JP4366103B2

JP4366103B2 - Manufacturing method of laminated iron core

Info

Publication number: JP4366103B2
Application number: JP2003110490A
Authority: JP
Inventors: 勝房藤田
Original assignee: Mitsui High Tech Inc
Current assignee: Mitsui High Tech Inc
Priority date: 2003-04-15
Filing date: 2003-04-15
Publication date: 2009-11-18
Anticipated expiration: 2023-04-15
Also published as: JP2004320878A

Description

【０００１】
【発明の属する技術分野】
本発明は、電動機の固定子に使用する積層鉄心の製造方法に関する。
【０００２】
【従来の技術】
図６に示すように、電動機の固定子に使用する積層鉄心９０は、磁極部９１への巻線を、作業性及び生産性よく行うために、積層鉄心９０を構成する鉄心片９２は磁極片部９３毎にヨーク片部９４が分割された分割鉄心片９５として打ち抜きされ、この分割鉄心片９５をかしめ部９６を介してかしめ積層して分割積層鉄心９７を形成し、この分割積層鉄心９７に巻線している。そして、巻線後に、各分割積層鉄心９７を環状に配置して積層鉄心９０を形成している（例えば、特許文献１参照）。
ここで、積層鉄心の形成方法として、分割積層鉄心の分割ヨーク部の一端に形成した連結用の貫通孔と、隣り合う分割積層鉄心の分割ヨーク部の他端に形成した貫通孔の各軸心を一致させ、この貫通孔にピンを挿入することで複数個の分割積層鉄心を回転自在に連結し、これらの分割積層鉄心を環状に配置することが行われている。
【０００３】
また、分割鉄心片９５のヨーク片部９４の一端に回動連結用の半抜き凹凸部９８を形成し、隣り合う分割鉄心片９５で上下に積層されるヨーク片部９４の他端にも同様の回動連結用の半抜き凹凸部９８を形成して、各半抜き凹凸部９８の凹部に対して積層する分割鉄心片９５に形成した半抜き凹凸部９８の凸部を嵌入して回動連結部を構成しながらかしめ部９６を介してかしめ積層して、回動自在に連結した分割積層鉄心９７を形成していた。
この製造方法では、分割鉄心片９５を打ち抜き形成しながら、分割鉄心片９５同士の回動自在な連結とかしめ積層を分割鉄心片９５を打抜き形成する金型装置内で行うことができ、金型装置外でのピン挿入作業等が不要になって、有用な製造手段となっている。
【０００４】
【特許文献１】
特開２０００−２０１４５８号公報
【０００５】
【発明が解決しようとする課題】
しかしながら、貫通孔にピンを挿入して複数個の分割積層鉄心を回転自在に連結して積層鉄心を形成する方法では、巻線の作業は容易となるが、分割積層鉄心を連結して環状に組み立ててピンを挿入する工程は分割鉄心片を打抜き形成する金型装置外で行わねばならず、時間を要するという問題がある。
一方、電動機の積層鉄心９０では、省エネルギー及び高効率化をより一層図るべく、例えば０．２ｍｍ未満の厚みを有する薄い電磁鋼板等の金属薄板から分割鉄心片９５を打ち抜き、積層鉄心９０を形成することが必要になっている。
しかしながら、薄い電磁鋼板や金属板から回動連結部を構成する半抜き凹凸部９８を有する分割鉄心片９５を安定して形成することは難しく、また、半抜き凹凸部９８から構成される回動連結部に不良が発生し易いという問題がある。このため、製造には高度の技術が要求され、高度な技術を有する熟練要員を養成しなければならないという問題が生じていた。
【０００６】
更に、分割鉄心片９５に半抜き凹凸部９８を形成するための金型装置が必要になると共に、製造工程が長くなるという問題が生じていた。
なお、このように金属薄板から打ち抜いた分割鉄心片をかしめ積層して積層鉄心を形成することは、電動機の積層鉄心に限らず一般の積層鉄心においても適用されることである。
本発明はかかる事情に鑑みてなされたもので、分割積層鉄心ブロックに回転軸となる回動連結部を特に形成することなく、分割積層鉄心ブロック同士を容易に連結でき、また極薄の金属薄板からでも製造可能で、かつ連結し合う分割ヨーク部に傷がつかない積層鉄心の製造方法を提供することを目的とする。
【０００７】
【課題を解決するための手段】
前記目的に沿う本発明に係る積層鉄心の製造方法は、磁極片部を平面視してその対称軸に対し該対称軸の両側に伸びた分割ヨーク片部の長さが非対称に形成される第１分割鉄心片、及び磁極片部を平面視してその対称軸に対し該対称軸の両側に伸びた分割ヨーク片部の長さが前記第１分割鉄心片とは逆非対称に形成される第２分割鉄心片を、回転子片が外形抜きされた帯状の電磁鋼板からそれぞれ環状に形成して打ち抜く工程と、
それぞれ環状に配置された前記第１分割鉄心片及び前記第２分割鉄心片をかしめ積層して、一方に凸部と凹部が交互に形成され、他方に凹部と凸部が交互に形成されて環状に連結された分割積層鉄心ブロックを形成する工程とを有し、
更に、前記第１分割鉄心片及び前記第２分割鉄心片は、それぞれ複数枚連続して交互に積層され、しかも、前記第１分割鉄心片及び前記第２分割鉄心片を複数枚連続して積層する中で最初に積層する前記第１分割鉄心片及び前記第２分割鉄心片はその分割ヨーク片部の分割切断線を下方から打ち抜き形成した後に外形抜きして形成され、前記第１分割鉄心片及び前記第２分割鉄心片を複数枚連続して積層する中で最後に積層する前記第１分割鉄心片及び前記第２分割鉄心片はその分割ヨーク片部の分割切断線を上方から打ち抜き形成した後に外形抜きして形成し、前記分割積層鉄心ブロックの分割ヨーク部の両側に形成される前記凸部の先端角部には、打ち抜き時に形成された抜きだれ部を形成する。
【０００８】
分割ヨーク片部の長さが非対称とは、磁極片部を平面視してその対称軸に対して一方側に伸びる分割ヨーク片部の長さが、他方側に伸びる分割ヨーク片部の長さと異なっていることを指す。
また、第２分割鉄心片を第１分割鉄心片とは逆非対称に形成するとは、第２分割鉄心片で一方側に伸びる分割ヨーク片部の長さを第１分割鉄心片で他方側に伸びる分割ヨーク片部の長さと実質的に同一とし、第２分割鉄心片で他方側に伸びる分割ヨーク片部の長さを第１分割鉄心片で一方側に伸びる分割ヨーク片部の長さと実質的に同一にすることを指す。
【０００９】
このように形成された第１分割鉄心片と第２分割鉄心片を複数枚毎交互にかしめ積層して分割積層鉄心ブロックを形成すると、例えば、形成された分割積層鉄心ブロックの分割ヨーク部の一方側では、第１分割鉄心片の一方側は突出し、第２分割鉄心片の一方側は後退して、凸部と凹部が交互に形成されている状態になる。また、分割ヨーク部の他方側では、第１分割鉄心片の他方側は後退し、第２分割鉄心片の他方側は突出して、凹部と凸部が交互に形成されている状態になる。
