JP3842146B2 - Manufacturing method of laminated iron core - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to the manufacture of a laminated core in which an iron core piece is punched out and laminated from a laminated material in which an amorphous thin plate and a metal plate are joined via an adhesive film.
[0002]
[Prior art]
Iron cores used in motors and transformers have been proposed to be manufactured as wound iron cores from amorphous thin plates with high magnetic permeability and extremely low iron loss in order to achieve higher efficiency, higher output, energy saving, miniaturization, etc. Yes.
[0003]
However, amorphous thin plates have strong brittle mechanical material properties, are generally very thin and difficult to punch, have low punching productivity, and are difficult to form caulking. For this reason, there are few proposals for laminated cores that are punched and crimped as core pieces.
[0004]
As the prior art, a plurality of amorphous thin plates are laminated and integrated through a heat-resistant adhesive, and an iron core piece is punched out from the amorphous laminated plate and caulked by caulking protrusions and caulking through holes formed on the iron core piece, and the laminated iron core is formed. There is something to manufacture.
[0005]
[Problems to be solved by the present invention]
Although the prior art has a certain effect, there is still a problem that amorphous itself is brittle and it is difficult to stably punch the core piece. Furthermore, the caulking protrusions for caulking the iron core pieces are formed by cutting and bending one part, but cracks and breakage may occur during the forming process. Also, even if caulking protrusions are formed, the core pieces laminated due to amorphous mechanical brittleness have low caulking strength, and the caulking becomes unstable when the size of the iron core piece increases, making it difficult to obtain a good quality laminated core. There is.
[0006]
An object of the present invention is to obtain a laminated core that can stably punch out an iron core piece from a laminated material including an amorphous thin plate, increase the caulking strength, and further achieve high efficiency, high output, and energy saving.
Another object of the present invention is to provide an industrially stable production of a laminated core by punching out core pieces from the laminated material with a good end face shape.
[0007]
[Means for achieving the object]
The first gist of the present invention is that an amorphous thin plate and a metal plate are bonded and integrated through an adhesive film, and the amorphous thin plate is positioned on the die surface side of a laminated material having a two-layer structure of the amorphous thin plate and the metal plate. Then, the punch is advanced and retracted from the metal plate side, and the laminated material of the two-layer structure is punched to form the required portion and the caulking portion of the iron core piece. Is a method of manufacturing a laminated iron core characterized in that a caulking portion is formed as a caulking projection while being narrowed by a projection forming punch and a receiving tool, the iron core pieces are trimmed and caulked and laminated. The second gist lies in that the metal plate bonded to the amorphous thin plate through an adhesive film is an electromagnetic steel plate, a low carbon steel plate, or an Fe—Ni alloy plate.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described based on one embodiment with reference to the drawings.
FIG. 1 is a view showing a laminated material in one embodiment of the present invention. FIG. 2 is a diagram for explaining a manufacturing process using a progressive die apparatus for a laminated core made of a laminated material, FIG. 3 is a diagram for explaining punching of an iron core piece from the laminated material, and FIG. 4 is a caulking projection on the iron core piece. FIG. 5 is a diagram showing the caulking lamination of iron core pieces, and FIG. 6 is a diagram showing the laminated iron core manufactured in one embodiment of the present invention.
[0009]
In the drawing, 1 is an amorphous thin plate. The amorphous thin plate 1 is extremely thin, for example, 0.02 to 0.06 mm thick and has excellent magnetic properties such as high magnetic permeability and extremely low iron loss. However, it has a hard and brittle property. In addition, it is difficult to industrially stably punch and core the core pieces from this alone and laminate them by caulking. For this reason, in the present invention, the amorphous thin plate 1 is first integrated as a laminated material 4 bonded to the metal plate 3 via the adhesive film 2. The joining is performed by inserting the adhesive film 2 between the amorphous thin plate 1 and the metal plate 3 respectively sent by the transport roll 5 and pressing the adhesive film 6.
[0010]
The said adhesive film 2 joins the amorphous thin plate 1 and the metal plate 3 as mentioned above, For example, a polyimide adhesive film, an epoxy adhesive film, etc. are employ | adopted and what has insulation is preferable.
