JP3313965B2 - Manufacturing method of laminated iron core using amorphous alloy foil strip - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a laminated iron core of a stator and a rotor of a motor, a laminated iron core of a transformer, and the like using a strip-shaped amorphous alloy foil plate.
The present invention relates to a method of manufacturing a laminated core using an amorphous alloy foil strip formed by laminating a plurality of amorphous alloy foil strips and laminating laminated foil core pieces by press working.

[0002]

2. Description of the Related Art Amorphous alloys are attracting industrial attention as metal materials having high hardness, tensile strength, corrosion resistance and magnetic properties. Focusing on these excellent magnetic properties, when using an amorphous alloy foil strip as a core material of a motor stator, which is an example of an electric component, conventionally, a progressive die in which a plurality of shape processing stations are appropriately arranged Using an apparatus, a foil plate of the amorphous alloy (plate thickness: 0.02-0.0
25mm) The strip material is supplied to this mold apparatus, and by press working, intermittent conveyance between the respective shaping stations is performed, and the unnecessary processing of the foil plate strip is sequentially punched and removed, and the required electric motor is formed. The required shape of the foil core of the stator is formed. Then, an outer shell of the foil sheet core pieces is formed, and these are sequentially laminated in the mold apparatus to form a laminated core of the stator of the electric motor. As is well known, the progressive die apparatus used for this machine is a first shape processing station for forming a positioning hole of each station and an inner diameter of a stator, and punching a stator slot of a laminated iron foil sheet. A second shaping station for forming the shape of the magnetic pole teeth, a third shaping station for intermittently forming through holes for separation of the laminated core, and a caulking projection for laminating and fixing the foil plate pieces of the laminated core; The configuration includes a fourth shaping station to be formed and a fifth shaping station to form a laminated core by performing punching to form an outer shape of the foil plate piece of the laminated core.

[0003] However, in the conventional method of manufacturing a laminated iron core using an amorphous alloy foil strip, when the foil strip is intermittently conveyed through the progressive die apparatus,
Since the plate thickness is as thin as 0.02-0.025 mm, even if a lifter for a foil strip is provided, the foil strip is adhered to the die apparatus surface by punching oil or the like during transportation. Wear
There was a problem that jamming of the foil strip occurred in the mold apparatus, a feeding failure occurred, and smooth intermittent conveyance was not possible, resulting in a decrease in productivity.

Further, since the stamped foil plate piece is fitted and fixed by the combination of the concave and convex portions of the caulking projection, the internal residual stress is accumulated around the fitting portion by crimping or the concave and convex portion is fitted. There has been a problem that a gap is generated between the iron pieces of the foil plate and the magnetic characteristics are deteriorated.

Further, since a plate holding plate (stripper plate) having a structure in which the plate holding of each shape processing station of the progressive die apparatus is integrated is used, each shape processing of a punched foil plate piece is performed. The required plate holding pressure is not added for each shape of the shape processing station, and the pull-in phenomenon of the foil plate material occurs, the punching clearance changes due to the inclination of the plate holder, and the residual distortion occurs around the punched portion. there were.

[0006]

DISCLOSURE OF THE INVENTION The present invention solves the above-mentioned problems of the prior art, and uses an amorphous alloy foil strip having high hardness, tensile strength, corrosion resistance and magnetic properties by press working. Even when manufacturing laminated cores, intermittent conveyance of foil strips is performed smoothly, and internal residual stress accumulated in the laminated core is suppressed, producing high-quality laminated cores with high long-term reliability. It is an object to provide a method for efficiently manufacturing.

[0007]

In order to solve the above problems, a required number of amorphous alloy foil plates (sheet thickness: 0.02
(-0.025 mm) A step of forming a laminated foil strip by bonding the strips to each other via a heat-resistant adhesive is provided.
By forming such a laminated foil strip, the transport strength of the strip can be ensured, and an amorphous alloy foil sheet (plate thickness: 0.02-0.025 mm) is used. Even so, intermittent conveyance in the next step of the press working step can be performed smoothly. Furthermore, since it is joined via the heat-resistant adhesive layer, it can function as a cushioning material when the caulking projection is formed.