従って、各分割積層鉄心ブロックを環状に並べて配置した際に、分割積層鉄心ブロックの分割ヨーク部の一方側の凸部並びに凹部に対して、隣り合う分割積層鉄心ブロックの分割ヨーク部の他方側の凹部並びに凸部をそれぞれ対応させることができる。
このため、各分割積層鉄心ブロックを環状に並べて分割積層鉄心ブロックの分割ヨーク部の一方側の凸部並びに凹部に対して、隣り合う分割積層鉄心ブロックの分割ヨーク部の他方側の凹部並びに凸部を入り込ませることができる。
その結果、各分割積層鉄心ブロック同士を相互に連結して一体化することができ、環状の積層鉄心を形成することができる。
【００１０】
本発明に係る積層鉄心の製造方法は、前記第１分割鉄心片及び前記第２分割鉄心片が、それぞれ複数枚連続して交互に積層され、しかも、前記第１分割鉄心片及び前記第２分割鉄心片を複数枚連続して積層する中で最初に積層する前記第１分割鉄心片及び前記第２分割鉄心片はその分割ヨーク片部を下方から打ち抜き形成した後に外形抜きして形成され、前記第１分割鉄心片及び前記第２分割鉄心片を複数枚連続して積層する中で最後に積層する前記第１分割鉄心片及び前記第２分割鉄心片はその分割ヨーク片部を上方から打ち抜き形成した後に外形抜きして形成される。
【００１１】
第１分割鉄心片及び第２分割鉄心片をダイとパンチを備えた金型装置で金属薄板から打ち抜いて形成する場合、打ち抜きパンチが切断を始める側の面には抜きだれ部（角が丸められた領域）が形成され、打ち抜きパンチが抜き出る側の面にはバリ部（微小切れ残り）が形成される。
ここで、第１分割鉄心片及び第２分割鉄心片をそれぞれ複数枚連続して積層する中で、最初に積層する第１分割鉄心片及び第２分割鉄心片では、その分割ヨーク片部の両端を打ち抜きパンチで下方から打ち抜いて形成し、その後に外形抜きする。これによって、最初に積層する第１分割鉄心片及び第２分割鉄心片では、分割ヨーク片部の上面側にバリ部が、下面側に抜きだれ部がそれぞれ形成される。
また、第１分割鉄心片及び第２分割鉄心片をそれぞれ複数枚連続して積層する中で、最後に積層する第１分割鉄心片及び第２分割鉄心片では、その分割ヨーク片部の両端を打ち抜きパンチで上方から打ち抜いて形成し、その後に外形抜きする。これによって、最後に積層する第１分割鉄心片及び第２分割鉄心片では、分割ヨーク片部の下面側にバリ部が、上面側に抜きだれ部がそれぞれ形成される。
【００１２】
従って、上記のようにして形成した第１分割鉄心片及び第２分割鉄心片をそれぞれ複数枚ずつ連続して交互にかしめ積層して形成される分割積層鉄心ブロックでは、分割ヨーク部の両側に形成される凸部の先端角部には抜きだれ部が配置される。
このため、隣の分割積層鉄心ブロックと接合連結する際、ヨーク面に傷をつけずに滑らかに連結を行うことができる。
【００１３】
【００１４】
このように、凸部の先端角部に抜きだれ部を配置することにより、先端角部が丸みを帯びた形状になる。
その結果、分割積層鉄心ブロックに巻線した後、分割積層鉄心ブロックの分割ヨーク部の一方側の凸部並びに凹部に対して、隣り合う分割積層鉄心ブロックの分割ヨーク部の他方側の凹部並びに凸部を入り込ませて連結する際、連結始めから連結終わりまでの抵抗を小さくすることができ、かつ、凸部と凹部の先端同士が密接した状態に連結する。また、容易に連結でき、入り込み合う分割ヨーク部の各面に傷がつかず、絶縁被膜が損傷されない。
【００１５】
【発明の実施の形態】
続いて、添付した図面を参照しつつ、本発明を具体化した実施の形態につき説明し、本発明の理解に供する。
ここに、図１は本発明の一実施の形態に係る積層鉄心の製造方法で製造された積層鉄心の斜視図、図２は同積層鉄心を構成する第１分割鉄心片を打ち抜き形成した際の平面図、図３は同積層鉄心を構成する第２分割鉄心片を打ち抜き形成した際の平面図、図４は同積層鉄心の分割積層鉄心ブロックの斜視図、図５は金型装置内の各ステーションで金属薄板に順次形成されていく第１分割鉄心片及び第２分割鉄心片をそれぞれ形成する形成過程を示す説明図である。
図１に示すように、本発明の一実施の形態に係る積層鉄心の製造方法を適用して製造された積層鉄心１０は、分割積層鉄心ブロック１３を、環状に複数個組み合わせて構成されている。そして、各分割積層鉄心ブロック１３は、第１分割鉄心片１１及び第２分割鉄心片１２をかしめ積層して形成されている。以下、これらについて詳細に説明する。
【００１６】
図２に示す第１分割鉄心片１１は、２枚毎連続して打ち抜きされて、かしめ積層される。
ここで、第１分割鉄心片１１は、分割切断線１５により分割ヨーク片部１８が相互に切り離されて形成され、磁極片部１６と、磁極片部１６の軸部１７を介して連結している分割ヨーク片部１８を備えている。
また、分割ヨーク片部１８は、磁極片部１６を平面視してその対称軸に対し対称軸の両側に伸びた長さが非対称、すなわち、磁極片部１６を平面視してその対称軸に対して一方側に伸びる長さが、他方側に伸びる長さと異なるように形成されている。
【００１７】
図３に示す第２分割鉄心片１２は、２枚毎連続して打ち抜きされて、かしめ積層される。
ここで、第２分割鉄心片１２は、分割切断線１５ａにより分割ヨーク片部１９が相互に切り離されて形成され、磁極片部１６と、磁極片部１６の軸部１７を介して連結している分割ヨーク片部１９を備えている。
また、分割ヨーク片部１９は、第１分割鉄心片１１の分割ヨーク片部１８とは逆非対称、すなわち、第２分割鉄心片１２の磁極片部１６を平面視してその対称軸に対して一方側に伸びる長さを、第１分割鉄心片１１で他方側に伸びる長さと実質的に同一とし、第２分割鉄心片１２で対称軸に対して他方側に伸びる長さを第１分割鉄心片１１で一方側に伸びる長さと実質的に同一になるように形成されている。
【００１８】
更に、第１分割鉄心片１１の分割ヨーク片部１８と磁極片部１６、及び第２分割鉄心片１２の分割ヨーク片部１９と磁極片部１６には、それぞれかしめ部２０が形成されている。そして、第１分割鉄心片１１と第２分割鉄心片１２を積層させた際に、第１分割鉄心片１１に現れるかしめ部２０の位置と第２分割鉄心片１２に現れるかしめ部２０の位置とは実質的に重なり合うように形成されている。
ここで、かしめ部２０は、周知の構造であって、一方が突起で他方が窪みであってもよいし、それぞれのかしめ部２０が表面側と裏面側で窪みと突起を組み合わせたような構造であってもよい。
以上のような構成とすることにより、第１分割鉄心片１１と第２分割鉄心片１２を、例えば、２枚毎交互にかしめ積層することにより、図４に示すように、外周側に配置される分割ヨーク部１４と、分割ヨーク部１４から内側に突出する磁極部２１を備えた分割積層鉄心ブロック１３を形成することができる。
【００１９】
