of the first portion of the first iron core piece.
The cross-sectional shape of the recess of the first iron core piece is such that a curved surface is formed between the bottom surface and the side surface.
The cross-sectional shape of the recess of the second iron core piece is any one of claims 1 to 9, wherein a curved surface is formed between the surface of the first portion and the side surface of the recess. The laminated iron core of the electric machine according to the first paragraph. Each of the first iron core piece and the second iron core piece is formed with a plurality of repeating patterns composed of the first portion and the second portion adjacent to each other in the parallel direction.
The plurality of repeating patterns of the first iron core piece and the plurality of repeating patterns of the second iron core piece are arranged at the same pitch as each other and are offset by a half pitch according to claim 1. Item 2. The laminated iron core of the electric machine according to any one of items up to item 12. An armature having an armature core composed of the laminated iron core of the electric machine according to any one of claims 1 to 15.
An electric machine provided with a field magnet arranged so as to face the armature with a gap. The method for manufacturing a laminated iron core of an electric machine according to any one of claims 1 to 15.
A crushing step of crushing a part of a steel sheet to prepare the steel sheet having the first portion and the second portion.
A method for manufacturing a laminated iron core of an electric machine, comprising: after the crushing step, a punching step of producing the plurality of iron core pieces having the first portion and the second portion from the steel plate sheet. The method for manufacturing a laminated iron core of an electric machine according to claim 17, wherein in the crushing step, a plurality of the second portions are formed at different timings from each other in the portion of the steel plate sheet constituting the one iron core piece. The method for manufacturing a laminated iron core of an electric machine according to claim 17, wherein in the crushing step, a plurality of the second portions are formed at the same timing as each other in the portion of the steel plate sheet constituting the one iron core piece. The production of a laminated iron core of an electric machine according to claim 17, wherein in the crushing step, all of the plurality of the second portions are formed at the same timing in the portion of the steel plate sheet constituting the one iron core piece. Method. The laminated iron core of the electric machine according to claim 17, wherein in the crushing step, a plurality of rollers sandwich the steel plate sheet in the plate thickness direction to prepare the steel plate sheet having the first portion and the second portion. Production method. The crushing step has a plurality of partial crushing steps executed at different timings from each other.
When the number of the partial crushing steps is n,
The pitch of the laminated iron core of the electric machine according to claim 21, wherein the pitch at which the second portion is formed in each of the partial crushing steps is n times the pitch at which the second portion is formed in the entire crushing step. Production method. The method for manufacturing a laminated iron core of an electric machine according to claim 22, wherein in the second and subsequent partial crushing steps, the already formed second portion is used as a positioning portion. A plurality of sets of the rollers are arranged side by side in the transport direction of the steel sheet sheet.
The method for manufacturing a laminated iron core of an electric machine according to claim 22 or 23, wherein the plurality of partial crushing steps are performed in a series. The method for manufacturing a laminated iron core of an electric machine according to claim 24, wherein the plurality of sets of the rollers are controlled to be synchronized with each other. In the crushing step, the plurality of rollers for crushing a part of the steel plate sheet portion constituting the first iron core piece and the plurality of rollers for crushing a part of the steel plate sheet portion constituting the second iron core piece. The method for manufacturing a laminated iron core of an electric machine according to any one of claims 22 to 25, wherein the rollers are different from each other. The method for manufacturing a laminated iron core of an electric machine according to any one of claims 17 to 26, further comprising an annealing step of annealing the steel sheet. The method for manufacturing a laminated iron core of an electric machine according to claim 27, wherein the punching step is executed before the annealing step or after the annealing step. The method for manufacturing a laminated iron core of an electric machine according to any one of claims 17 to 26, further comprising an annealing step of annealing the steel sheet sheet after the crushing step. The method for manufacturing a laminated iron core of an electric machine according to claim 29, wherein the punching step is executed before the annealing step or after the annealing step. The method for manufacturing a laminated iron core of an electric machine according to claim 29 or 30, wherein in the crushing step, the steel plate sheet having the first portion and the second portion is wound in a hoop shape. A method for manufacturing an electric machine, which comprises the method for manufacturing a laminated iron core of an electric machine according to any one of claims 17 to 31.

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