[0011]
As the metal plate 3, for example, a steel sheet with a thin plate thickness and a low iron loss in order to reduce the motor's high output, high efficiency, energy saving and downsizing with a laminated iron core. A low carbon steel plate having excellent properties or a Fe—Ni alloy plate having high magnetic permeability and excellent workability and corrosion resistance is employed. These metal plates 3 have punching workability and, together with the adhesive film 2, assist the punching of the amorphous thin plate 1 and have the effect of preventing the occurrence of cracks and breakage.
[0012]
The laminated material 4 is passed through the progressive die apparatus so that the amorphous thin plate 1 side is the die surface side so as to be punched from the metal plate 3 side, and as shown in FIG. It is formed by punching at intervals on both sides.
[0013]
In the station 2, slots 9 are punched radially around the planned axial hole region 8. As shown in FIG. 3, the punch 10 is first brought into contact with the metal plate 3 to start punching shearing and proceeds to the amorphous thin plate 1 through the adhesive film 2, but the metal plate 3 is formed by punching workability. Since the amorphous thin plate 1 is integrally bonded to this via the adhesive film 2, the amorphous thin plate 1 is punched together with the metal plate 3 and the adhesive film 2 without causing cracks or breakage.
[0014]
The clearance between the punch 10 and the die 11 of the press die apparatus for punching the laminated material 4 is made narrower than that when a single metal plate having the same thickness as the laminated material 4 is punched, and is determined based on the thickness of the amorphous thin plate 1. Yes. Thus, the thickness of the amorphous thin plate 1 is weighted more than the thickness of the entire laminated material 4, and thus the clearance is determined, so that the laminated material 4 that passes through the amorphous thin plate 1 with the die side is punched in a good end face shape.
.
In the laminated material 4 from which the slots 9 are removed, the caulking portion 12 is formed at the station 3. A caulking portion 12 is punched and punched as a through hole 12a in the first laminated core piece, and a caulking protrusion and a caulking protrusion 12b in which a recess is formed on the back surface thereof are formed in the second and subsequent laminated iron core pieces. The through holes 12a and the caulking projections 12b can be easily changed by changing the depth of advancement and retraction of the punch (not shown) forming the caulking portion toward the die by a known slide cam or the like.
[0016]
The through-holes 12a and the caulking projections 12b constituting the caulking portion 12 are formed on the inner side and the outer side of the slot 9 on the circumference centering on the center of the planned shaft hole region 8 with a predetermined interval. This through-hole 12a is formed by punching in a narrow region, and the caulking projection 12b is formed by narrowing the projection while leaving one part and the other part as shown in FIG. Cracks and bending breakage occur frequently in the process of punching and forming, but in the present invention, the amorphous thin plate 1 is joined to the metal plate 3 with good workability via the adhesive film 2. 3 is cut down without cracking or breaking, thereby forming a caulking projection 12b.
[0017]
Further, when forming the caulking protrusion 12b, it is preferable that the side to be cut down is supported by the support 14 as shown in FIG. 4 and the caulking protrusion 12b is formed in a pinched state with the protrusion forming punch 15. In this way, the forming process is performed with the load applied from both sides, so that the formation process of the caulking protrusion 12b is further stably performed from the laminated material 4 in which the amorphous thin plates 1 are laminated.
[0018]
In this embodiment, the caulking portions 12 are formed at three locations inside the slot 9 and at nine locations outside, but the number can be changed depending on the shape and size of the iron core piece. Moreover, the formation location can be changed as appropriate according to the shape and size of the core piece, the thickness of the processed material, and the like.
[0019]
The laminated material 4 on which the caulking portion 12 is formed is sent to the station 4. The station 4 is a play station in this embodiment.
[0020]
In the laminated material 4 sent to the station 5, the iron core piece 16 is punched out, that is, the inner shape 17 and the outer shape 18 are punched, and the punched iron core is shown in FIG. The piece 16 is caulked with the caulking protrusion 12b entering the caulking recess of the iron core piece 19 previously laminated in the die hole (not shown). The punching of the iron core piece 16 and the caulking and laminating of the laminated iron core pieces 19 are repeated until a desired thickness is obtained, and a laminated iron core 20 as shown in FIG. 6 is obtained.
[0021]
Since the obtained laminated core 20 is formed by laminating the amorphous thin plate 1 with the metal plate 3, it has high output, high efficiency, low iron loss, and if it has the same output, it becomes smaller than a laminated core made of only metal plates. .
