JP4001277B2

JP4001277B2 - Laminated iron core and method for producing laminated iron core

Info

Publication number: JP4001277B2
Application number: JP2002233260A
Authority: JP
Inventors: 徳夫鳥巣
Original assignee: Mitsui High Tech Inc
Current assignee: Mitsui High Tech Inc
Priority date: 2002-08-09
Filing date: 2002-08-09
Publication date: 2007-10-31
Anticipated expiration: 2022-08-09
Also published as: JP2004072983A

Description

【０００１】
【発明の属する技術分野】
本発明は、所定個数の分割ヨーク積層鉄心を互いに接続して成る環形状のヨーク部と、このヨーク部の中心方向に突出する態様で組付けられた所定個数のティース部とを備えて成る積層鉄心、および上述した積層鉄心を製造するための積層鉄心の製造方法に関するものである。
【０００２】
【従来の技術】
図２０は、電動機の固定子を構成する従来の積層鉄心Ａであり、この積層鉄心Ａは、所定枚数の鉄心片Ａａを積層してカシメ結合することによって製造され、環形状のヨーク部Ａｙと該ヨーク部Ａｙから内方に突出した複数のティース部Ａｔ、Ａｔ…とを有している。
【０００３】
上記積層鉄心Ａにおける各ティース部Ａｔには、それぞれ巻線が施されるのであるが、ヨーク部Ａｙが環形状を呈していることと、隣り合うティース部Ａｔ同士の間隔が狭いことから、巻線作業は極めて困難なものとなっていた。
【０００４】
上述した如き問題点を解決する策の１つとして、図２１および図２２に示す如き積層鉄心Ｂが提供されている。
【０００５】
この積層鉄心Ｂは、所定枚数の鉄心片Ｂａを積層して製造される１個のヨーク部Ｂｙと、所定枚数の鉄心片Ｂｂを積層して製造される複数個のティース部Ｂｔとを備え、ヨーク部Ｂｙの内周に形成された組付け溝Ｂｇ、Ｂｇ…にティース部Ｂｔの組付け突起Ｂｄを嵌合させ、上記ティース部Ｂｔをヨーク部Ｂｙの中心方向に突出する態様で組付けることで、環形状のヨーク部Ｂｙと所定数のティース部Ｂｔとを備えた積層鉄心Ｂを構成している。
【０００６】
【発明が解決しようとする課題】
ところで、図２１および図２２に示した積層鉄心Ｂにおいては、個々のティース部Ｂｔに巻線を施したのち、ヨーク部Ｂｙに各ティース部Ｂｔ、Ｂｔ…を組付けて積層鉄心Ｂを製造することにより、個々のティース部Ｂｔに対する巻線作業は極めて容易なものとなる。
【０００７】
しかし、上述した構成の積層鉄心Ｂにおいては、ヨーク部Ｂｙに各ティース部Ｂｔ、Ｂｔ…を組付ける際、ヨーク部Ｂｙの組付け溝Ｂｇにティース部Ｂｔの組付け突起Ｂｄを圧入しているため、この圧入作業時の負荷によって積層鉄心のプロポーションが変形する虞れがあり、特に板厚の薄い、具体的には 0.3mm以下の鉄心片を採用している積層鉄心では顕著な問題となっていた。
【０００８】
本発明は上記実状に鑑みて、巻線作業を容易に実施し得るとともに、製造時におけるプロポーションの変形を未然に防止し得る、積層鉄心および積層鉄心の製造方法を提供することにある。
【０００９】
【課題を解決するための手段】
上記目的を達成するべく、本発明に関わる積層鉄心は、所定個数の分割ヨーク積層鉄心を互いに接続して成る環形状のヨーク部と、前記ヨーク部の中心方向に突出する態様で前記ヨーク部に組付けられた所定個数のティース部とを備えて成る積層鉄心であって、分割ヨーク積層鉄心は互いに積層して結合される第１分割鉄心片および第２分割鉄心片を備え、第１分割鉄心片および第２分割鉄心片は互いに積層された状態において周方向の反対方向に延びる接続端部を有し、第１分割鉄心片の接続端部および第２分割鉄心片の接続端部は互いに隣接する一方の分割ヨーク積層鉄心と他方の分割ヨーク積層鉄心とに亘ってヨーク部の内方に臨むティース部組付け溝を構成する切欠きを有し、第１分割鉄心片における接続端部は突起を備え、第２分割鉄心片における接続端部は周方向に沿って延びる長孔を備え、互いに隣接する一方の分割ヨーク積層鉄心における第１分割鉄心片の突起を他方の分割ヨーク積層鉄心における第２分割鉄心片の長孔に遊嵌させ、所定個数の分割ヨーク積層鉄心を無端状に連結して環形状を呈する前記ヨーク部を拡径自在に構成し、ヨーク部の拡径に伴ってティース部組付け溝を拡大自在に構成している。
【００１０】
また、本発明に関わる積層鉄心の製造方法は、上述した如き構成の積層鉄心を製造する方法であって、薄板材料の所定位置に内径部の開口を形成する工程と、薄板材料に開口を中心として所定数のスロットを形成し所定数のティース相当部を放射状かつ等間隔に形成するとともにティース相当部にカシメ部を形成する工程と、薄板材料からティース相当部を打抜いてティース鉄心片を形成するとともにティース部組付け溝を構成する切欠きを形成しかつティース鉄心片を互いに積層するとともにカシメ結合して所定枚数のティース鉄心片を積層して成るティース部を作成する工程と、薄板材料に切離しを放射状かつ等間隔に入れて所定数の第１分割鉄心片を分離する工程と、薄板材料に切離しを放射状かつ等間隔に入れて所定数の第２分割鉄心片を分離する工程と、各第１分割鉄心片における接続端部に突起を形成する工程と、各第２分割鉄心片における接続端部に長孔を形成する工程と、各第１分割鉄心片および各第２分割鉄心片にカシメ部を形成する工程と、各第１分割鉄心片および各第２分割鉄心片の外径を打ち抜いて個々の第１分割鉄心片および第２分割鉄心片を分離形成するとともに第１分割鉄心片の突起を第２分割鉄心片の長孔に嵌入させた状態で第１分割鉄心片と第２分割鉄心片とを互いに積層してカシメ結合し所定枚数の第１分割鉄心片と第２分割鉄心片とを積層して成る所定個数の分割ヨーク積層鉄心を無端状に連結してヨーク部を作成する工程と、ヨーク部を拡径させてティース部組付け溝を拡大させる工程と、拡大したティース部組付け溝にティース部の組付け突起を挿入する工程と、ヨーク部を製品としての所定形状に縮径させティース部組付け溝を縮小させて該ティース部組付け溝にティース部の組付け突起を嵌合させヨーク部にティース部を組付けて一体に固定する工程とを含んでいる。
【００１１】
【発明の実施の形態】
以下、実施例を示す図面に基づいて、本発明を詳細に説明する。
図１および図２は、電動機の固定子を構成する積層鉄心に本発明を適用した実施例であり、この積層鉄心１は環形状を呈するヨーク部２と、該ヨーク部２の内方に突出する所定数のティース部３、３…とを備えている。
【００１２】
上記積層鉄心１におけるヨーク部２とティース部３とは、互いに別体から構成されており、ヨーク部２における内周の所定位置に形成されたティース部組付け溝２Ｇ(以下、組付け溝２Ｇと称する)に、ティース部３の基端に形成された組付け突起３Ｄを嵌合させ、個々のティース部３をヨーク部２の中心方向に突出する態様で組付けることにより、環形状のヨーク部２と所定数のティース部３とを備えた積層鉄心１が構成されている。
【００１３】
上記積層鉄心１におけるヨーク部２は、所定個数の分割ヨーク積層鉄心１０、１０…を、後述する態様で互いに接続することにより構成され、また上記ヨーク部２における各組付け溝２Ｇ、２Ｇ…は、互いに隣接する一方の分割ヨーク積層鉄心１０と他方の分割ヨーク積層鉄心１０とに亘って、ヨーク部２の内方に臨む態様で形成されている。
【００１４】
一方、上記積層鉄心１における個々のティース部３は、所定枚数のティース鉄心片３ｓを積層し、且つ互いにカシメ結合することによって構成されている。
【００１５】
図３および図４に示す如く、個々の分割ヨーク積層鉄心１０は、所定枚数の第１分割鉄心片１１と第２分割鉄心片１２とを有し、これら第１分割鉄心片１１と第２分割鉄心片１２とを交互に積層し、且つ互いにカシメ結合することによって構成されている。
【００１６】
第１分割鉄心片１１は、図５(ａ)に示す如く湾曲形成されており、一方（図中右方）の端縁は突出した山形に形成され、他方の(図中左方)の端縁は凹んだ山形に形成されており、上記一方の端縁に臨んで切欠き１１ｎが形成されている。
【００１７】
第２分割鉄心片１２は、図５(ｂ)に示す如く湾曲形成されており、上述した第１分割鉄心片１１を反転させた形状を呈し、一方(図中右方)の端縁は凹んだ山形に形成され、他方の(図中左方)の端縁は突出した山形に形成されており、上記他方の端縁に臨んで切欠き１２ｎが形成されている。
【００１８】
図３および図５に示すように、第１分割鉄心片１１および第２分割鉄心片１２は、互いに積層されて分割ヨーク積層鉄心１０を構成した状態(図３参照)において、それぞれ反対方向に延びる接続端部１１ｅおよび接続端部１２ｅを有している。