ここで、第１分割鉄心片１１を２枚連続してかしめ積層する場合、最初の第１分割鉄心片１１では、分割ヨーク片部１８に抜きだれ部２２が形成された側を下面側になるように載置する。そして、２枚目の（すなわち、最後に積層する）第１分割鉄心片１１では、分割ヨーク片部１８に抜きだれ部２２が形成された側を上面側になるように載置して、かしめ積層を行う。
かしめ積層された第１分割鉄心片１１の上に第２分割鉄心片１２を２枚連続してかしめ積層する場合、最初の第２分割鉄心片１２では、分割ヨーク片部１９に抜きだれ部２２が形成された側を下面側になるように載置する。そして、２枚目の（すなわち、最後に積層する）第２分割鉄心片１２では、分割ヨーク片部１９に抜きだれ部２２が形成された側を上面側になるように載置して、かしめ積層を行う。
【００２０】
このようにして得られた分割積層鉄心ブロック１３では、分割ヨーク部１４の一方側においては第１分割鉄心片１１の一方側を突出させ、第２分割鉄心片１２の一方側を後退させて、凸部２３と凹部２４が交互に形成されている。
また、分割ヨーク部１４の他方側では第１分割鉄心片１１の他方側を後退させ、第２分割鉄心片１２の他方側を突出させて、凹部２４と凸部２３が交互に形成されている。
そして、各凸部２３の先端角部、及び各凹部２４の底角部には、いずれも抜きだれ部２２が配置されている状態になっている。
従って、各凸部２３の先端角部に抜きだれ部２２を配置することにより、先端角部に丸みが形成された凸部２３を形成することができ、凹部２４の底角部に抜きだれ部２２を配置することにより、底角部に逃がし空間を備えた凹部２４を形成することができる。
【００２１】
このため、分割積層鉄心ブロック１３の磁極部２１に別途巻線した後、分割積層鉄心ブロック１３同士を並べて、分割積層鉄心ブロック１３の分割ヨーク部１４の一方側の凸部２３並びに凹部２４に対して、隣り合う分割積層鉄心ブロック１３の分割ヨーク部１４の他方側の凹部２４並びに凸部２３を入り込ませる際に、入り込ませるときの抵抗を小さくすることができ、分割積層鉄心ブロック１３同士の連結が容易になり、また、分割ヨーク部１４の面に傷を付けることがない。
従って、分割積層鉄心ブロック１３を環状に複数個並べて配置し、分割積層鉄心ブロック１３の分割ヨーク部１４の一方側の凸部２３並びに凹部２４に対して、隣り合う分割積層鉄心ブロック１３の分割ヨーク部１４の他方側の凹部２４並びに凸部２３を入り込ませることにより、各分割積層鉄心ブロック１３同士を相互に連結して一体化し環状の積層鉄心１０を容易に形成することができる。
【００２２】
次に、本発明の一実施の形態に係る積層鉄心の製造方法について説明する。
図５に示すように、電磁鋼板等の磁気特性に優れた帯状の金属薄板２５の幅方向の両側に所定間隔でガイド孔２６を設け、このガイド孔２６に図示しないガイド部材を挿入して金属薄板２５を打ち抜き用の図示しない金型装置内に装入する。
ここで、金型装置内には、上流側から順に回転子片２８の外形抜きを行うステーションＡ、磁極片部１６の形成を行うステーションＢ、第１分割鉄心片１１の各分割ヨーク片部１８の分割切断線１５を形成するステーションＣ、第２分割鉄心片１２の各分割ヨーク片部１９の分割切断線１５ａを形成するステーションＤ、第１分割鉄心片１１及び第２分割鉄心片１２にそれぞれかしめ部２０を形成するステーションＥ、並びに第１分割鉄心片１１及び第２分割鉄心片１２をそれぞれ外形抜きするステーションＦが設けられている。なお、図中、ステーションＥ２はアイドル工程を示す。
【００２３】
金型装置内のステーションＡにおいては、金属薄板２５を図示しないダイ上でストリッパーにより挟持しながら回転子片外形抜きパンチで回転子片２８を順次外形抜きする。そして、回転子片２８が外形抜きされた金属薄板２５は、順次ステーションＢに通板する。
ステーションＢにおいては、図示しないダイ上でストリッパーにより挟持しながら回転子片２８が外形抜きされて形成された孔２９の外側に磁極片形成パンチで磁極片部１６を順次形成する。
そして、磁極片部１６が形成された金属薄板２５は、次いでステーションＣに通板する。
【００２４】
ステーションＣにおいては、磁極片部１６が形成された金属薄板２５に対して、図示しないダイ上でストリッパーにより挟持しながら、分割切断線形成パンチを下方から移動させて磁極片部１６の外側に第１分割鉄心片１１の各分割ヨーク片部１８の分割切断線１５を形成し、次に通板されてくる金属薄板２５に対しては分割切断線形成パンチを上方から移動させて磁極片部１６の外側に第１分割鉄心片１１の各分割ヨーク片部１８の分割切断線１５を形成する。その際、ステーションＤの稼動は停止させる。
そして、ステーションＣにおいて第１分割鉄心片１１の各分割ヨーク片部１８の分割切断線１５の形成が連続して２回行われた後では、ステーションＣの稼動を停止させて、ステーションＢにおいて磁極片部１６が形成された金属薄板２５をステーションＤまで通板させて、分割切断線形成パンチを下方から移動させて第２分割鉄心片１２の磁極片部１６の外側に各分割ヨーク片部１９の分割切断線１５ａを形成し、次に通板されてくる金属薄板２５に対しては分割切断線形成パンチを上方から移動させて磁極片部１６の外側に第２分割鉄心片１２の各分割ヨーク片部１９の分割切断線１５ａを形成する。
ステーションＤにおいて第２分割鉄心片１２の各分割ヨーク片部１９の分割切断線１５ａの形成が連続して２回行われた後では、ステーションＤの稼動を停止させて、ステーションＣの稼動を再開する。
このように、この実施の形態においては、ステーションＣ、Ｄでは、一方のステーションを２回連続して稼動させながら他方のステーションの稼動を停止し、このような稼動と停止を各ステーションで交互に行う。
【００２５】
第１分割鉄心片１１及び第２分割鉄心片１２の各分割ヨーク片部１８、１９用の各分割切断線１５、１５ａがそれぞれ形成された金属薄板２５がステーションＥに通板してくると、図示しないダイ上でストリッパーにより挟持しながらかしめ部形成パンチでかしめ部２０を順次形成する。そして、かしめ部２０が形成された金属薄板２５は、ステーションＦに通板する。
従って、ステーションＥを通過した金属薄板２５には、第１分割鉄心片１１用の磁極片部１６、分割ヨーク片部１８の分割切断線１５、及びかしめ部２０の形成されている領域と、第２分割鉄心片１２用の磁極片部１６、分割ヨーク片部１９の分割切断線１５ａ、及びかしめ部２０が形成されている領域が２組ずつ交互に形成された状態になっている。
ステーションＦにおいては、図示しないダイ上でストリッパーにより挟持しながら、第１分割鉄心片１１及び第２分割鉄心片１２を外形抜きする分割鉄心片パンチで外形抜きし図示しないダイホール内に順次抜き込み、ダイホール内に設けられた受け台上にてかしめ積層していく。
【００２６】
このとき、受け台上には、第１分割鉄心片１１及び第２分割鉄心片１２が２枚連続して交互に順次載置されるが、連続の中の始めに載置される第１分割鉄心片１１及び第２分割鉄心片１２では、それぞれ分割ヨーク片部１８、１９に抜きだれ部２２が形成されている面を下側にして載置され、２枚目の第１分割鉄心片１１及び第２分割鉄心片１２では、分割ヨーク片部１８、１９に抜きだれ部２２が形成されている面を上側にして載置される。