[0022]
In the above embodiment, the laminated iron core is the rotor laminated iron core, but the present invention is not limited to this, and a stator laminated iron core, a transformer laminated iron core, and the like can be manufactured in the same manner.
[0023]
Further, in the above embodiment, the caulking portion is constituted by the caulking projection and the through hole which are cut down on one side, but not limited to this, the caulking portion is formed by the V-shaped projection or the reverse C-shaped projection and the through hole. Can be configured.
[0024]
According to the embodiment of the present invention, an amorphous thin plate and a metal plate are joined and integrated through an adhesive film, and the laminated material is passed through a press mold apparatus so that the amorphous thin plate side is located on the die surface. The punch is advanced and retracted from the metal plate side, and the laminated material is punched to form the required portion of the iron core piece and the caulking portion. The outer shape of the iron core piece is punched, so the punch is first punched and sheared from the metal plate with good workability. At first, the punching shear progresses to reach an amorphous thin plate joined through an adhesive film, and the amorphous thin plate is punched without being cracked or broken by the metal plate and the adhesive film, and the core pieces are laminated.
[0025]
Also, the caulking part is formed by narrowing the through hole in the first core piece in the stack and the caulking projection in the second and subsequent core pieces while narrowing with the protrusion forming punch and the receiving tool. Is formed more stably, the strength of caulking the iron core pieces is strong, and the shape accuracy of the laminated iron core becomes better.
[0026]
In addition, according to the embodiment of the present invention, the metal plate to be bonded to the amorphous thin plate through an adhesive film is an electromagnetic steel plate, a low carbon steel plate, or an Fe-Ni alloy plate. Provides a laminated iron core with high output, high efficiency and great energy saving. In the case of the low carbon steel plate, the core piece can be easily punched and the crimped portion can be formed more easily, and a low cost laminated core can be obtained. Moreover, what was made into the Fe-Ni alloy plate has an effect that the output and efficiency are good, and a strong laminated core is obtained in a bad environment.
[0027]
Further, according to the embodiment of the present invention, an amorphous thin plate facing the die has a clearance between the die and the punch of the press die apparatus for punching by punching the punch from the metal plate side to the die side with respect to the laminated material. Because it is determined based on the thickness, even laminated materials including amorphous thin plates can be punched into a predetermined shape with a good punched end face shape, and the appearance and shape of the iron core formed by stacking the punched core pieces are excellent. There is.
[Brief description of the drawings]
FIG. 1 is a view showing a laminated material used in one embodiment of the present invention.
FIG. 2 is a view showing a manufacturing process of a laminated iron core by a progressive die apparatus in one embodiment of the present invention.
FIG. 3 is a view for explaining punching of an iron core piece from a laminated material in one embodiment of the present invention.
FIG. 4 is a diagram showing the formation of caulking protrusions on the iron core piece in one embodiment of the present invention.
FIG. 5 is a view showing a part of a caulking stack of iron core pieces in one embodiment of the present invention.
FIG. 6 is a view showing a laminated iron core manufactured in one example of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Amorphous thin plate 2 Adhesive film 3 Metal plate 4 Laminated material 5 Conveyance roll 6 Adhesive roll 7 Guide roll 8 Planned shaft hole area 9 Slot 10 Punch 11 Die 12 Caulking part 13 Stripper 14 Receiving tool 15 Protrusion forming punch 16 Iron core piece 17 Inner shape 18 Outline 19 Stacked core pieces 20 Stacked core

Claims (2)

The method of manufacturing a core for punching caulking laminated core pieces from laminated material comprising an amorphous sheet,
The amorphous thin plate and the metal plate are bonded and integrated through an adhesive film, and the laminated material of the two-layer structure of the amorphous thin plate and the metal plate is passed through the press mold apparatus so that the amorphous thin plate is located on the die surface side. Then, the punch is advanced and retracted from the metal plate side to punch out the laminated material of the two-layer structure to form the required portion and the caulking portion of the iron core piece, and the second and subsequent iron core pieces are narrowed by the protrusion forming punch and the receiving tool. A method of manufacturing a laminated core, comprising: forming a caulking portion as a caulking projection while removing the outer shape of the iron core piece, and caulking and laminating. 2. The method of manufacturing a laminated core according to claim 1, wherein the metal plate bonded to the amorphous thin plate through an adhesive film is an electromagnetic steel plate, a low carbon steel plate, or an Fe—Ni alloy plate.

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