[0008] Further, a progressive die having a shaping station for alternately forming components of a first laminated foil core piece and a second laminated foil core piece in which crimping projections and through holes are alternately arranged. It is to provide a press working process with the equipment. With this configuration, polymerization can be performed by a combination of the through hole of the component and the crimping projection, and the internal residual stress due to fitting and fixing can be reduced as compared with the conventional combination of projections and depressions of the caulking projection. Generation can be suppressed, and the gap between the iron core pieces of the laminated foil plate is eliminated, thereby improving the adhesion.

[0009] Further, the plurality of shape processing stations of the progressive die apparatus are divided mold apparatuses divided for each of the shape processing stations, and these are mounted on a press station having an independent press function. Are arranged in a proper order through a loop device in a tandem arrangement. Thus, the plate holding pressure suitable for each shape processing station can be increased as much as possible, and the manufacture of a high-precision punching die apparatus can be facilitated, and high-precision punching can be performed.

[0010] Further, the press station is provided with a pair of punching devices arranged vertically and alternately a plurality of times from above and below using a conventional up-down punching method. Giving shearing deformation to part or all,
A push-back function for pushing this back into the hole of the laminated foil plate and a function for removing the punched piece are provided. With such a configuration, it is possible to prevent punching burrs from occurring due to fatigue fracture of the strip.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention is to laminate and integrate a plurality of amorphous alloy foil strips via a heat-resistant adhesive layer,
A lamination processing step of forming a laminated strip of the foil plate of the amorphous alloy, and a first laminated foil sheet core piece in which through holes into which the crimping protrusions and the crimping protrusions are inserted are alternately arranged downstream thereof. A required shape is formed with a through-hole at the position of the caulking projection of the first laminated foil sheet core piece and a second laminated foil sheet core piece at which the caulking projection is alternately arranged at the position of the through-hole. A plurality of shape processing stations including a shape processing station, a lamination processing station for fitting a first laminated foil sheet core piece and a second laminated foil sheet core piece by a combination of a caulking projection and a through hole are arranged. And a press working step using the progressive die apparatus described above.

In addition, the progressive die device is divided into a plurality of divided die devices for each shape processing station, and these are divided into a plurality of die devices each having an independent press function and an intermittent transport function at both ends or at one of the press functions. The press station is mounted on each of the press stations, and is provided with a press working process in which the press stations are arranged in a proper order in tandem directly or via a loop. Here, it is also possible to use a conventional vertical punching method as the press function.

Further, as the amorphous alloy foil strip material, a material having a heat-resistant organic or inorganic insulating coating layer on one or both surfaces thereof can be used.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the accompanying drawings, a description will be given of a manufacturing process of a laminated stator core of an electric motor using a laminated foil strip of an amorphous alloy. FIG. 1 is an explanatory view showing an outline of a manufacturing process of a laminated stator core of a motor as an example of an embodiment of the present invention. Here, the example shown in the figure shows a case where two amorphous alloy foil strips are laminated to form a laminated stator core of an electric motor.

According to FIG. 1, a process for manufacturing a laminated stator core 100 of an electric motor (see FIG. 3), which is an example of an embodiment of the present invention, includes two amorphous alloy foil strips 10a, A laminating step 12 for forming a laminated foil plate strip 10 by pressing the laminate 10b via an insulating adhesive layer 11, and downstream of the laminating step 12, the laminated stator core 1
The required shape of the laminated laminated sheet iron core piece 13a, which is the component part 00, and the laminated laminated laminated sheet iron core pieces 13 of the first and second laminated laminated foil core pieces 13b and 13c (see FIGS. 2 and 3) are formed. First to sixth shape processing stations 14 of progressive die apparatus 14
a, 14b, 14c, 14d, 14e, and 14f (see FIG. 2) are divided into a plurality of divided mold devices for each shaping station. First to sixth press stations 1 arranged in tandem via a loop device 14h
And a press working step 16 mounted on 5a, 15b, 15c, 15d, and 15f. Hereinafter, the configuration of the laminating step 12 and the pressing step 16 will be described in detail.