従って、受け台上に２枚ずつ連続して載置された第１分割鉄心片１１及び第２分割鉄心片１２では、打ち抜き時に分割ヨーク片部１８、１９に形成された抜きだれ部２２が外側に面し、打ち抜き時に形成されたバリ部同士が互いに当接した状態になって、かしめ積層されている。
【００２７】
そして、第１分割鉄心片１１及び第２分割鉄心片１２のかしめ積層を所望の積厚さまで繰り返すことにより分割積層鉄心ブロック１３を形成する。
なお、形成された各分割積層鉄心ブロック１３の分割ヨーク部１４の一方側においては、第１分割鉄心片１１の一方側が突出し、第２分割鉄心片１２の一方側が後退して、凸部２３と凹部２４が交互に形成されている。また、分割ヨーク部１４の他方側においては、第１分割鉄心片１１の他方側が後退し、第２分割鉄心片１２の他方側が突出して、凹部２４と凸部２３が交互に形成されている。
従って、この実施の形態で製造された分割積層鉄心ブロック１３は環状に連結した積層鉄心１０の状態になっている。
【００２８】
巻線に際しては、形成された各分割積層鉄心ブロック１３を個々に離して、あるいは、分割ヨーク部１４同士が連結した状態で各磁極部２１の間隔を広げるように各分割積層鉄心ブロック１３を離した状態にする。そして、各磁極部２１に巻線した後、各分割積層鉄心ブロック１３を環状に配置しなおし、分割積層鉄心ブロック１３の分割ヨーク部１４の一方側の凸部２３並びに凹部２４に対して、隣り合う分割積層鉄心ブロック１３の分割ヨーク部１４の他方側の凹部２４並びに凸部２３を入り込ませ、各分割積層鉄心ブロック１３同士を相互に連結して一体化し、環状の積層鉄心１０を形成する。
ここで、各凸部２３の先端角部、及び各凹部２４の底角部には、いずれも抜きだれ部２２が配置されているので、各凸部２３の先端角部は丸みを帯びており、各凹部２４の底角部には逃がし空間が形成されている。
このため、分割積層鉄心ブロック１３の分割ヨーク部１４の一方側の凸部２３並びに凹部２４に対して、隣り合う分割積層鉄心ブロック１３の分割ヨーク部１４の他方側の凹部２４並びに凸部２３を入り込ませる際の抵抗を小さくすることができ、回動連結部を特に設けずとも分割積層鉄心ブロック１３同士の連結が容易にできる。
【００２９】
以上、本発明の実施の形態を説明したが、本発明は、この実施の形態に限定されるものではなく、発明の要旨を変更しない範囲での変更は可能であり、前記したそれぞれの実施の形態や変形例の一部又は全部を組み合わせて本発明の積層鉄心の製造方法を構成する場合も本発明の権利範囲に含まれる。例えば、本実施の形態では第１分割鉄心片と第２分割鉄心片をそれぞれ２枚連続して交互にかしめ積層して分割積層鉄心ブロックを形成したが、３枚以上毎連続してかしめ積層してもよい。また、積層の途中から第１分割鉄心片と第２分割鉄心片の枚数を変化させてもよい。
本実施の形態では第１分割鉄心片及び第２分割鉄心片をそれぞれ環状に形成した。
【００３０】
【発明の効果】
請求項１記載の積層鉄心の製造方法においては、磁極片部を平面視してその対称軸に対し対称軸の両側に伸びた分割ヨーク片部の長さが非対称に形成される第１分割鉄心片、及び磁極片部を平面視してその対称軸に対し該対称軸の両側に伸びた分割ヨーク片部の長さが第１分割鉄心片とは逆非対称に形成される第２分割鉄心片を、回転子片が外形抜きされた帯状の電磁鋼板からそれぞれ環状に形成して打ち抜く工程と、それぞれ環状に配置された第１分割鉄心片及び第２分割鉄心片をかしめ積層して、一方に凸部と凹部が交互に形成され、他方に凹部と凸部が交互に形成されて環状に連結された分割積層鉄心ブロックを形成する工程とを有するので、製造不良が発生し易い半抜き凹凸部から構成される回動連結部を特に設けずに分割積層鉄心ブロックを連結してなる積層鉄心を容易に製造することが可能になる。そして、高度な技術を有する熟練要員を必要とせずに、しかも、任意の厚さの金属薄板を用いて安定して積層鉄心を製造することが可能になる。
また、回動連結部を形成するための金型装置が不要になると共に、積層鉄心の製造工程を短縮化することが可能になり、積層鉄心の製造コストの上昇を抑制することができる。
【００３１】
特に、この積層鉄心の製造方法においては、第１分割鉄心片及び第２分割鉄心片は、それぞれ複数枚連続して交互に積層され、しかも、第１分割鉄心片及び第２分割鉄心片を複数枚連続して積層する中で最初に積層する第１分割鉄心片及び第２分割鉄心片は分割ヨーク片部を下方から打ち抜き形成した後に外形抜きして形成され、第１分割鉄心片及び第２分割鉄心片を複数枚連続して積層する中で最後に積層する第１分割鉄心片及び第２分割鉄心片は分割ヨーク片部を上方から打ち抜き形成した後に外形抜きして形成されるので、得られた分割積層鉄心ブロックでは、その分割ヨーク部の両側にそれぞれ形成される凸部の先端角部には、いずれも抜きだれ部が配置される状態にすることができ、分割積層鉄心ブロックの分割ヨーク部の一方側の凸部並びに凹部に対して、隣り合う分割積層鉄心ブロックの分割ヨーク部の他方側の凹部並びに凸部をそれぞれ入り込ませて連結する際の抵抗を小さくすることができ、また、分割ヨーク部の面に傷を付けることがない。その結果、連結作業を容易に行うことが可能になって、積層鉄心の生産性を向上させることが可能になる。
更に、極薄い金属薄板、例えば、０．２ｍｍ未満のものから積層鉄心を安定して製造することができる。その結果、省エネルギー及び高効率化が一層進展した積層鉄心を得ることができる。
【００３２】
【図面の簡単な説明】
【図１】本発明の一実施の形態に係る積層鉄心の製造方法で製造された積層鉄心の斜視図である。
【図２】同積層鉄心を構成する第１分割鉄心片を打ち抜き形成した際の平面図である。
【図３】同積層鉄心を構成する第２分割鉄心片を打ち抜き形成した際の平面図である。
【図４】同積層鉄心の分割積層鉄心ブロックの斜視図である。
【図５】金型装置内の各ステーションで金属薄板に順次形成されていく第１分割鉄心片及び第２分割鉄心片をそれぞれ形成する形成過程を示す説明図である。
【図６】従来例の積層鉄心の説明図である。
【符号の説明】
１０：積層鉄心、１１：第１分割鉄心片、１２：第２分割鉄心片、１３：分割積層鉄心ブロック、１４：分割ヨーク部、１５、１５ａ：分割切断線、１６：磁極片部、１７：軸部、１８、１９：分割ヨーク片部、２０：かしめ部、２１：磁極部、２２：抜きだれ部、２３：凸部、２４：凹部、２５：金属薄板、２６：ガイド孔、２８：回転子片、２９：孔[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a laminated core used for a stator of an electric motor.