【００１９】
また、第１分割鉄心片１１と第２分割鉄心片１２とを積層した状態(図３参照)では、第１分割鉄心片１１の接続端部１１ｅに形成した切欠き１１ｎにより、分割ヨーク積層鉄心１０の一方端部に、組付け溝２Ｇ(図２参照)を構成する切欠き１０ｇが形成され、且つ第２分割鉄心片１２の接続端部１２ｅに形成した切欠き１２ｎにより、分割ヨーク積層鉄心１０の他方端部に、組付け溝２Ｇ(図２参照)を構成する切欠き１０ｇが形成されている。
【００２０】
図４および図５に示す如く、第１分割鉄心片１１における接続端部１１ｅには突起１１ｐが形成されている一方、第２分割鉄心片１２における接続端部１２ｅには、上記第２分割鉄心片１２の周方向に沿って延びる長孔１２ｈが形成されている。
【００２１】
図６に示す如く、互いに隣接している分割積層鉄心１０同士は、一方の分割積層鉄心１０における第１分割鉄心片１１の接続端部１１ｅと、他方の分割積層鉄心１０における第２分割鉄心片１２の接続端部１２ｅとを互いに重ね合い、一方の分割積層鉄心１０における第１分割鉄心片１１の突起１１ｐを、他方の分割積層鉄心１０における第２分割鉄心片１２の長孔１２ｈに嵌入した態様で互いに接続されている。
【００２２】
また、積層鉄心１を構成する所定個数の分割積層鉄心１０、１０…は、隣接する分割積層鉄心１０同士が上述した態様で接続されることによって、図１および図２に示す如く無端状に連結されて環形状のヨーク部２を形成している。
【００２３】
また、上述した構成の積層鉄心１においては、図７(ａ)および図８(ａ)に示す如く、隣接する分割積層鉄心１０同士が係合、詳しくは一方の分割積層鉄心１０における第１分割鉄心片１１および第２分割鉄心片１２の端縁が、他方の分割積層鉄心１０における第１分割鉄心片１１および第２分割鉄心片１２の端縁と当接して、所定形状の積層鉄心１を形成している状態から、図７(ｂ)および図８(ｂ)に示す如く、隣接する分割積層鉄心１０同士を、それぞれの周方向に沿って離隔させることができる。
【００２４】
このように、隣接する分割積層鉄心１０同士を周方向に沿って離隔させること、すなわち積層鉄心１における環形状のヨーク部２(図１、２参照)を拡径させることにより、一方の分割ヨーク積層鉄心１０における切欠き１０ｇと、他方の分割ヨーク積層鉄心１０における切欠き１０ｇとから構成されている組付け溝２Ｇが、図７(ａ)から図７(ｂ)に示す如く著しく拡大することとなる。
【００２５】
ここで、環形状のヨーク部２(図１、２参照)を拡径して、組付け溝２Ｇを拡大させることにより、ティース部３における組付け突起３Ｄ(図２参照)を、上記組付け溝２Ｇに挿入させる際、大きな圧力を加えて圧入することなく、極めて容易に挿入させることが可能となる。
【００２６】
一方、各ティース部３，３…は、上述した如くヨーク部２とは別体に構成されているため、個々のティース部３，３…に対する巻線作業を、極めて容易に実施することができる。
【００２７】
また、上記構成の積層鉄心１では、巻線作業を終えたティース部３の組付け突起３Ｄ(図２参照)を、ヨーク部２(図１、２参照)を拡径して拡大させた組付け溝２Ｇに挿入した後、ヨーク部２を製品としての所定形状に縮径させて、隣接する分割積層鉄心１０同士を係合、詳しくは一方の分割積層鉄心１０における第１分割鉄心片１１および第２分割鉄心片１２の端縁を、他方の分割積層鉄心１０における第１分割鉄心片１１および第２分割鉄心片１２の端縁に当接させることで、所定形状の積層鉄心１を構成することができる。
【００２８】
ここで、ヨーク部２を所定形状に縮径させることによって組付け溝２Ｇが縮小し、この縮小した組付け溝２Ｇにティース部３の組付け突起３Ｄが嵌合することにより、ヨーク部２に対してティース部３が一体に組付けられて固定されることとなる。
【００２９】
このように、上述した構成の積層鉄心１においては、ティース部３に対する巻線作業を極めて容易に実施することができ、また圧入作業を要することなくティース部３をヨーク部２に組みつけることができるので、製造時におけるプロポーションの不用意な変形を未然に防止することが可能となる。
【００３０】
以下では、上述した構成の積層鉄心１を製造する方法について説明する。
図９は、本発明に関わる積層鉄心の製造方法に基づいて、図示していない順送り金型装置により加工された帯状鋼板(薄板材料)の平面図であり、積層鉄心１を製造するための順送り金型装置(図示せず)は、内径抜きステーションＩ、スロット抜きステーション II、ティース部打抜き／カシメ結合ステーションIII、第１切離しステーション IV、第２切離しステーションＶ、長孔形成ステーション VI、突起形成ステーション VII、カシメ部形成ステーションVIII、およびヨーク部打抜き／カシメ結合ステーション IXを備えている。
【００３１】
また、順送り金型装置(図示せず)の各ステーションＩ〜 IX では、図１０(ａ)に示す如く所定数の第１分割鉄心片１１、１１…を環状に配置した第１加工パターンＰ１、および図１０(ｂ)に示す如く所定数の第２分割鉄心片１２、１２…を環状に配置した第２加工パターンＰ２により、個々の第１分割鉄心片１１、１１…、および個々の第２分割鉄心片１２、１２…の形成を実施する。
【００３２】
上述した順送り金型装置(図示せず)による積層鉄心の製造工程は、先ず、内径抜きステーションＩにおいて、帯状鋼板(薄板材料)Ｍの所定位置に、後述する各ティース相当部Ｔ(ティース鉄心片３ｓ)における内径部を構成する丸穴状の開口Ｏを形成する。
【００３３】
次いで、スロット抜きステーション II において、開口Ｏの周囲に所定数のスロットＳ、Ｓ…を打抜き、開口Ｏを中心に所定数のティース相当部Ｔを放射状かつ等間隔に形成するとともに、各々のティース相当部Ｔにカシメ部Ｃｔを形成する。
【００３４】
ティース部打抜き／カシメ結合ステーション IIIにおいては、各々のティース相当部Ｔを打抜いてティース鉄心片３ｓを形成する。
【００３５】
ここで、上記ティース部打抜き／カシメ結合ステーション IIIにおいては、ティース鉄心片３ｓを形成すると同時に、製品においてヨーク部２の組付け溝２Ｇ(図２参照)を構成する凹部２ｇ，２ｇ…と、製品においてティース部３の組付け突起３Ｄ(図２参照)を構成する凸部３ｄ，３ｄ…とを形成する。
【００３６】
また、上記ティース部打抜き／カシメ結合ステーション IIIにおいては、次々に打抜き形成されるティース鉄心片３ｓ，３ｓ…を積層するとともに、各々のカシメ部Ｃｔ，Ｃｔ…を介して互いにカシメ結合する。すなわち、ティース鉄心片３ｓを所定の枚数だけ積層し、且つ互いにカシメ結合することによって、所定形状のティース３が製造されることとなる。
【００３７】
第１切離しステーション IV においては、上記凹部２ｇ，２ｇ…の外周領域、すなわちヨーク部の形成領域に、所定数の切離しｓ２、ｓ２…を放射状かつ等間隔に入れて、第２加工パターンＰ２における各第２分割鉄心片１２，１２…を分離する。
【００３８】
第２切離しステーションＶにおいては、上記凹部２ｇ，２ｇ…の外周領域、すなわちヨーク部の形成領域に、所定数の切離しｓ１、ｓ１…を放射状かつ等間隔に入れて、第１加工パターンＰ１における各第１分割鉄心片１１，１１…を分離する。
【００３９】
ここで、ティース部打抜き／カシメ結合ステーション IIIでティース３を製造した後、第１切離しステーション IV における切離しｓ２、ｓ２…の形成、あるいは第２切離しステーションＶにおける切離しｓ１、ｓ１…の形成が、選択的に実施される。
【００４０】
こののち、長孔形成ステーション VI において、第２加工パターンＰ２の各第２分割鉄心片１２における分割ヨーク部１２ｙの接続端部１２ｅに、それぞれ長孔１２ｈを形成する。
【００４１】
次いで、突起形成ステーション VIIにおいて、第１加工パターンＰ１の各第１分割鉄心片１１における分割ヨーク部１１ｙの接続端部１１ｅに、それぞれ突起１１ｐを形成する。
【００４２】
こののち、カシメ部形成ステーション VIII おいて、第１加工パターンＰ１における各第１分割鉄心片１１、および第２加工パターンＰ２における各第２分割鉄心片１２に、それぞれカシメ部Ｃｙを形成する。
【００４３】
ヨーク部打抜き／カシメ結合ステーション IX においては、第１加工パターンＰ１における各第１分割鉄心片１１の外径を打ち抜いて、個々の第１分割鉄心片１１、１１…を分離形成する。
【００４４】
また、ヨーク部打抜き／カシメ結合ステーション IX においては、第２加工パターンＰ２における各第２分割鉄心片１２の外径を打ち抜いて、個々の第２分割鉄心片１２、１２…を分離形成する。
【００４５】