First, referring to FIG. 1, the laminating step 12 for forming the laminated foil strip 10 by pressing the amorphous alloy foil strips 10a and 10b will be described.

According to the drawing, the laminating step 12 comprises two steps.
The foil strips 10a and 10b are unwound from the first and second unwinding devices 17 and 18 in which the strips of amorphous alloy foil strips 10a and 10b are wound. Then, an insulating adhesive 11 is applied to the back surface of the foil plate strip 10a by a coating roller group 20 of a conventional adhesive coating device 19 provided on the back side of the unwound foil plate strip 10a. A thin film layer 21 of an insulating adhesive is formed to form the foil strip material 10.
a, the foil plate strips 10b are aligned by the alignment roller group 22, and then the foil plate strips 10a, 10b are compressed by the pressure roller group 23 via the thin film layer 21 of the adhesive. To form a laminated foil strip 10 of the foil strips 10a and 10b.

Next, the press working step 16 will be described with reference to FIGS. FIG. 2 is a process diagram of punching a laminated foil core piece, which is a component of the laminated stator core of the electric motor, which is sequentially formed by the press station shown in FIG. 1, and FIGS. 3 (a), (b) and (c) BRIEF DESCRIPTION OF THE DRAWINGS It is a schematic explanatory drawing which shows the state which fitted and fixed the laminated foil plate piece which is a component of the laminated stator iron core of the electric motor which shows an example of Embodiment of this invention.

In the first press station 15a, the laminated foil sheet strip 10 supplied from the laminating step 12 is added to the laminated foil sheet core piece 1 at each press station.
In performing the shape processing of No. 3, a pilot hole 24 functioning as a positioning member is formed to be spaced apart in the width direction of the strip, and an inner diameter hole 25 of a laminated foil plate core piece 13 which is a component of the laminated stator core 100 of the electric motor. Of the laminated foil plate iron core piece 13 that is formed by punching out. Here, the inner diameter hole 25 is formed as an inner diameter hole that leaves a connection ring so as to connect the tips of the magnetic pole teeth formed in the next step, and is configured to remove the connection ring after performing a required shape processing. It is also possible. Here, the laminated foil core 13 is a general term for the separating laminated foil core 13a, the first laminated foil core 13b, and the second laminated foil core 13c.

In the second press station 15b, a required number of winding slots 26 are punched into the laminated foil strip 10 formed in the first press station 15a, and a plurality of magnetic pole teeth 27 are laminated. It is configured to be stamped and formed along the inner diameter hole 25 of the foil sheet core piece 13.

In the third press station 15c, the crimping projections 28 (final pieces) are provided on the laminated foil plate strip 10 formed in the second press station 15b every required number of laminated stator cores 100. A predetermined number of through-holes 29 (four in this embodiment) to be fitted are intermittently punched out to form a predetermined number of through holes 29 (four in this embodiment).
The intermittent processing for forming the required shape is performed. Here, when the third press station 15c is operating, the fourth press station 15d and the fifth press station 15e are not operating.
Here, the caulking protrusion 28 is a general term for the caulking protrusions 28a and 28b.

In the fourth press station 15d, the laminated foil plate strip 10 formed in the third press station 15c has a through-hole formed in a laminated foil core piece which is a component of the laminated stator core 100. A predetermined number of first through-holes 29a into which the first caulking projections 28a (four in this embodiment) that fit into the first and second caulking projections 28b fit.
(Four places in this embodiment) are alternately arranged to intermittently form the required shape of the first laminated foil core piece 13b which is a component of the laminated stator core 100 of the motor. I have. Here, the fourth press station 15d
Is operating, the third press station 15
c and the fifth press station 15e are not operating.

In the fifth press station 15e, the first crimping projection 28a formed on the laminated foil strip 10 formed on the laminated foil strip 10 formed on the fourth press station 15d. A laminated stator of an electric motor in which second through holes 29b are aligned at positions where the alignment is performed, and second crimping protrusions 28b are alternately arranged at positions where the second through holes 29a are formed at the laminated foil plate material 10. The required shape of the second laminated foil core piece 13c which is a component of the iron core 100 is formed intermittently. Here, when the fifth press station 15e is operating, the third press station 15c and the fourth press station 15d are not operating.