[0002]
[Prior art]
As shown in FIG. 6, the laminated core 90 used for the stator of the electric motor has a pole piece 92 that constitutes the laminated core 90 in order to perform winding to the magnetic pole portion 91 with good workability and productivity. The yoke piece 94 is punched into divided core pieces 95 for each portion 93, and the divided core pieces 95 are caulked and laminated via caulking portions 96 to form divided laminated cores 97. Winding. Then, after the winding, each divided laminated iron core 97 is arranged in an annular shape to form a laminated iron core 90 (see, for example, Patent Document 1).
Here, as a method of forming the laminated iron core, each axial center of the connecting through hole formed at one end of the divided yoke portion of the divided laminated core and the through hole formed at the other end of the divided yoke portion of the adjacent divided laminated core. And by inserting a pin into this through hole, a plurality of divided laminated cores are rotatably connected, and these divided laminated cores are arranged in an annular shape.
[0003]
Further, a half-recessed concave / convex portion 98 for rotational connection is formed at one end of the yoke piece portion 94 of the divided core piece 95, and the same is applied to the other end of the yoke piece portion 94 that is laminated vertically by the adjacent divided core pieces 95. The half-recessed uneven portion 98 for rotating connection is formed, and the convex portions of the half-recessed uneven portion 98 formed on the divided core piece 95 that is stacked on the recessed portions of each half-recessed uneven portion 98 are fitted and rotated. The divided laminated iron core 97 is formed by caulking and laminating via the caulking portion 96 while constituting the connecting portion, so as to be rotatably connected.
In this manufacturing method, while the divided core pieces 95 are formed by punching, the divided core pieces 95 can be pivotally connected and caulked in a mold apparatus that punches and forms the divided core pieces 95. This eliminates the need for pin insertion work outside the apparatus, and is a useful manufacturing means.
[0004]
[Patent Document 1]
JP 2000-201458 A
[0005]
[Problems to be solved by the invention]
However, in the method of inserting a pin into a through hole and rotatably connecting a plurality of divided laminated iron cores to form a laminated iron core, the winding work becomes easy, but the divided laminated iron cores are connected to form a ring. The process of assembling and inserting the pins must be performed outside the mold apparatus for punching and forming the divided core pieces, which requires time.
On the other hand, in the laminated core 90 of the electric motor, in order to further save energy and increase the efficiency, for example, the divided core piece 95 is punched from a thin metal plate such as a thin electromagnetic steel sheet having a thickness of less than 0.2 mm to form the laminated core 90. It is necessary.
However, it is difficult to stably form the divided core piece 95 having the half-recessed uneven portion 98 that constitutes the rotational connection portion from a thin electromagnetic steel plate or metal plate, and the rotation composed of the half-recessed uneven portion 98. There is a problem that defects are likely to occur in the connecting portion. For this reason, a high level of technology is required for production, and there has been a problem that skilled personnel having high level of technology must be trained.
[0006]
In addition, a mold apparatus for forming the half punched uneven portion 98 on the divided core piece 95 is required, and the manufacturing process becomes long.
It should be noted that the formation of a laminated core by caulking and splitting core pieces punched from a thin metal plate in this manner is applicable not only to a laminated core of an electric motor but also to a general laminated core.
The present invention has been made in view of such circumstances, and it is possible to easily connect the divided laminated core blocks to each other without particularly forming a rotation connecting portion serving as a rotating shaft in the divided laminated core block, and to form an extremely thin metal sheet. It is an object of the present invention to provide a method of manufacturing a laminated iron core that can be manufactured even from the beginning and that does not damage the connecting divided yoke portions.
[0007]
[Means for Solving the Problems]
In the method for manufacturing a laminated core according to the present invention that meets the above-described object, the length of the split yoke piece portion that is extended in both sides of the symmetry axis with respect to the symmetry axis in a plan view of the magnetic pole piece portion is formed asymmetrically. A length of the split yoke piece extending on both sides of the symmetry axis with respect to the symmetry axis in a plan view of the one-segment iron core piece and the magnetic pole piece is formed asymmetrically opposite to the first division core piece. 2 piece iron core pieceFrom a strip-shaped electrical steel sheet with a rotor piece cut outRespectivelyFormed in a ringPunching process,
Each arranged in a ringCaulking and laminating the first divided core pieces and the second divided core pieces, Convex portions and concave portions are alternately formed on one side, and concave portions and convex portions are alternately formed on the other side and connected in an annular shapeForming a split laminated core block; andHave,
Further, a plurality of the first divided core pieces and a plurality of the second divided core pieces are alternately laminated in succession, and a plurality of the first divided core pieces and the second divided core pieces are continuously laminated. In the process, the first divided core piece and the second divided core piece that are first laminated are formed by punching and forming the divided cutting line of the divided yoke piece portion from below, and then removing the outer shape. In addition, the first divided core piece and the second divided core piece to be laminated lastly are formed by punching a dividing cutting line of the divided yoke piece portion from above. Later, the outer shape is cut out, and at the corner of the tip of the convex portion formed on both sides of the divided yoke portion of the divided laminated core block, a dripping portion formed at the time of punching is formed..
[0008]
The length of the divided yoke piece is asymmetrical. The length of the divided yoke piece extending to one side with respect to the axis of symmetry when the magnetic pole piece is viewed in plan is the length of the divided yoke piece extending to the other side. Refers to being different.
In addition, the second divided core piece is formed in a reverse asymmetric manner with respect to the first divided core piece. The length of the divided yoke piece portion that extends to one side by the second divided core piece extends to the other side by the first divided core piece. The length of the split yoke piece is substantially the same as the length of the split yoke piece, and the length of the split yoke piece extending to the other side by the second split core piece is substantially the same as the length of the split yoke piece extending to the one side by the first split core piece. To be the same.
[0009]
When a divided laminated core block is formed by alternately caulking and laminating a plurality of first divided core pieces and second divided core pieces formed in this way, for example, one of the divided yoke portions of the formed divided laminated core block On the side, one side of the first divided core piece protrudes, and one side of the second divided core piece recedes, so that convex portions and concave portions are alternately formed. Further, on the other side of the divided yoke portion, the other side of the first divided core piece is retreated, the other side of the second divided core piece is projected, and the concave portions and the convex portions are alternately formed.
Therefore, when the divided laminated core blocks are arranged side by side in a ring shape, the other side of the divided yoke part of the adjacent divided laminated core block is opposite to the convex part and the concave part of the divided yoke part of the divided laminated core block. A concave part and a convex part can be made to correspond, respectively.
For this reason, the respective divided laminated core blocks are arranged in a ring shape, and the concave and convex portions on the other side of the divided yoke portions of the adjacent divided laminated core blocks are opposed to the convex portions and concave portions of the divided yoke portions of the divided laminated core blocks. Can enter.
As a result, the divided laminated core blocks can be connected and integrated with each other, and an annular laminated iron core can be formed.