さらに、ヨーク部打抜き／カシメ結合ステーション IX においては、第１加工パターンＰ１における各第１分割鉄心片１１の突起１１ｐを、第２加工パターンＰ２における各第２分割鉄心片１２の長孔１２ｈに嵌入させた状態で、第１加工パターンＰ１の各第１分割鉄心片１１と、第２加工パターンＰ２の各第２分割鉄心片１２とを互いに積層するとともに、各々のカシメ部Ｃｙ、Ｃｙ…を介して互いにカシメ結合する。
【００４６】
すなわち、ヨーク打抜き／カシメ結合ステーション IX では、図１１(ａ)に示す如く、第１加工パターンＰ１における各第１分割鉄心片１１と、第２加工パターンＰ２における各第２分割鉄心片１２とを、それぞれ所定の枚数だけ交互に積層し且つ互いにカシメ結合することで、図１１(ｂ)に示す如く、第１分割鉄心片１１の突起１１ｐと第２分割鉄心片１２の長孔１２ｈとを介して互いに連結された所定数の分割積鉄心１０、１０…が製造され、もって所定数の分割積鉄心１０、１０…を無端状に連結して成る所定形状のヨーク部２が製造される。
【００４７】
ティース部打抜き／カシメ結合ステーション IIIにおいて製造されたティース３を、図示していない順送り金型装置から取り出したのち、図１２に示す如く巻線Ｌの巻回されたボビン４をティース部３に挿入することにより、個々のティース部３，３…に対する巻線作業を実施する。
【００４８】
一方、ヨーク打抜き／カシメ結合ステーション IX において製造されたヨーク部２を、図示していない順送り金型装置から取り出したのち、例えば専用の治具(図示せず)にセットし、図１３に示す如く所定形状を呈しているヨーク部２の内周面から外方に向けて力を加え、図１４に示す如くヨーク部２を拡径させることによって、上記ヨーク部２における各組付け溝２Ｇ，２Ｇ…を拡大させる。
【００４９】
次いで、拡大された各組付け溝２Ｇ，２Ｇ…に対して、既に巻線作業の完了している個々のティース部３，３…、詳しくは個々のティース部３における組付け突起３Ｄを挿入する。
【００５０】
このとき、各組付け溝２Ｇ，２Ｇ…は拡大されているため、ヨーク部２に対するティース部３(組付け突起３Ｄ)の挿入は、圧入等の大きな力を作用させる作業を必要とすることなく、極めてスムーズかつ容易に行われることとなる。
【００５１】
ヨーク部２の各組付け溝２Ｇ，２Ｇ…に、各ティース部３の組付け突起３Ｄを挿入したのち、図１４に示す如く拡径しているヨーク部２の外周面から内方に向けて力を加え、図１５に示す如くヨーク部２を縮径させることによって、上記ヨーク部２における各組付け溝２Ｇ，２Ｇ…を縮小させる。
【００５２】
このとき、ヨーク部２を所定形状に縮径させるで縮小した組付け溝２Ｇ，２Ｇ…に、各ティース部３の組付け突起３Ｄが嵌合することにより、ヨーク部２に対して所定個数のティース部３が一体に組付けられて固定されることとなる。
【００５３】
次いで、ヨーク部２の外周に筒状のフレーム５を勘合することにより、積層鉄心１の各ティース部３，３…に巻線を施して成る、製品としての固定子１００が完成することとなる。
【００５４】
このように、本発明に関わる積層鉄心の製造方法によれば、各ティース部３がヨーク部２と別体に構成されているため、個々のティース部３に対する巻線作業を極めて容易に実施することができる。
【００５５】
また、上述した製造方法によって製造された積層鉄心１は、ヨーク部２を拡径して組付け溝２Ｇを拡大させることにより、ヨーク部２に対してティース部３を組付ける際に、大きな圧力の付加を要する圧入作業を行うことなく、上記組付け溝２Ｇに対してティース部３を容易に挿入させることができる。
【００５６】
このように、本発明に関わる積層鉄心の製造方法においては、ティース部３に対する巻線作業を極めて容易に実施することができ、また圧入作業を要することなくティース部３をヨーク部２に組みつけることができるので、製造時における積層鉄心のプロポーションの変形を未然に防止することが可能となる。
【００５７】
なお、上述した実施例においては、積層鉄心１を構成する全ての第１分割鉄心片１１に突起１１ｐを形成し、また全ての第２分割鉄心片１２に長孔１２ｈを形成しているが、例えば積層鉄心の上層部および下層部、あるいは中層部を構成する数枚の分割鉄心片にのみ突起／長孔を設ける構成であっても、上述した積層鉄心１と同様の作用効果が得られることは言うまでもない。
【００５８】
また、上述した実施例においては、隣接する第１分割鉄心片１１同士、および隣接する第２分割鉄心片１２同士の切離しの形状を山形としているが、上記切離しの形状としては波形状や台形状等、任意の形状を採用し得ることは言うまでもない。
【００５９】
また、積層鉄心を製造する方法の実施例では、第２分割鉄心片１２を分離する切離しｓ２を形成した後、第１分割鉄心片１１を分離する切離しｓ１を形成しているが、これら切離しｓ１、ｓ２の形成順序を逆転させて実施することも可能である。
【００６０】
また、上述した実施例では、第２分割鉄心片１２に長孔１２ｈを形成した後、第１分割鉄心片１１に突起１１ｐを形成しているが、これら長孔１２ｈおよび突起１１ｐの形成順序を逆転させて実施することも可能である。
【００６１】
また、上述した製造方法では、第２分割鉄心片に長孔を形成した後、第１分割鉄心片に突起を形成し、次いで第１分割鉄心片／第２分割鉄心にカシメ部を形成しているが、これら長孔、突起、カシメ部の形成順序も適宜に設定することが可能である。
【００６２】
図１６〜図１９は、電動機の固定子を構成する積層鉄心に本発明を適用した他の実施例であり、この積層鉄心１′は環形状を呈するヨーク部２′と、該ヨーク部２′の内方に突出する所定数のティース部３′、３′…とを備えている。
【００６３】
上記積層鉄心１′におけるヨーク部２′とティース部３′とは、互いに別体から構成されており、所定数のティース部３′，３′…は、各々の柱部を外方へ放射状に展開する姿勢で互いに連結された一体のティース部ユニット３０′を構成している。
【００６４】
また、ヨーク部２′における内周の所定位置に形成された組付け溝（ティース部組付け溝）２Ｇ′に、ティース部ユニット３０′における各ティース部３′の基端に形成された組付け突起３Ｄ′を嵌合させ、個々のティース部３′をヨーク部２′の中心方向に突出する態様で組付けることにより、環形状のヨーク部２′と所定数のティース部３′とを備えた積層鉄心１′が構成されている。
【００６５】
ここで、上述した積層鉄心１′の構成は、所定数のティース部３′が一体のティース部ユニット３０′から構成されている以外、図１〜図８に示した積層鉄心１と基本的に同一なので、積層鉄心１′の構成要素において積層鉄心１の構成要素と同一の作用を成すものには、図１６〜図１９において図１〜図８と同一の符号に′(ダッシュ)を附すことで詳細な説明は省略する。
【００６６】
また、上述した積層鉄心１′の製造方法に関しても、順送り金型装置における製造工程は、所定数のティース部３′を一体のティース部ユニット３０′として形成する以外、図９〜図１１に示した積層鉄心１の製造工程と基本的に同一であり、さらに巻線の施された電動機の固定子を完成させるまでの工程に関しても、図１２〜図１５に示した積層鉄心１の製造工程と基本的に同一である。
【００６７】
すなわち、図示していない順送り金型装置から取り出したティース部ユニット３０′に対して、図１７に示す如く巻線Ｌ′の巻回されたボビン４′を個々のティース部３′，３′…に挿入することで、個々のティース部３′，３′…に対する巻線作業を実施する。
【００６８】
一方、図示していない順送り金型装置から取り出したヨーク部２′を専用の治具(図示せず)にセットし、ヨーク部２′の内周面から外方に向けて力を加えて拡径させ、図１８に示す如く上記ヨーク部２′における各組付け溝２Ｇ′，２Ｇ′…を拡大させる。
【００６９】
次いで、拡大された各組付け溝２Ｇ′，２Ｇ′…に対して、既に巻線作業の完了しているティース部ユニット３０′、詳しくは個々のティース部３′における組付け突起３Ｄ′を挿入したのち、ヨーク部２′の外周面から内方に向けて力を加えて縮径させ、図１９に示す如く上記ヨーク部２′における各組付け溝２Ｇ′，２Ｇ′…を縮小させる。
【００７０】
このとき、ヨーク部２′を所定形状に縮径させるで縮小した組付け溝２Ｇ′，２Ｇ′…に、各ティース部３′の組付け突起３Ｄ′が嵌合することにより、ヨーク部２′に対して所定個数のティース部３′が一体に組付けられて固定されることとなる。
【００７１】
次いで、図１９に示す如くヨーク部２′の外周に筒状のフレーム５′を勘合することで、積層鉄心１′の各ティース部３′，３′…に巻線を施して成る、製品としての固定子１００′が完成することとなる。
【００７２】
以上のように、上述した構成の積層鉄心１′および該積層鉄心１′の製造方法においても、図１〜図１５に示した積層鉄心１および該積層鉄心１の製造方法と同様に、巻線作業を容易に実施し得るとともに製造時におけるプロポーションの変形を未然に防止することができる。
【００７３】
なお、上述した各実施例においては、電動機の固定子を構成する積層鉄心に本発明を適用した例を示したが、電動機の固定子以外の様々な積層鉄心に対しても本発明を有効に適用し得ることは言うまでもない。