In the sixth pressing station 15f, first, the laminated foil strip 13a for separation is first formed from the laminated foil strip 10 formed in the fifth press station 15e.
Is punched out to form a laminated foil plate piece 13a for separation. Subsequently, an outer shell is punched on the through-hole 29 of the separating laminated foil plate 13a on the separating laminated foil plate 13a to form the first caulking projection 2 of the first laminated foil plate 13b.
8a are fitted, and the separating laminated foil plate piece 13a and the first laminated foil plate piece 13b are fitted and fixed. Next, an outer shell is punched into the first through-hole 29a of the first laminated foil plate piece, and the second caulking projection 28b of the second laminated foil plate piece 13c is fitted to the first laminated foil sheet piece 13c. Plate 13b and second laminated foil plate 13c
Are fitted and fixed. Similarly, the first crimping projection 28a of the first laminated foil plate 13b is fitted into the second through hole 29b of the second laminated foil plate 13c, and the second laminated foil plate 13c and the first And the laminated foil plate piece 13b. This is sequentially performed, and the first laminated foil plate 13b is placed on the separating foil plate 13a.
And the second laminated foil plate pieces 13c are alternately laminated and laminated to a predetermined stacking thickness, and then the separation laminated foil plate pieces 13a are punched and formed to separately form the predetermined laminated stator core 100. Processing is performed. Here, the shape of the caulking projection 28 is a V shape shown in FIG.
3C or the cut-and-bent shape shown in FIG. 3C, and it is particularly preferable to use the cut-and-bend shape shown in FIG. 3C. Thereby, generation of internal residual stress can be suppressed.

As described above, as a preferred embodiment of the method of forming the laminated core of the stator of the electric motor, a plurality of split mold devices divided for each shaping station are mounted on each of a plurality of press stations, and this is mounted. Although the description has been given as a configuration including a pressing step arranged in a tandem shape in an appropriate order, a first laminated foil plate core piece in which crimping projections and through holes into which the crimping projections are inserted are alternately arranged, A shaping station for forming a required shape with a second laminated foil core piece in which through holes are alternately arranged at the positions of caulking projections of the laminated foil core pieces and the crimping projections are alternately arranged at the positions of the through holes. And a press working step using a progressive die apparatus in which a plurality of shape working stations including the above are arranged.

[0026]

According to the present invention, even if an amorphous alloy foil strip is used for the laminated core of an electric component, a step of forming the laminated foil strip of the amorphous alloy foil is provided. The transport strength of the material can be secured, and intermittent transport can be performed smoothly. As a result, productivity can be improved.

Further, since the component parts of the first laminated foil plate piece and the second laminated foil plate piece in which the crimping projections and the through-holes are alternately arranged are formed alternately, the through-holes of the above-mentioned component parts, etc. Polymerization can be performed by a combination of staking protrusions,
As compared with the conventional combination of the projections and depressions of the caulking projection, the generation of the internal residual stress due to the fitting and fixing can be suppressed, and the gap between the laminated foil plates can be eliminated to improve the adhesion. As a result, the magnetic characteristics of the laminated core can be improved.

Further, since a plurality of shape processing stations of the progressive die apparatus are arranged in a tandem arrangement with press stations each having a divided die apparatus which is divided for each of the shape processing stations. The plate holding pressure suitable for the shape processing station can be increased as much as possible, and the manufacture of a high-precision punching die becomes easy, and high-precision punching can be performed.

Further, since the press station is configured to use a vertical punching method, it is possible to prevent punching burrs due to fatigue fracture of the strip.

[Brief description of the drawings]

FIG. 1 is a schematic diagram illustrating a manufacturing process of a laminated foil core according to an embodiment of the present invention.

FIG. 2 is a press-punching process diagram showing a process of forming a laminated foil sheet core piece according to an embodiment of the present invention.