[0010]
Manufacturing method of laminated core according to the present inventionIsThe first divided core piece and the second divided core pieceButA plurality of the first divided core pieces and the second divided core pieces, and the first divided core pieces and the second divided core pieces, which are first laminated in the plurality of successive laminated pieces. The two-divided core piece is formed by punching and forming the divided yoke piece from below, and finally laminating a plurality of the first divided core pieces and the second divided core pieces in succession. The first divided iron core piece and the second divided iron core piece are formed by punching the divided yoke piece portion from above and then removing the outer shape.
[0011]
When the first divided core piece and the second divided core piece are formed by punching from a thin metal plate with a die apparatus having a die and a punch, the punched portion (rounded corners are rounded) on the surface where the punch starts. Area), and a burr portion (small cut residue) is formed on the surface from which the punching punch is extracted.
Here, in laminating a plurality of the first divided core pieces and the second divided core pieces continuously, in the first divided core piece and the second divided core piece to be laminated first, both ends of the divided yoke piece portion. Is formed by punching from below with a punch, and then the outer shape is punched. Thereby, in the first divided core piece and the second divided core piece to be laminated first, the burr portion is formed on the upper surface side of the divided yoke piece portion, and the extracted portion is formed on the lower surface side.
Moreover, in laminating a plurality of the first divided core pieces and the second divided core pieces continuously, in the first divided core piece and the second divided core piece to be laminated last, both ends of the divided yoke piece portions are It is formed by punching from above with a punch, and then the outer shape is punched. As a result, in the first divided core piece and the second divided core piece to be finally laminated, the burr portion is formed on the lower surface side of the divided yoke piece portion, and the extracted portion is formed on the upper surface side.
[0012]
Therefore, in the divided laminated core block formed by alternately caulking and laminating a plurality of the first divided core pieces and the second divided core pieces formed as described above, it is formed on both sides of the divided yoke portion. A dripping portion is arranged at the tip corner of the convex portion.
For this reason, when it joins and connects with an adjacent division | segmentation laminated | stacked iron core block, it can connect smoothly, without damaging a yoke surface.
[0013]
[0014]
In this way, by arranging the extracted portion at the tip corner of the convex portion, the tip corner becomes rounded.
As a result, after winding the split laminated core block, the concave and convex portions on the other side of the split yoke part of the adjacent split core block are adjacent to the convex part and concave part of the split yoke part of the split laminated core block. When the part is inserted and connected, the resistance from the start of connection to the end of connection can be reduced, and the protrusions and the tips of the recesses are connected in close contact. Further, it can be easily connected, and each surface of the divided yoke portion that enters is not damaged, and the insulating coating is not damaged.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described with reference to the accompanying drawings for understanding of the present invention.
FIG. 1 is a perspective view of a laminated core manufactured by the method for manufacturing a laminated core according to an embodiment of the present invention, and FIG. 2 is a view when a first divided core piece constituting the laminated core is punched and formed. FIG. 3 is a plan view when the second divided core piece constituting the laminated core is punched and formed, FIG. 4 is a perspective view of a divided laminated core block of the laminated core, and FIG. It is explanatory drawing which shows the formation process in which the 1st division | segmentation core piece and the 2nd division | segmentation core piece which are sequentially formed in a metal thin plate in a station are each formed.
As shown in FIG. 1, a laminated core 10 manufactured by applying the method for manufacturing a laminated core according to an embodiment of the present invention is configured by combining a plurality of divided laminated core blocks 13 in a ring shape. . Each divided laminated core block 13 is formed by caulking and laminating the first divided core pieces 11 and the second divided core pieces 12. Hereinafter, these will be described in detail.
[0016]
The first divided core pieces 11 shown in FIG. 2 are punched out continuously every two sheets and are caulked and laminated.
Here, the first divided core piece 11 is formed by separating the divided yoke piece portions 18 from each other by the divided cutting line 15, and is connected to the magnetic pole piece portion 16 via the shaft portion 17 of the magnetic pole piece portion 16. The divided yoke piece 18 is provided.
The split yoke piece 18 has an asymmetrical length extending to both sides of the axis of symmetry with respect to the axis of symmetry when the pole piece 16 is viewed in plan, i.e., the axis of symmetry of the pole piece 16 with respect to its axis of symmetry. In contrast, the length extending to one side is different from the length extending to the other side.
[0017]
The second divided core pieces 12 shown in FIG. 3 are punched out continuously every two sheets and are caulked and laminated.
Here, the second divided iron core piece 12 is formed by separating the divided yoke piece parts 19 from each other by a dividing cutting line 15 a and is connected to the magnetic pole piece part 16 via the shaft part 17 of the magnetic pole piece part 16. A split yoke piece 19 is provided.
The divided yoke piece 19 is reversely asymmetric with the divided yoke piece 18 of the first divided core piece 11, that is, the magnetic pole piece 16 of the second divided core piece 12 is viewed in plan with respect to its axis of symmetry. The length extending to one side is substantially the same as the length extending to the other side in the first divided core piece 11, and the length extending to the other side with respect to the symmetry axis in the second divided core piece 12 is the first divided core. It is formed so as to be substantially the same as the length of the piece 11 extending to one side.
[0018]
Further, a caulking portion 20 is formed in each of the divided yoke piece portion 18 and the magnetic pole piece portion 16 of the first divided iron core piece 11 and the divided yoke piece portion 19 and the magnetic pole piece portion 16 of the second divided iron core piece 12. . And when laminating | stacking the 1st division | segmentation iron core piece 11 and the 2nd division | segmentation iron core piece 12, the position of the caulking part 20 which appears in the 1st division | segmentation iron core piece 11, and the position of the caulking part 20 which appears in the 2nd division | segmentation iron core piece 12 Are formed so as to substantially overlap.
Here, the caulking part 20 may have a well-known structure, and one may be a protrusion and the other may be a depression, or each caulking part 20 may be a combination of a depression and a protrusion on the front side and the back side. It may be.
By setting it as the above structures, the 1st division | segmentation iron core piece 11 and the 2nd division | segmentation iron core piece 12 are arrange | positioned on an outer peripheral side, as shown in FIG. The divided laminated iron core block 13 including the divided yoke portion 14 and the magnetic pole portion 21 protruding inward from the divided yoke portion 14 can be formed.
[0019]
Here, when two first divided core pieces 11 are continuously caulked and laminated, in the first first divided core piece 11, the side on which the cutout portion 22 is formed on the divided yoke piece 18 becomes the lower surface side. To be placed. In the second divided core piece 11 (that is, the last laminated layer), the side of the divided yoke piece 18 where the extracted portion 22 is formed is placed on the upper surface side and caulked. Laminate.
In the case where two second divided core pieces 12 are continuously caulked and laminated on the first divided iron core pieces 11 that have been caulked and laminated, the first second divided iron core pieces 12 are separated into the divided yoke piece 19 and the extracted portion 22. The side on which the is formed is placed so as to be the lower surface side. In the second divided core piece 12 (that is, the last laminated layer), the side where the cutout portion 22 is formed on the divided yoke piece 19 is placed so as to be the upper surface side and caulked. Laminate.
[0020]
In the divided laminated core block 13 obtained in this way, one side of the first divided core piece 11 protrudes on one side of the divided yoke part 14 and one side of the second divided core piece 12 retreats, Convex portions 23 and concave portions 24 are alternately formed.
Further, on the other side of the divided yoke portion 14, the other side of the first divided core piece 11 is retreated, and the other side of the second divided core piece 12 is protruded, so that concave portions 24 and convex portions 23 are alternately formed. .