【００７４】
【発明の効果】
以上、詳述した如く、本発明に関わる積層鉄心は、所定個数の分割ヨーク積層鉄心を互いに接続して成る環形状のヨーク部と、前記ヨーク部の中心方向に突出する態様で前記ヨーク部に組付けられた所定個数のティース部とを備えて成る積層鉄心であって、分割ヨーク積層鉄心は互いに積層して結合される第１分割鉄心片および第２分割鉄心片を備え、第１分割鉄心片および第２分割鉄心片は互いに積層された状態において周方向の反対方向に延びる接続端部を有し、第１分割鉄心片の接続端部および第２分割鉄心片の接続端部は互いに隣接する一方の分割ヨーク積層鉄心と他方の分割ヨーク積層鉄心とに亘ってヨーク部の内方に臨むティース部組付け溝を構成する切欠きを有し、第１分割鉄心片における接続端部は突起を備え、第２分割鉄心片における接続端部は周方向に沿って延びる長孔を備え、互いに隣接する一方の分割ヨーク積層鉄心における第１分割鉄心片の突起を他方の分割ヨーク積層鉄心における第２分割鉄心片の長孔に遊嵌させ、所定個数の分割ヨーク積層鉄心を無端状に連結して環形状を呈する前記ヨーク部を拡径自在に構成し、ヨーク部の拡径に伴ってティース部組付け溝を拡大自在に構成している。
【００７５】
上記構成によれば、各ティース部はヨーク部と別体に構成されているため、個々のティース部に対する巻線作業を極めて容易に実施することができる。
【００７６】
また、上記構成によれば、ヨーク部を拡径してティース部組付け溝を拡大させることにより、ヨーク部に対してティース部を組付ける際に、大きな圧力の付加を要する圧入作業を行うことなく、上記組付け溝に対してティース部を容易に挿入させることができる。
【００７７】
このように、本発明に関わる積層鉄心においては、ティース部に対する巻線作業を極めて容易に実施することができ、また圧入作業を要することなくティース部をヨーク部に組みつけることができるので、製造時におけるプロポーションの不用意な変形を未然に防止することが可能となる。
【００７８】
一方、本発明に関わる積層鉄心の製造方法は、上述した如き構成の積層鉄心を製造する方法であって、薄板材料の所定位置に内径部の開口を形成する工程と、薄板材料に開口を中心として所定数のスロットを形成し所定数のティース相当部を放射状かつ等間隔に形成するとともにティース相当部にカシメ部を形成する工程と、薄板材料からティース相当部を打抜いてティース鉄心片を形成するとともにティース部組付け溝を構成する切欠きを形成しかつティース鉄心片を互いに積層するとともにカシメ結合して所定枚数のティース鉄心片を積層して成るティース部を作成する工程と、薄板材料に切離しを放射状かつ等間隔に入れて所定数の第１分割鉄心片を分離する工程と、薄板材料に切離しを放射状かつ等間隔に入れて所定数の第２分割鉄心片を分離する工程と、各第１分割鉄心片における接続端部に突起を形成する工程と、各第２分割鉄心片における接続端部に長孔を形成する工程と、各第１分割鉄心片および各第２分割鉄心片にカシメ部を形成する工程と、各第１分割鉄心片および各第２分割鉄心片の外径を打ち抜いて個々の第１分割鉄心片および第２分割鉄心片を分離形成するとともに第１分割鉄心片の突起を第２分割鉄心片の長孔に嵌入させた状態で第１分割鉄心片と第２分割鉄心片とを互いに積層してカシメ結合し所定枚数の第１分割鉄心片と第２分割鉄心片とを積層して成る所定個数の分割ヨーク積層鉄心を無端状に連結してヨーク部を作成する工程と、ヨーク部を拡径させてティース部組付け溝を拡大させる工程と、拡大したティース部組付け溝にティース部の組付け突起を挿入する工程と、ヨーク部を製品としての所定形状に縮径させティース部組付け溝を縮小させて該ティース部組付け溝にティース部の組付け突起を嵌合させヨーク部にティース部を組付けて一体に固定する工程とを含んでいる。
【００７９】
上記構成によれば、ヨーク部と該ヨーク部に組付けられた所定個数のティース部とを備えるとともに、環形状を呈するヨーク部が拡径自在に構成され、且つヨーク部の拡径に伴ってティース部組付け溝が拡大自在に構成された積層鉄心が製造されることとなる。
【００８０】
すなわち、上述した製造方法によって製造された積層鉄心は、各ティース部がヨーク部と別体に構成されているため、個々のティース部に対する巻線作業を極めて容易に実施することができる。
【００８１】
また、上述した製造方法によって製造された積層鉄心は、ヨーク部を拡径してティース部組付け溝を拡大させることにより、ヨーク部に対してティース部を組付ける際に、大きな圧力の付加を要する圧入作業を行うことなく、上記組付け溝に対してティース部を容易に挿入させることができる。
【００８２】
このように、本発明に関わる積層鉄心の製造方法においては、ティース部に対する巻線作業を極めて容易に実施することができ、また圧入作業を要することなくティース部をヨーク部に組付けることができるので、製造時における積層鉄心のプロポーションの変形を未然に防止することが可能となる。
【図面の簡単な説明】
【図１】 (ａ)および(ｂ)は、本発明に関わる積層鉄心の一実施例を上面側から観た斜視図および底面側から観た斜視図。
【図２】図１に示した積層鉄心の上面図。
【図３】図１に示した積層鉄心を構成する分割積層鉄心の上面図。
【図４】図１に示した積層鉄心を構成する分割積層鉄心の図３中におけるIV−IV線断面図。
【図５】 (ａ)および(ｂ)は、図１に示した積層鉄心における分割積層鉄心を構成する第１分割鉄心片および第２分割鉄心片の平面図。
【図６】図１に示した積層鉄心を構成する分割積層鉄心同士における連結部の図２中におけるVI−VI線断面図。
【図７】 (ａ)および(ｂ)は、図１の積層鉄心における変形態様を示す要部平面図。
【図８】 (ａ)および(ｂ)は、図１の積層鉄心における変形態様を示す要部断面図。
【図９】本発明に関わる積層鉄心の製造方法における順送り金型装置の各ステーションでの加工工程を示した帯状鋼板の平面図。
【図１０】 (ａ)および(ｂ)は、本発明に関わる積層鉄心の製造方法におけるヨーク部打抜き／カシメ結合工程で打抜き形成される分割鉄心片を示す平面図。
【図１１】 (ａ)および(ｂ)は、本発明に関わる積層鉄心の製造方法におけるヨーク部打抜き／カシメ結合工程で積層される分割鉄心片を概念的に示す要部断面図。
【図１２】 (ａ)および(ｂ)は、図１の積層鉄心おけるティース部への巻線作業を概念的に示す平面図。
【図１３】図１の積層鉄心におけるヨーク部を概念的に示す平面図。
【図１４】図１の積層鉄心におけるヨーク部へのティース部の組付け作業を概念的に示す全体平面図。
【図１５】図１に示した積層鉄心に巻線を施した状態の固定子を概念的に示す全体平面図。
【図１６】本発明に関わる積層鉄心の他の実施例を示す概念的な全体平面図。
【図１７】図１６の積層鉄心おけるティース部への巻線作業を概念的に示す平面図。
【図１８】図１６の積層鉄心におけるヨーク部を概念的に示す平面図。
【図１９】図１６に示した積層鉄心に巻線を施した状態の固定子を概念的に示す全体平面図。
【図２０】従来の積層鉄心を示す外観斜視図。
【図２１】従来の他の積層鉄心を示す外観斜視図。
【図２２】 (ａ)および(ｂ)は、図２２に示した積層鉄心のティース部およびヨーク部を示す外観斜視図。
【符号の説明】
１、１′…積層鉄心、
２、２′…ヨーク部、
２Ｇ、２Ｇ′…ティース部組付け溝、
３、３′…ティース部、
３Ｄ、３Ｄ′…組付け突起、
３ｓ…ティース鉄心片、
１０…分割ヨーク積層鉄心、
１０ｇ…切欠き、
１１…第１分割鉄心片、
１１ｎ…切欠き、
１１ｐ…突起、
１２…第２分割鉄心片、
１２ｎ…切欠き、
１２ｈ…長孔、
Ｍ…帯状鋼板(薄板材料)、
Ｏ…開口、
Ｓ…スロット、
ｓ１、ｓ２…切離し、
Ｃｔ、Ｃｙ…カシメ部。[0001]
BACKGROUND OF THE INVENTION
The present invention provides a laminate comprising a ring-shaped yoke portion formed by connecting a predetermined number of divided yoke laminated iron cores to each other, and a predetermined number of teeth portions assembled in a manner protruding in the center direction of the yoke portion. The present invention relates to an iron core and a method for producing a laminated iron core for producing the laminated iron core described above.