FIG. 3 is a schematic explanatory view showing a form of fitting and fixing of a laminated foil sheet core piece according to the embodiment of the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 100 laminated stator iron core of electric motor 10 laminated foil strip material 10 a amorphous alloy foil strip material 10 b amorphous alloy foil strip material 11 insulating adhesive layer 12 lamination processing step 13 laminated foil core piece 13 a lamination for separation Foil sheet iron piece 13b First laminated foil sheet iron piece 13c Second laminated foil sheet iron piece 14 Progressive die apparatus 14a First shape processing station 14b Second shape processing station 14c Third shape processing station 14d First Fourth shape processing station 14e Fifth shape processing station 14f Sixth shape processing station 15 Press processing device 15a First press station 15b Second press station 15c Third press station 15d Fourth press Station 15e Fifth press station 15f 6 press station 16 press working process 17 first unwinding device 18 second unwinding device 19 adhesive coating device 20 coating roller group 21 thin film layer of heat-resistant insulating material 22 alignment roller group 23 crimping roller Group 24 pilot hole 25 inner diameter hole 26 winding slot 27 magnetic pole teeth 28 caulking protrusion 28a first caulking protrusion 28b second caulking protrusion 29 through hole 29a first through hole 29b second through hole 30 shell

──────────────────────────────────────────────────続 き Continuing on the front page (51) Int.Cl. ⁷ identification code FI H01F 41/02 H01F 41/02 C (58) Investigated field (Int.Cl. ⁷ , DB name) H02K 15/02 B21D 28 / 02 B30B 13/00 B32B 15/01 B32B 31/08 H01F 41/02

Claims (5)

(57) [Claims] 1. A foil plate piece is shaped by press working using a progressive die apparatus in which a plurality of shape processing stations are appropriately arranged, and the foil plate pieces are sequentially laminated and formed in the mold apparatus. A method for manufacturing a laminated electric component using a foil strip of an amorphous alloy, wherein a plurality of foil strips of an amorphous alloy are laminated and integrated via a heat-resistant adhesive layer, and the foil of the amorphous alloy is formed. A first laminating foil piece and a first laminating step in which a laminating step of forming a laminated foil strip of a plate and a downstream through-hole in which a crimping projection and a crimping projection are inserted are alternately arranged; A progressive feed including a plurality of shape processing stations for forming a required shape of a second laminated foil plate piece in which a through hole is formed at a position of a caulking protrusion of a foil plate piece and a caulking protrusion is alternately arranged at the position of the through hole. Pressing process with mold equipment And forming the required shapes of the first and second laminated foil strips while intermittently transporting the laminated foil strip in the progressive die apparatus. And laminating them alternately. A method of manufacturing a laminated iron core using an amorphous alloy foil strip. 2. Forming of a foil plate by press working using a progressive die device in which a plurality of shape processing stations are appropriately arranged, and forming the foil plate by sequentially laminating the foil plate in the die device. In the method for manufacturing a laminated electrical component using the amorphous alloy foil strip material, a plurality of amorphous alloy foil strip materials are laminated via a heat-resistant adhesive layer upstream of the pressing step. A laminating step of integrating and forming a laminated foil strip of the amorphous alloy foil plate,
Forming mold devices obtained by dividing the progressive die device for each forming station are mounted on a plurality of press stations arranged in tandem via a loop device in an appropriate order, each having an independent press function. And a press working step. A method for manufacturing a laminated iron core using an amorphous alloy foil strip. 3. The laminated strip material of the amorphous alloy foil plate has a three-layer structure in which a heat-resistant adhesive layer is sandwiched between the amorphous alloy foil plate members. A method for manufacturing a laminated iron core using an amorphous alloy foil strip. 4. The press station includes a pair of punching blades arranged vertically and alternately a predetermined number of times from the upper and lower surfaces of the laminated foil strip material. Press function to give shearing deformation to part or all,
4. The amorphous alloy foil plate strip according to claim 2, wherein a push back function of pushing back the hole into the hole of the laminated foil plate and a function of removing the punched piece are provided. Manufacturing method of laminated iron core. 5. The strip-shaped amorphous alloy foil plate,
4. The method according to claim 1, wherein a heat-resistant insulating coating layer is provided on one or both surfaces thereof.