And the extraction | drawer part 22 is arrange | positioned at the front-end | tip corner | angular part of each convex part 23, and the bottom corner | angular part of each recessed part 24, respectively.
Therefore, by arranging the extracted portion 22 at the tip corner portion of each convex portion 23, it is possible to form the convex portion 23 in which the tip corner portion is rounded, and the extracted portion at the bottom corner portion of the recess 24. By arranging 22, it is possible to form a recess 24 having a relief space at the bottom corner.
[0021]
For this reason, after separately winding on the magnetic pole part 21 of the divided laminated core block 13, the divided laminated core blocks 13 are arranged side by side with respect to the convex part 23 and the concave part 24 on one side of the divided yoke part 14 of the divided laminated core block 13. Thus, when the concave portion 24 and the convex portion 23 on the other side of the divided yoke portion 14 of the adjacent divided laminated core block 13 are inserted, the resistance when entering can be reduced, and the divided laminated core blocks 13 are connected to each other. And the surface of the split yoke portion 14 is not damaged.
Therefore, a plurality of the divided laminated core blocks 13 are arranged in a ring shape, and the divided yokes of the adjacent divided laminated core blocks 13 with respect to the convex portion 23 and the concave portion 24 on one side of the divided yoke portion 14 of the divided laminated core block 13 are arranged. By inserting the concave portion 24 and the convex portion 23 on the other side of the portion 14, the divided laminated core blocks 13 can be connected to each other and integrated to form the annular laminated core 10 easily.
[0022]
Next, the manufacturing method of the laminated iron core which concerns on one embodiment of this invention is demonstrated.
As shown in FIG. 5, guide holes 26 are provided at predetermined intervals on both sides in the width direction of a strip-shaped thin metal plate 25 having excellent magnetic properties, such as an electromagnetic steel plate, and a guide member (not shown) is inserted into the guide hole 26 to form a metal. The thin plate 25 is inserted into a die device (not shown) for punching.
Here, in the mold apparatus, station A for removing the outer shape of the rotor piece 28 in order from the upstream side, station B for forming the magnetic pole piece 16, and each divided yoke piece 18 of the first divided iron core piece 11. Station C for forming the divided cutting line 15, station D for forming the divided cutting line 15 a of each divided yoke piece portion 19 of the second divided core piece 12, the first divided core piece 11, and the second divided core piece 12, respectively. A station E for forming the caulking portion 20 and a station F for removing the outer shapes of the first divided core piece 11 and the second divided core piece 12 are provided. In the figure, station E2 represents an idle process.
[0023]
In the station A in the mold apparatus, the rotor pieces 28 are sequentially contoured by a rotor piece contouring punch while the metal thin plate 25 is held on a die (not shown) by a stripper. Then, the thin metal plate 25 from which the outer shape of the rotor piece 28 is removed passes through the station B sequentially.
In the station B, the magnetic pole piece portions 16 are sequentially formed by the magnetic pole piece forming punch outside the hole 29 formed by extracting the outer shape of the rotor piece 28 while being held by a stripper on a die (not shown).
Then, the metal thin plate 25 on which the pole piece portion 16 is formed passes through the station C.
[0024]
In the station C, the divided cutting line forming punch is moved from below to the outside of the magnetic pole piece 16 while being held by a stripper on a die (not shown) with respect to the thin metal plate 25 on which the magnetic pole piece 16 is formed. The divided cutting line 15 of each divided yoke piece part 18 of the one-piece iron core piece 11 is formed, and the divided cutting line forming punch is moved from the upper side to the metal thin plate 25 to be passed next, and the magnetic pole piece part 16 is moved. The dividing cutting line 15 of each divided yoke piece portion 18 of the first divided iron core piece 11 is formed on the outer side. At that time, the operation of the station D is stopped.
Then, after the formation of the divided cutting lines 15 of the divided yoke pieces 18 of the first divided core piece 11 at the station C is performed twice in succession, the operation of the station C is stopped and the magnetic poles at the station B are stopped. The thin metal plate 25 on which the piece portion 16 is formed is passed through to the station D, and the divided cutting line forming punch is moved from below to move the divided yoke piece portions 19 to the outside of the magnetic pole piece portion 16 of the second divided core piece 12. The divided cutting line 15a is formed, and the divided cutting line forming punch is moved from above to the thin metal plate 25 to be passed next, so that the second divided core piece 12 is divided outside the magnetic pole piece portion 16. A split cutting line 15a of the yoke piece 19 is formed.
After the formation of the divided cutting line 15a of each divided yoke piece portion 19 of the second divided iron core piece 12 in the station D is performed twice in succession, the operation of the station D is stopped and the operation of the station C is resumed. To do.
As described above, in this embodiment, in the stations C and D, one station is continuously operated twice while the other station is stopped, and such operation and stop are alternately performed in each station. Do.
[0025]
When the metal thin plate 25 formed with the respective divided cutting lines 15 and 15a for the divided yoke pieces 18 and 19 of the first divided core piece 11 and the second divided core piece 12 passes through the station E, The caulking portion 20 is sequentially formed by a caulking portion forming punch while being sandwiched by a stripper on a die (not shown). The thin metal plate 25 on which the caulking portion 20 is formed passes through the station F.
Therefore, the thin metal plate 25 that has passed through the station E has a magnetic pole piece portion 16 for the first divided iron core piece 11, a divided cutting line 15 of the divided yoke piece portion 18, and a region where the caulking portion 20 is formed, Two sets of regions in which the magnetic pole piece portion 16 for the two-divided iron core piece 12, the divided cutting line 15a of the divided yoke piece portion 19, and the caulking portion 20 are formed are alternately formed.
In the station F, while being held by a stripper on a die (not shown), the first divided core piece 11 and the second divided core piece 12 are externally extracted with a divided core piece punch for externally extracting and sequentially drawn into a die hole (not shown) Caulking and stacking is performed on a cradle provided in the die hole.
[0026]
At this time, on the cradle, the first divided core pieces 11 and the second divided core pieces 12 are successively and alternately placed one after another, but the first divided pieces placed at the beginning of the continuation. The iron core piece 11 and the second divided iron core piece 12 are placed with the surface on which the extracted portion 22 is formed on the divided yoke piece portions 18 and 19 being placed downward, respectively. And in the 2nd division | segmentation iron core piece 12, the surface in which the extraction part 22 is formed in the division | segmentation yoke piece parts 18 and 19 is mounted.
Therefore, in the first divided iron core piece 11 and the second divided iron core piece 12 which are continuously placed two by two on the cradle, the extracted portion 22 formed in the divided yoke piece portions 18 and 19 at the time of punching is outside. Facing each other and the burrs formed at the time of punching are in contact with each other, and are caulked and laminated.
[0027]
And the division | segmentation laminated core block 13 is formed by repeating the crimping | stacking lamination | stacking of the 1st division | segmentation iron core piece 11 and the 2nd division | segmentation iron core piece 12 to desired stacking thickness.
In addition, on one side of the divided yoke portion 14 of each divided laminated core block 13 formed, one side of the first divided core piece 11 protrudes, one side of the second divided core piece 12 recedes, and the convex portion 23 and The recesses 24 are alternately formed. Further, on the other side of the divided yoke portion 14, the other side of the first divided core piece 11 retreats, the other side of the second divided core piece 12 protrudes, and concave portions 24 and convex portions 23 are alternately formed.