[0002]
[Prior art]
FIG. 20 shows a conventional laminated iron core A constituting a stator of an electric motor. The laminated iron core A is manufactured by laminating a predetermined number of iron core pieces Aa and caulking and joining them, and an annular yoke portion Ay and A plurality of teeth portions At, At... Projecting inward from the yoke portion Ay.
[0003]
Each tooth portion At in the laminated iron core A is wound with a coil, but the winding of the yoke portion Ay has a ring shape and the interval between adjacent tooth portions At is narrow. Line work has become extremely difficult.
[0004]
As one of the measures for solving the above-described problems, a laminated iron core B as shown in FIGS. 21 and 22 is provided.
[0005]
The laminated core B includes one yoke part By manufactured by stacking a predetermined number of core pieces Ba, and a plurality of teeth parts Bt manufactured by stacking a predetermined number of core pieces Bb. The assembly protrusion Bd of the teeth portion Bt is fitted into the assembly grooves Bg, Bg... Formed on the inner periphery of the yoke portion By, and the teeth portion Bt is assembled in a manner protruding in the center direction of the yoke portion By. Thus, a laminated iron core B having an annular yoke part By and a predetermined number of teeth parts Bt is configured.
[0006]
[Problems to be solved by the invention]
Incidentally, in the laminated core B shown in FIG. 21 and FIG. 22, after the individual teeth Bt are wound, the teeth Bt, Bt,... Are assembled to the yoke part By to produce the laminated core B. As a result, the winding work for the individual teeth Bt becomes extremely easy.
[0007]
However, in the laminated core B having the above-described configuration, when the teeth Bt, Bt... Are assembled to the yoke part By, the assembly protrusion Bd of the tooth part Bt is press-fitted into the assembly groove Bg of the yoke part By. Therefore, there is a risk that the proportion of the laminated core will be deformed by the load during this press-fitting operation, and this is a significant problem especially in laminated cores that use thin core pieces, specifically, core pieces of 0.3 mm or less. It was.
[0008]
In view of the above situation, the present invention is to provide a laminated core and a method for producing a laminated core, which can easily perform a winding operation and can prevent a deformation of a proportion at the time of manufacture.
[0009]
[Means for Solving the Problems]
In order to achieve the above object, a laminated iron core according to the present invention includes a ring-shaped yoke portion formed by connecting a predetermined number of divided yoke laminated iron cores to each other, and a protruding manner toward the center of the yoke portion. A laminated iron core comprising a predetermined number of assembled tooth portions, wherein the divided yoke laminated iron core includes a first divided iron core piece and a second divided iron core piece which are laminated and joined to each other, and the first divided iron core The piece and the second divided core piece have connection end portions extending in opposite directions in the circumferential direction in a state where they are laminated with each other, and the connection end portion of the first divided core piece and the connection end portion of the second divided core piece are adjacent to each other And a notch that constitutes a tooth assembly groove facing the inside of the yoke portion across the one divided yoke laminated core and the other divided yoke laminated iron core, and the connecting end portion of the first divided iron core piece projects With the second minute The connecting end portion of the iron core piece has a long hole extending along the circumferential direction, and the protrusion of the first divided iron core piece in one of the divided yoke laminated cores adjacent to each other is the length of the second divided iron core piece in the other divided yoke laminated core. The yoke part, which is ring-shaped by freely fitting into the hole and connecting a predetermined number of split yoke laminated cores in an endless manner, is configured to be able to expand the diameter, and the tooth assembly mounting groove is expanded as the diameter of the yoke part increases. It is configured freely.
[0010]
The method for manufacturing a laminated core according to the present invention is a method for producing a laminated core having the above-described configuration, the step of forming an opening of the inner diameter portion at a predetermined position of the thin plate material, and the opening in the thin plate material. Forming a predetermined number of slots, forming a predetermined number of teeth corresponding portions radially and at equal intervals, and forming a caulking portion on the teeth corresponding portion, and punching the teeth corresponding portion from a thin plate material to form a tooth core piece And forming a notch that constitutes the teeth assembling groove and laminating the teeth core pieces together and caulking them together to create a teeth portion formed by laminating a predetermined number of teeth core pieces, and a sheet material A step of separating a predetermined number of first divided iron core pieces with radial separation at equal intervals, and a predetermined number of second divided irons with radial separation at equal intervals A step of separating the pieces, a step of forming protrusions at the connection end portions of the first divided core pieces, a step of forming long holes at the connection end portions of the second divided core pieces, and the first divided core pieces. And a step of forming a crimping portion on each second divided core piece, and punching out the outer diameter of each first divided core piece and each second divided core piece to separate individual first divided core pieces and second divided core pieces. The first divided core pieces and the second divided core pieces are stacked and caulked and joined together in a state where the protrusions of the first divided core pieces are inserted into the long holes of the second divided core pieces. A step of connecting endlessly a predetermined number of divided yoke laminated cores formed by laminating the divided iron core pieces and the second divided iron core pieces to create a yoke portion, and expanding the yoke portion to provide a tooth portion assembling groove The process of expanding and assembling the teeth section in the expanded teeth section mounting groove A step of inserting a protrusion, a diameter of the yoke portion is reduced to a predetermined shape as a product, a tooth portion mounting groove is reduced, and a tooth portion mounting groove is fitted into the tooth portion mounting groove so that the teeth are attached to the yoke portion. And assembling and fixing the parts together.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail with reference to the drawings illustrating embodiments.
1 and 2 show an embodiment in which the present invention is applied to a laminated iron core constituting a stator of an electric motor. This laminated iron core 1 has a ring-shaped yoke portion 2 and an inward protruding portion of the yoke portion 2. A predetermined number of teeth portions 3, 3.
[0012]
The yoke part 2 and the tooth part 3 in the laminated core 1 are formed separately from each other, and the tooth part assembly groove 2G (hereinafter referred to as the assembly groove 2G) formed at a predetermined position on the inner periphery of the yoke part 2. Is attached to the base end of the tooth portion 3 and the individual tooth portions 3 are assembled in a manner protruding in the center direction of the yoke portion 2, whereby an annular yoke is assembled. A laminated core 1 including a portion 2 and a predetermined number of teeth portions 3 is configured.
[0013]
The yoke portion 2 in the laminated core 1 is configured by connecting a predetermined number of divided yoke laminated cores 10, 10... In a manner described later, and each assembly groove 2G, 2G. The first and second divided yoke laminated iron cores 10 and 10 are formed so as to face the inside of the yoke portion 2.
[0014]
On the other hand, each tooth portion 3 in the laminated core 1 is configured by laminating a predetermined number of teeth core pieces 3s and caulking them together.
[0015]
As shown in FIGS. 3 and 4, each divided yoke laminated core 10 has a predetermined number of first divided core pieces 11 and second divided core pieces 12, and these first divided core pieces 11 and second divided pieces. It is configured by alternately laminating the core pieces 12 and caulking together.
[0016]
As shown in FIG. 5 (a), the first divided iron core piece 11 is formed in a curved shape, with one end (right side in the figure) having a protruding chevron and the other end (left side in the figure). The edge is formed in a concave mountain shape, and a notch 11n is formed facing the one end edge.
[0017]
The second divided core piece 12 is curved as shown in FIG. 5B and has a shape obtained by inverting the first divided core piece 11 described above, and one end (right side in the figure) is recessed. The other edge (left side in the figure) is formed in a protruding mountain shape, and a notch 12n is formed facing the other edge.
[0018]
As shown in FIGS. 3 and 5, the first divided iron core piece 11 and the second divided iron core piece 12 extend in opposite directions in a state in which the divided yoke laminated iron core 10 is formed by being laminated with each other (see FIG. 3). It has a connection end 11e and a connection end 12e.
[0019]
In the state where the first divided core piece 11 and the second divided core piece 12 are laminated (see FIG. 3), the divided yoke laminated core is formed by the notch 11n formed in the connection end portion 11e of the first divided core piece 11. 10 is formed with a notch 10g forming an assembly groove 2G (see FIG. 2), and a notch 12n formed at a connection end 12e of the second segmented core piece 12 has a split yoke laminated core. A notch 10g that constitutes the assembly groove 2G (see FIG. 2) is formed at the other end of 10.
[0020]
As shown in FIGS. 4 and 5, a projection 11p is formed on the connection end portion 11e of the first divided core piece 11, while the second divided core is formed on the connection end portion 12e of the second divided core piece 12. A long hole 12h extending along the circumferential direction of the piece 12 is formed.
[0021]
As shown in FIG. 6, the divided laminated cores 10 adjacent to each other include a connection end portion 11 e of the first divided iron core piece 11 in one divided laminated iron core 10 and a second divided iron core piece in the other divided laminated iron core 10. 12 connecting end portions 12e are overlapped with each other, and the protrusion 11p of the first divided core piece 11 in one divided laminated core 10 is fitted into the long hole 12h of the second divided core piece 12 in the other divided laminated core 10. Are connected to each other in a manner.
[0022]
Further, the predetermined number of divided laminated cores 10, 10... Constituting the laminated core 1 are connected endlessly as shown in FIGS. 1 and 2 by connecting the adjacent divided laminated cores 10 in the manner described above. Thus, the ring-shaped yoke portion 2 is formed.