Therefore, the divided laminated core block 13 manufactured in this embodiment is in the state of the laminated iron core 10 connected in an annular shape.
[0028]
In winding, the divided laminated core blocks 13 are separated individually or separated so that the intervals between the magnetic pole portions 21 are widened with the divided yoke portions 14 connected to each other. To the state. And after winding to each magnetic pole part 21, each division | stacking laminated core block 13 is arrange | positioned cyclically | annularly, and it is adjacent to the convex part 23 and the recessed part 24 of the one side of the division | segmentation yoke part 14 of the division | segmentation laminated core block 13. The recessed portion 24 and the protruding portion 23 on the other side of the divided yoke portion 14 of the matching divided laminated core block 13 are inserted, and the divided laminated core blocks 13 are connected and integrated with each other to form the annular laminated core 10.
Here, since each of the protruding corners 23 and the bottom corners of the recesses 24 are provided with the extracted portions 22, the leading corners of the convex portions 23 are rounded. A relief space is formed at the bottom corner of each recess 24.
For this reason, the concave portion 24 and the convex portion 23 on the other side of the divided yoke portion 14 of the adjacent divided laminated core block 13 are made different from the convex portion 23 and the concave portion 24 on one side of the divided yoke portion 14 of the divided laminated core block 13. The resistance at the time of entering can be reduced, and the divided laminated iron core blocks 13 can be easily connected to each other without particularly providing a rotation connecting portion.
[0029]
As mentioned above, although embodiment of this invention was described, this invention is not limited to this embodiment, The change in the range which does not change the summary of invention is possible, Each above-mentioned embodiment is possible. A case where the method for manufacturing a laminated core of the present invention is configured by combining some or all of the forms and modifications is also included in the scope of the right of the present invention. For example, in the present embodiment, the first divided iron core pieces and the second divided iron core pieces are each continuously and caulked and laminated to form a divided laminated iron core block, but every three or more pieces are continuously caulked and laminated. May be. Moreover, you may change the number of 1st division | segmentation core pieces and a 2nd division | segmentation core piece from the middle of lamination | stacking.
In this embodiment, the first divided core piece and the second divided core piece are each formed in an annular shape..
[0030]
【The invention's effect】
Claim1In the laminated core manufacturing method described above, the first divided core piece in which the lengths of the divided yoke pieces extending asymmetrically with respect to the symmetry axis in a plan view of the magnetic pole piece are formed asymmetrically; and A second split core piece in which the length of the split yoke piece extending from both sides of the symmetry axis in a plan view of the magnetic pole piece is formed in a reverse asymmetric manner with respect to the first split core piece.From a strip-shaped electrical steel sheet with a rotor piece cut outRespectivelyFormed in a ringPunching process,Each arranged in a ringCaulking and laminating the first divided core piece and the second divided core piece, Convex portions and concave portions are alternately formed on one side, and concave portions and convex portions are alternately formed on the other side and connected in an annular shapeProcess for forming split laminated core blockAndTherefore, it is possible to easily manufacture a laminated iron core formed by connecting divided laminated iron core blocks without particularly providing a rotation connecting portion constituted by a half-punched concavo-convex portion that is likely to cause a manufacturing failure. And it becomes possible to manufacture a laminated iron core stably using the metal thin plate of arbitrary thickness, without requiring the skilled staff who has an advanced technique.
In addition, a mold apparatus for forming the rotation connecting portion is not necessary, and the manufacturing process of the laminated core can be shortened, and an increase in the manufacturing cost of the laminated core can be suppressed.
[0031]
In particular,thisIn the method of manufacturing a laminated core, a plurality of first divided core pieces and a plurality of second divided core pieces are alternately laminated in succession, and a plurality of first divided core pieces and second divided core pieces are continuously provided. The first divided core piece and the second divided core piece that are first laminated are formed by punching and forming the divided yoke piece from below, and then forming the first divided core piece and the second divided core piece. Since the first divided core piece and the second divided core piece to be laminated lastly are formed by punching the divided yoke piece from above and forming the outer shape, the obtained divided pieces are laminated. In the laminated core block, the leading corners of the convex portions respectively formed on both sides of the divided yoke portion can be in a state in which the extracted portions are arranged, and the divided yoke portion of the divided laminated core block can be arranged. Convex part on one side It is possible to reduce the resistance when the concave portion and the convex portion on the other side of the divided yoke portion of the adjacent divided laminated core block are respectively connected to the concave portion, and the surface of the divided yoke portion is damaged. There is no sticking. As a result, the connecting operation can be easily performed, and the productivity of the laminated core can be improved.
Furthermore, a laminated iron core can be stably manufactured from an extremely thin metal sheet, for example, one having a thickness of less than 0.2 mm. As a result, it is possible to obtain a laminated core in which energy saving and higher efficiency are further advanced.
[0032]
[Brief description of the drawings]
FIG. 1 is a perspective view of a laminated core manufactured by a method for manufacturing a laminated core according to an embodiment of the present invention.
FIG. 2 is a plan view when a first divided core piece constituting the laminated core is punched and formed.
FIG. 3 is a plan view when a second divided core piece constituting the laminated core is formed by punching.
FIG. 4 is a perspective view of a divided laminated core block of the laminated iron core.
FIG. 5 is an explanatory view showing a forming process of forming a first divided core piece and a second divided core piece that are sequentially formed on a metal thin plate at each station in the mold apparatus;
FIG. 6 is an explanatory view of a laminated core of a conventional example.
[Explanation of symbols]
10: laminated iron core, 11: first divided iron core piece, 12: second divided iron core piece, 13: divided laminated iron core block, 14: divided yoke part, 15, 15a: divided cutting line, 16: magnetic pole piece part, 17: Shaft part, 18, 19: Split yoke piece part, 20: Caulking part, 21: Magnetic pole part, 22: Pull-out part, 23: Convex part, 24: Concave part, 25: Metal thin plate, 26: Guide hole, 28: Rotation Child, 29: hole

Claims

The first split core piece, in which the length of the split yoke piece extending on both sides of the symmetry axis in a plan view of the magnetic pole piece portion is formed asymmetrically with respect to the symmetry axis, and the magnetic pole piece portion in plan view The second split core piece, in which the length of the split yoke piece extending on both sides of the symmetric axis with respect to the symmetric axis is formed in a reverse asymmetric manner with respect to the first split core piece, is a belt-like shape in which the rotor piece is cut out. Forming and punching each electromagnetic steel sheet in an annular shape ,
The first divided core pieces and the second divided core pieces arranged in an annular shape are respectively caulked and laminated , and convex portions and concave portions are alternately formed on one side, and concave portions and convex portions are alternately formed on the other side. and a step of forming a concatenated laminated core segments blocks,
Further, a plurality of the first divided core pieces and a plurality of the second divided core pieces are alternately laminated in succession, and a plurality of the first divided core pieces and the second divided core pieces are continuously laminated. In the process, the first divided core piece and the second divided core piece that are first laminated are formed by punching and forming the divided cutting line of the divided yoke piece portion from below, and then removing the outer shape. In addition, the first divided core piece and the second divided core piece to be laminated lastly are formed by punching a dividing cutting line of the divided yoke piece portion from above. An outer shape is formed after the outer shape is removed, and a cutout portion formed at the time of punching is formed at the tip corners of the convex portions formed on both sides of the divided yoke portion of the divided laminated core block. Manufacturing method of iron core.