[0023]
Moreover, in the laminated core 1 of the structure mentioned above, as shown to Fig.7 (a) and FIG.8 (a), adjacent division | stacking laminated cores 10 engage, and the 1st division | segmentation in one division | segmentation laminated core 10 in detail. The edge of the iron core piece 11 and the second divided iron core piece 12 is in contact with the edge of the first iron core piece 11 and the second iron core piece 12 in the other divided laminated iron core 10 so that the laminated iron core 1 having a predetermined shape is obtained. From the formed state, as shown in FIGS. 7B and 8B, the adjacent divided laminated cores 10 can be separated from each other in the circumferential direction.
[0024]
Thus, by separating the adjacent divided laminated cores 10 from each other in the circumferential direction, that is, by expanding the diameter of the ring-shaped yoke portion 2 (see FIGS. 1 and 2) in the laminated core 1, one divided yoke is obtained. The assembly groove 2G composed of the notch 10g in the laminated core 10 and the notch 10g in the other divided yoke laminated core 10 is significantly enlarged as shown in FIGS. 7 (a) to 7 (b). It becomes.
[0025]
Here, the ring-shaped yoke portion 2 (see FIGS. 1 and 2) is expanded in diameter, and the assembly groove 2G is expanded, so that the assembly protrusion 3D (see FIG. 2) in the tooth portion 3 is attached to the assembly portion. When inserting into the groove 2G, it can be inserted very easily without applying a large pressure and press-fitting.
[0026]
On the other hand, since each tooth part 3,3 ... is comprised separately from the yoke part 2 as mentioned above, the winding operation | work with respect to each tooth part 3,3 ... can be implemented very easily. .
[0027]
Further, in the laminated core 1 having the above-described configuration, the assembly protrusion 3D (see FIG. 2) of the tooth portion 3 after the winding work is expanded by expanding the diameter of the yoke portion 2 (see FIGS. 1 and 2). After inserting into the attaching groove 2G, the yoke part 2 is reduced in diameter to a predetermined shape as a product, and the adjacent divided laminated cores 10 are engaged with each other. Specifically, the first divided core pieces 11 in one divided laminated core 10 and The laminated core 1 having a predetermined shape is configured by bringing the end edge of the second divided core piece 12 into contact with the end edges of the first divided core piece 11 and the second divided core piece 12 in the other divided laminated core 10. be able to.
[0028]
Here, by reducing the diameter of the yoke part 2 to a predetermined shape, the assembly groove 2G is reduced, and the assembly protrusion 3D of the teeth part 3 is fitted into the reduced installation groove 2G, whereby the yoke part 2 is On the other hand, the teeth part 3 is assembled and fixed integrally.
[0029]
Thus, in the laminated iron core 1 having the above-described configuration, the winding work on the tooth portion 3 can be performed very easily, and the tooth portion 3 can be assembled to the yoke portion 2 without requiring a press-fitting operation. Therefore, it is possible to prevent inadvertent deformation of the proportion at the time of manufacture.
[0030]
Below, the method to manufacture the laminated core 1 of the structure mentioned above is demonstrated.
FIG. 9 is a plan view of a strip-shaped steel plate (thin plate material) processed by a progressive die apparatus (not shown) based on the method for producing a laminated core according to the present invention. The die unit (not shown) is made up of an inner diameter punching station I, a slot punching station II, a teeth punching / crimping station III, a first cutting station IV, a second cutting station V, a long hole forming station VI, a projection forming station. VII, a crimping part forming station VIII, and a yoke part punching / crimping station IX.
[0031]
Further, in each station I to IX of the progressive die apparatus (not shown), as shown in FIG. 10 (a), a first processing pattern P1, in which a predetermined number of first divided core pieces 11, 11,. As shown in FIG. 10 (b), each of the first divided core pieces 11, 11,... And each of the second divided core pieces 12, 11,... The division | segmentation iron core pieces 12, 12 ... are formed.
[0032]
In the manufacturing process of the laminated core by the progressive die apparatus (not shown) described above, first, at the inner diameter removing station I, each tooth-corresponding portion T (teeth core piece) described later is placed at a predetermined position of the strip steel plate (thin plate material) M. A round hole-shaped opening O constituting the inner diameter portion in 3 s) is formed.
[0033]
Next, in the slot removal station II, a predetermined number of slots S, S... Are punched around the opening O, and a predetermined number of teeth corresponding portions T are formed radially and equidistantly around the opening O, corresponding to each tooth. A crimped portion Ct is formed in the portion T.
[0034]
In the tooth part punching / crimping station III, each tooth equivalent part T is punched to form a tooth core piece 3s.
[0035]
Here, in the tooth part punching / crimping station III, the tooth core pieces 3s are formed, and at the same time, recesses 2g, 2g... Constituting the assembly groove 2G (see FIG. 2) of the yoke part 2 in the product, In FIG. 2, the projections 3d, 3d,.
[0036]
In the tooth part punching / crimping station III, the teeth core pieces 3s, 3s,... Which are successively punched and formed are stacked and caulked and connected to each other via the respective caulking parts Ct, Ct,. That is, a predetermined number of teeth 3 are manufactured by laminating a predetermined number of teeth core pieces 3s and caulking them together.
[0037]
In the first separation station IV, a predetermined number of separations s2, s2,... Are radially and equally spaced in the outer peripheral area of the recesses 2g, 2g. 2nd division | segmentation iron core pieces 12, 12, ... are isolate | separated.
[0038]
In the second separation station V, a predetermined number of separations s1, s1,... Are radially and equally spaced in the outer peripheral area of the recesses 2g, 2g. 1st division | segmentation iron core piece 11,11 ... is isolate | separated.
[0039]
Here, after the teeth 3 are manufactured at the teeth cutting / crimping station III, the formation of the separations s2, s2,... At the first separation station IV, or the formation of the separations s1, s1,. Implemented.
[0040]
After that, at the long hole forming station VI, the long holes 12h are formed in the connection end portions 12e of the divided yoke portions 12y in the second divided core pieces 12 of the second processed pattern P2.
[0041]
Next, in the projection forming station VII, the projections 11p are formed on the connection end portions 11e of the divided yoke portions 11y in the first divided core pieces 11 of the first processing pattern P1, respectively.
[0042]
Thereafter, in the crimping portion forming station VIII, the crimping portion Cy is formed in each of the first divided core pieces 11 in the first machining pattern P1 and in each of the second divided core pieces 12 in the second machining pattern P2.
[0043]
In the yoke punching / crimping station IX, the outer diameters of the first divided core pieces 11 in the first processing pattern P1 are punched to separate and form the first divided core pieces 11, 11.
[0044]
In the yoke punching / crimping station IX, the outer diameter of each of the second divided core pieces 12 in the second machining pattern P2 is punched to separate and form the individual second divided core pieces 12, 12,.
[0045]
Furthermore, at the yoke punching / crimping station IX, the projections 11p of the first divided core pieces 11 in the first machining pattern P1 are fitted into the long holes 12h of the second divided core pieces 12 in the second machining pattern P2. In this state, the first divided core pieces 11 of the first machining pattern P1 and the second divided core pieces 12 of the second machining pattern P2 are stacked on each other, and the caulking portions Cy, Cy,. And are caulked together.
[0046]
That is, at the yoke punching / crimping station IX, as shown in FIG. 11A, the first divided core pieces 11 in the first machining pattern P1 and the second divided core pieces 12 in the second machining pattern P2 are combined. Then, by laminating a predetermined number of sheets alternately and crimping them together, as shown in FIG. 11 (b), the projections 11p of the first divided core piece 11 and the long holes 12h of the second divided core piece 12 are interposed. Thus, a predetermined number of divided product cores 10, 10... Connected to each other are manufactured, and thus a predetermined shape yoke portion 2 formed by connecting a predetermined number of divided product cores 10,.
[0047]
After the teeth 3 manufactured at the tooth part punching / crimping station III are taken out from a progressive mold apparatus (not shown), the bobbin 4 around which the winding L is wound is inserted into the teeth part 3 as shown in FIG. By doing so, the winding operation | work with respect to each teeth part 3,3 ... is implemented.
[0048]
On the other hand, after the yoke part 2 manufactured in the yoke punching / crimping station IX is taken out from a progressive mold apparatus (not shown), it is set in a dedicated jig (not shown), for example, as shown in FIG. By applying a force outward from the inner peripheral surface of the yoke part 2 having a predetermined shape and expanding the diameter of the yoke part 2 as shown in FIG. Enlarge….
[0049]
Next, the individual tooth portions 3, 3..., Which have already been wound, are inserted into the enlarged assembly grooves 2 G, 2 G. .
[0050]
At this time, since each of the assembly grooves 2G, 2G... Is enlarged, the insertion of the teeth part 3 (assembly protrusion 3D) into the yoke part 2 does not require a work for applying a large force such as press-fitting. It will be done very smoothly and easily.
[0051]
After inserting the assembly protrusion 3D of each tooth portion 3 into each of the assembly grooves 2G, 2G... Of the yoke portion 2, as shown in FIG. Applying force to reduce the diameter of the yoke portion 2 as shown in FIG. 15, the size of each of the mounting grooves 2G, 2G,.
[0052]
At this time, assembling projections 3D of the respective tooth portions 3 are fitted into the assembling grooves 2G, 2G..., Which are reduced by reducing the diameter of the yoke portion 2 to a predetermined shape. The teeth part 3 is assembled and fixed integrally.
[0053]
Next, by fitting the cylindrical frame 5 to the outer periphery of the yoke portion 2, the stator 100 as a product is completed, which is formed by winding the teeth portions 3, 3,. .
[0054]
Thus, according to the manufacturing method of the laminated core concerning this invention, since each teeth part 3 is comprised separately from the yoke part 2, the winding operation | work with respect to each teeth part 3 is implemented very easily. be able to.
[0055]
Further, the laminated core 1 manufactured by the above-described manufacturing method has a large pressure when the tooth portion 3 is assembled to the yoke portion 2 by expanding the diameter of the yoke portion 2 and expanding the assembly groove 2G. The tooth portion 3 can be easily inserted into the assembly groove 2G without performing a press-fitting operation requiring the addition of.
[0056]
As described above, in the method of manufacturing a laminated core according to the present invention, the winding work on the tooth portion 3 can be performed very easily, and the tooth portion 3 is assembled to the yoke portion 2 without requiring a press-fitting operation. Therefore, it becomes possible to prevent the proportion of the laminated iron core from being deformed at the time of manufacture.
[0057]
In the embodiment described above, the protrusions 11p are formed on all the first divided core pieces 11 constituting the laminated core 1, and the long holes 12h are formed on all the second divided core pieces 12. For example, even if it is the structure which provides protrusions / long holes only in several divided core pieces constituting the upper layer portion and the lower layer portion or the middle layer portion of the laminated core, it is possible to obtain the same effect as the laminated core 1 described above. Needless to say.
[0058]
Moreover, in the Example mentioned above, although the shape of separation of adjacent 1st division | segmentation core pieces 11 and adjacent 2nd division | segmentation core pieces 12 is made into the mountain shape, as said separation shape, it is a wave shape or trapezoid shape. Needless to say, any shape can be adopted.
[0059]
In the embodiment of the method of manufacturing the laminated core, the cut s2 for separating the second divided core piece 12 is formed, and then the cut s1 for separating the first divided core piece 11 is formed. , S2 can be formed in reverse order.
[0060]
Further, in the above-described embodiment, after the long holes 12h are formed in the second divided core piece 12, the protrusions 11p are formed in the first divided core piece 11, but the formation order of the long holes 12h and the protrusions 11p is changed. It is also possible to carry out in reverse.
[0061]
Further, in the manufacturing method described above, after forming a long hole in the second divided core piece, forming a protrusion on the first divided core piece, and then forming a crimped portion on the first divided core piece / second divided core. However, the order of forming these long holes, protrusions, and caulking portions can be set as appropriate.
[0062]
FIGS. 16 to 19 show another embodiment in which the present invention is applied to a laminated iron core constituting a stator of an electric motor. The laminated iron core 1 ′ includes a yoke portion 2 ′ having a ring shape and the yoke portion 2 ′. Are provided with a predetermined number of teeth portions 3 ', 3',.
[0063]
In the laminated core 1 ', the yoke portion 2' and the teeth portion 3 'are formed separately from each other, and the predetermined number of teeth portions 3', 3 '... An integral teeth unit 30 'connected to each other in a deployed posture is formed.
[0064]
In addition, an assembly groove formed at a predetermined position on the inner periphery of the yoke portion 2 '(tooth portion assembly groove) 2G' is assembled at the base end of each tooth portion 3 'in the tooth portion unit 30'. By fitting the protrusions 3D ′ and assembling the individual tooth portions 3 ′ so as to protrude toward the center of the yoke portion 2 ′, an annular yoke portion 2 ′ and a predetermined number of teeth portions 3 ′ are provided. A laminated core 1 'is formed.
[0065]
Here, the structure of the laminated core 1 ′ described above is basically the same as that of the laminated core 1 shown in FIGS. 1 to 8 except that a predetermined number of teeth portions 3 ′ are constituted by an integral teeth portion unit 30 ′. Since they are the same, components having the same action as the components of the laminated core 1 in the laminated core 1 'are denoted by the same reference numerals as those in FIGS. Detailed description will be omitted.
[0066]
Further, regarding the manufacturing method of the laminated core 1 ′ described above, the manufacturing process in the progressive die apparatus is shown in FIGS. 9 to 11 except that a predetermined number of teeth portions 3 ′ are formed as an integral teeth portion unit 30 ′. The manufacturing process of the laminated iron core 1 shown in FIGS. 12 to 15 is basically the same as the manufacturing process of the laminated iron core 1 and the process until the stator of the electric motor with the windings is completed. Basically the same.
[0067]
That is, the bobbin 4 'around which the winding L' is wound as shown in FIG. 17 is applied to the individual tooth portions 3 ', 3'. By inserting the wire into the wire, the winding work is performed on each of the tooth portions 3 ', 3'.
[0068]
On the other hand, the yoke part 2 'taken out from a progressive die apparatus (not shown) is set in a dedicated jig (not shown), and is expanded by applying a force outward from the inner peripheral surface of the yoke part 2'. As shown in FIG. 18, the assembly grooves 2G ′, 2G ′... In the yoke portion 2 ′ are enlarged.
[0069]
Then, a tooth portion unit 30 ', which has already been wound, is inserted into each of the enlarged assembly grooves 2G', 2G ', more specifically, the assembly protrusion 3D' in each tooth portion 3 '. After that, a force is applied inward from the outer peripheral surface of the yoke portion 2 'to reduce the diameter, and the assembly grooves 2G', 2G ', etc. in the yoke portion 2' are reduced as shown in FIG.
[0070]
At this time, assembling projections 3D ′ of the respective tooth portions 3 ′ are fitted into the assembling grooves 2G ′, 2G ′,... Reduced by reducing the diameter of the yoke portion 2 ′ to a predetermined shape, whereby the yoke portion 2 ′. On the other hand, a predetermined number of tooth portions 3 'are assembled and fixed integrally.
[0071]
Next, as shown in FIG. 19, by fitting a cylindrical frame 5 'to the outer periphery of the yoke portion 2', winding the teeth portions 3 ', 3' ... of the laminated core 1 'as a product. This completes the stator 100 '.
[0072]
As described above, in the laminated core 1 ′ having the above-described configuration and the method for manufacturing the laminated core 1 ′, as in the laminated core 1 and the method for manufacturing the laminated core 1 shown in FIGS. Work can be easily performed, and deformation of the proportion at the time of manufacture can be prevented.
[0073]
In each of the above-described embodiments, the example in which the present invention is applied to the laminated iron core constituting the stator of the electric motor has been shown. However, the present invention is effectively applied to various laminated iron cores other than the stator of the electric motor. It goes without saying that it can be applied.
[0074]
【The invention's effect】
As described above in detail, the laminated iron core according to the present invention includes an annular yoke portion formed by connecting a predetermined number of divided yoke laminated iron cores to each other, and a protruding shape in the central direction of the yoke portion. A laminated iron core comprising a predetermined number of assembled tooth portions, wherein the divided yoke laminated iron core includes a first divided iron core piece and a second divided iron core piece which are laminated and joined to each other, and the first divided iron core The piece and the second divided core piece have connection end portions extending in opposite directions in the circumferential direction in a state where they are laminated with each other, and the connection end portion of the first divided core piece and the connection end portion of the second divided core piece are adjacent to each other And a notch that constitutes a tooth assembly groove facing the inside of the yoke portion across the one divided yoke laminated core and the other divided yoke laminated iron core, and the connecting end portion of the first divided iron core piece projects The second divided iron The connecting end portion of the piece has a long hole extending in the circumferential direction, and the protrusion of the first divided core piece in one of the divided yoke laminated cores adjacent to each other is the long hole of the second divided core piece in the other divided yoke laminated core. The yoke part, which has a ring shape, can be expanded freely by connecting it to the endlessly of a predetermined number of divided yoke laminated cores, and the teeth assembling groove can be expanded as the yoke part expands. It is configured.
[0075]
According to the said structure, since each teeth part is comprised separately from the yoke part, the winding operation | work with respect to each teeth part can be implemented very easily.
[0076]
In addition, according to the above configuration, when the tooth portion is assembled to the yoke portion by performing a press-fitting operation that requires a large pressure by expanding the diameter of the yoke portion and expanding the tooth portion assembling groove. The teeth portion can be easily inserted into the assembly groove.
[0077]
Thus, in the laminated iron core according to the present invention, the winding work on the tooth part can be performed very easily, and the tooth part can be assembled to the yoke part without the need for press-fitting work. It becomes possible to prevent inadvertent deformation of the proportion at the time.
[0078]
On the other hand, the method for manufacturing a laminated core according to the present invention is a method for producing a laminated core having the above-described structure, and includes a step of forming an opening of an inner diameter portion at a predetermined position of a thin plate material, and a center of the opening in the thin plate material. Forming a predetermined number of slots, forming a predetermined number of teeth corresponding portions radially and at equal intervals, and forming a caulking portion on the teeth corresponding portion, and punching the teeth corresponding portion from a thin plate material to form a tooth core piece And forming a notch that constitutes the teeth assembling groove and laminating the teeth core pieces together and caulking them together to create a teeth portion formed by laminating a predetermined number of teeth core pieces, and a sheet material A step of separating a predetermined number of first divided iron core pieces with radial separation at equal intervals, and a predetermined number of second divided irons with radial separation at equal intervals A step of separating the pieces, a step of forming protrusions at the connection end portions of the first divided core pieces, a step of forming long holes at the connection end portions of the second divided core pieces, and the first divided core pieces. And a step of forming a crimping portion on each second divided core piece, and punching out the outer diameter of each first divided core piece and each second divided core piece to separate individual first divided core pieces and second divided core pieces. The first divided core pieces and the second divided core pieces are stacked and caulked and joined together in a state where the protrusions of the first divided core pieces are inserted into the long holes of the second divided core pieces. A step of connecting endlessly a predetermined number of divided yoke laminated cores formed by laminating the divided iron core pieces and the second divided iron core pieces to create a yoke portion, and expanding the yoke portion to provide a tooth portion assembling groove The process of expanding and assembling the teeth section in the expanded teeth section mounting groove A step of inserting a protrusion, a diameter of the yoke portion is reduced to a predetermined shape as a product, a tooth portion mounting groove is reduced, and a tooth portion mounting groove is fitted into the tooth portion mounting groove so that the teeth are attached to the yoke portion. And assembling and fixing the parts together.
[0079]
According to the above configuration, the yoke portion and the predetermined number of teeth portions assembled to the yoke portion are provided, and the yoke portion having an annular shape is configured to be able to expand the diameter, and as the diameter of the yoke portion increases. A laminated core in which the teeth assembling grooves are configured to be expandable is manufactured.
[0080]
That is, in the laminated iron core manufactured by the above-described manufacturing method, each tooth portion is configured separately from the yoke portion, so that the winding operation for each tooth portion can be performed very easily.
[0081]
In addition, the laminated iron core manufactured by the above-described manufacturing method applies a large pressure when the tooth portion is assembled to the yoke portion by expanding the diameter of the yoke portion and expanding the tooth portion assembling groove. The teeth portion can be easily inserted into the assembly groove without performing the necessary press-fitting work.
[0082]
As described above, in the method of manufacturing a laminated core according to the present invention, the winding work on the tooth portion can be performed very easily, and the tooth portion can be assembled to the yoke portion without requiring press-fitting work. Therefore, it becomes possible to prevent deformation of the proportion of the laminated iron core at the time of manufacture.
[Brief description of the drawings]
FIGS. 1A and 1B are a perspective view of an embodiment of a laminated iron core according to the present invention as viewed from the top surface side and a perspective view as viewed from the bottom surface side.
FIG. 2 is a top view of the laminated iron core shown in FIG.
3 is a top view of a divided laminated core that constitutes the laminated core shown in FIG. 1; FIG.
4 is a cross-sectional view taken along the line IV-IV in FIG. 3 of the divided laminated core constituting the laminated iron core shown in FIG.
FIGS. 5A and 5B are plan views of a first divided core piece and a second divided core piece constituting the divided laminated core in the laminated core shown in FIG. 1;
6 is a cross-sectional view taken along the line VI-VI in FIG. 2 of a connecting portion between the divided laminated cores constituting the laminated iron core shown in FIG.
7A and 7B are main part plan views showing a deformation mode in the laminated iron core of FIG. 1;
FIGS. 8A and 8B are cross-sectional views of a main part showing a deformation mode in the laminated iron core of FIG. 1;
FIG. 9 is a plan view of a strip steel plate showing the processing steps at each station of the progressive die apparatus in the method for manufacturing a laminated core according to the present invention.
FIGS. 10A and 10B are plan views showing divided core pieces that are formed by punching in the yoke punching / caulking joining step in the method of manufacturing a laminated core according to the present invention.
FIGS. 11A and 11B are main part cross-sectional views conceptually showing divided core pieces stacked in a yoke punching / caulking joining step in the method for manufacturing a laminated core according to the present invention.
12 (a) and 12 (b) are plan views conceptually showing a winding work around a tooth portion in the laminated iron core of FIG.
13 is a plan view conceptually showing a yoke portion in the laminated iron core of FIG. 1. FIG.
14 is an overall plan view conceptually showing an assembling operation of a tooth portion to a yoke portion in the laminated iron core of FIG. 1; FIG.
15 is an overall plan view conceptually showing the stator in a state in which the laminated iron core shown in FIG. 1 is wound. FIG.
FIG. 16 is a conceptual overall plan view showing another embodiment of a laminated iron core according to the present invention.
17 is a plan view conceptually showing a winding work around a tooth portion in the laminated iron core of FIG. 16. FIG.
18 is a plan view conceptually showing a yoke portion in the laminated iron core of FIG. 16. FIG.
19 is an overall plan view conceptually showing the stator in a state where a winding is applied to the laminated iron core shown in FIG.
FIG. 20 is an external perspective view showing a conventional laminated iron core.
FIG. 21 is an external perspective view showing another conventional laminated iron core.
22 (a) and 22 (b) are external perspective views showing a tooth portion and a yoke portion of the laminated core shown in FIG.
[Explanation of symbols]
1, 1 '... laminated iron core,
2, 2 '... Yoke part,
2G, 2G '... Teeth assembly groove,
3, 3 '... Teeth,
3D, 3D '... assembly protrusion,
3s ... Teeth core piece,
10: Divided yoke laminated iron core,
10g ... Notch,
11 ... 1st divided core piece,
11n ... Notch,
11p ... protrusions,
12 ... 2nd division iron core piece,
12n ... Notch,
12h ... long hole,
M ... strip steel plate (thin plate material),
O ... opening,
S ... Slot,
s1, s2, ...
Ct, Cy ... caulking part.

Claims

A laminate comprising a ring-shaped yoke portion formed by connecting a predetermined number of divided yoke laminated iron cores to each other, and a predetermined number of teeth portions assembled to the yoke portion so as to protrude in the center direction of the yoke portion. An iron core,
The divided yoke laminated iron core includes a first divided iron core piece and a second divided iron core piece that are laminated and bonded to each other,
The first divided core pieces and the second divided core pieces have connection end portions extending in opposite directions in the circumferential direction in a state where they are stacked on each other,
The connecting end portion of the first divided core piece and the connecting end portion of the second divided core piece extend from one of the divided yoke laminated iron cores to the other divided yoke laminated iron core and the other divided yoke laminated iron core. A notch that constitutes the teeth assembling groove facing the direction, the connection end of the first divided core piece includes a protrusion, and the connection end of the second divided core piece extends in the circumferential direction. With holes,
The protrusions of the first divided core piece in one of the divided yoke laminated cores adjacent to each other are loosely fitted in the long holes of the second divided core piece in the other divided yoke laminated core, thereby making a predetermined number of divided yoke laminated cores endless. A laminated iron core comprising: the yoke part which is connected and configured to be able to expand the diameter of the yoke part, and is configured to be able to expand the teeth part assembly groove as the diameter of the yoke part increases.

A predetermined number of teeth portions protruding in the center direction of the yoke portion having an annular shape and assembled, and a predetermined number of divided yoke laminated iron cores that are connected to each other to form the yoke portion, the divided yoke laminated iron cores being mutually connected A first split core piece and a second split core piece that are stacked and joined, and the first split core piece and the second split core piece extend in opposite directions in the circumferential direction in a state of being stacked on each other. And the connection end of the first divided core piece and the connection end of the second divided core piece span one adjacent divided yoke laminated core and the other divided yoke laminated core. It has a notch which constitutes a tooth part assembling groove facing the inside of the yoke part, the connection end part in the first divided core piece is provided with a protrusion, and the connection end part in the second divided core piece is in the circumferential direction Along And a projection of the first divided core piece in one of the divided yoke laminated cores adjacent to each other is loosely fitted in the long hole of the second divided core piece in the other divided yoke laminated core, and a predetermined number of divided yokes are provided. A method of manufacturing a laminated core in which the laminated iron cores are connected endlessly so that the yoke part having an annular shape can be expanded in diameter, and the teeth assembling grooves can be expanded as the yoke part expands in diameter. Because
Forming an opening of the inner diameter portion at a predetermined position of the thin plate material;
Forming a predetermined number of slots around the opening in the thin plate material, forming a predetermined number of teeth-corresponding portions radially and at equal intervals, and forming a caulking portion in the teeth-corresponding portions;
Teeth-corresponding portions are punched out of the thin plate material to form teeth core pieces and notches that form the teeth assembly grooves, and the teeth core pieces are stacked on each other and caulked and joined together to form a predetermined number of teeth. A step of creating a teeth portion formed by stacking iron core pieces;
Separating the predetermined number of first divided core pieces by separating the thin plate material radially and at equal intervals; and
Separating the predetermined number of second divided core pieces by radially separating the thin plate material at equal intervals; and
Forming a protrusion on the connection end of each first divided core piece;
Forming a long hole in the connection end of each second divided core piece;
Forming a crimped portion on each first divided core piece and each second divided core piece;
The outer diameter of each first divided core piece and each second divided core piece is punched to separate and form the first divided core pieces and the second divided core pieces, and the protrusions of the first divided core pieces are formed as second divided cores. The first divided core piece and the second divided core piece are laminated and caulked with each other in a state of being inserted into the long hole of the piece, and a predetermined number of first divided core pieces and second divided core pieces are laminated. A step of creating a yoke portion by connecting a predetermined number of divided yoke laminated iron cores in an endless manner;
Expanding the yoke section to expand the teeth section mounting groove;
Inserting the assembly protrusion of the teeth portion into the expanded teeth assembly groove,
Reduce the diameter of the yoke part to a predetermined shape as a product, reduce the tooth part assembly groove, fit the tooth part assembly groove to the tooth part assembly protrusion, and assemble the tooth part to the yoke part. Fixing to one piece,
A method for producing a laminated iron core, comprising: