JP4392030B2 - Manufacturing method of iron core for cylindrical coil - Google Patents

Description

  The present invention relates to a method for manufacturing an iron core for a cylindrical coil composed of a plurality of iron plate pieces having different widths.

  For example, a substantially cylindrical iron core (hereinafter referred to as a cylindrical coil iron core) in which a plurality of iron plate pieces having different widths are stacked and fixed is used for the iron core of the ignition coil. This iron core for a cylindrical coil is manufactured by punching a plurality of iron plate pieces having different widths from a steel strip, and laminating and fixing these iron plate pieces by caulking or the like (see, for example, Patent Document 1).

  In the manufacturing method described in Patent Literature 1, two slits extending in the longitudinal direction of the strip (in the transport direction of the strip) are formed by a punching mechanism with respect to the strip that is intermittently transported. These two slits are formed so as to face each other in the width direction of the steel strip. Subsequently, caulking projections or through holes are formed in a region to be punched between the two slits in the steel strip. The region to be punched in which the protrusions or through holes are formed is punched from the steel strip as an iron plate piece. The punched iron plate piece is placed on the previously punched iron plate piece, and is integrated with the iron plate piece directly below by press-fitting fitting of protrusions or by press-fitting fitting of protrusions into the through holes. In the manufacturing method described in Patent Document 1, an iron core is manufactured by repeatedly performing these steps. The punching mechanism includes a punch and a die, and is configured to be movable in the width direction of the steel strip so as to change the interval between the slits. Therefore, the width of the iron plate piece to be punched can be easily changed by changing the position of the punching mechanism.

Japanese Patent Laid-Open No. 10-163051

  By the way, an electromagnetic steel sheet produced by adding silicon to iron is suitably used for the iron plate (strip steel) that is the material of the iron core. Electrical steel sheets, particularly grain-oriented electrical steel sheets, are expensive compared to other steel sheets, and in addition, prices have recently increased. Therefore, in order to manufacture the iron core at a low cost, it is desirable to increase the material yield as high as possible. For this purpose, it is necessary to prevent as much scrap as possible in the process of manufacturing the iron core. However, the manufacturing method described in Patent Document 1 has a problem that part of the steel strip punched out to form the slits becomes scrap and the material yield is poor.

  Moreover, in the manufacturing method of patent document 1, in order to manufacture one iron core, the said process of punching one piece at a time from a steel strip and laminating and fixing it is repeated by the number of iron plate pieces constituting the iron core. It was necessary and production efficiency was bad. Furthermore, in order to change the width of the steel sheet piece punched from the steel strip, it is necessary to perform fine control on the punching mechanism, and complicated equipment is required to manufacture the iron core.

  Moreover, in the manufacturing method described in Patent Document 1, since the steel plate pieces are punched one by one by moving the punching mechanism while intermittently feeding the steel strip, a dimensional error is likely to occur in each steel plate piece. As a result, there is a problem that an accurate cylindrical iron core cannot be manufactured.

  The present invention has been made in view of such problems, and provides a method for manufacturing a cylindrical coil core that can improve the yield of materials and can efficiently manufacture a cylindrical coil core with simple equipment. The purpose is to do.

  It is another object of the present invention to provide a method for manufacturing a cylindrical coil core that can easily manufacture an accurate cylindrical coil core.

(1) A method for manufacturing an iron core for a cylindrical coil according to the present invention is a method for manufacturing an iron core for a cylindrical coil composed of a predetermined number of iron plate pieces having different widths, and is substantially the same as the total width of the iron plate pieces. After pressing one iron plate having the same constant width to form a crimping portion at each position corresponding to each iron plate piece, the one iron plate is divided in the width direction to form each iron plate piece. The first step of forming a predetermined number of strip-shaped iron plates corresponding to each other, and the narrow and long strip-shaped iron plates are sequentially opposed to each other centering on the wide strip-shaped iron plate to form a column cross section of the cylindrical coil iron core. Obtained by a second step of arranging in a row toward both outer sides of the direction, a third step of laminating and fixing the above-mentioned predetermined number of strip-shaped iron plates by caulking between the caulking portions of each other, and the above laminating and fixing. Cutting the laminated body at predetermined intervals in the axial direction. 4 steps.

  The iron core for cylindrical coils manufactured by this manufacturing method is composed of a predetermined number of iron plate pieces having different widths. Here, the predetermined number of iron plate pieces having different widths include the case where the predetermined number of iron plate pieces have the same width in addition to the case where all the iron plate pieces have different widths. . When manufacturing the iron core for cylindrical coils, the iron plate which has a fixed width is parted in the width direction in a 1st process. Thereby, a predetermined number of strip-shaped iron plates having different widths are formed. The predetermined number of strip-shaped iron plates respectively correspond to the predetermined number of iron plate pieces. In other words, a predetermined number of strip-shaped iron plates having a predetermined length and cut in the width direction correspond to a predetermined number of iron plate pieces, respectively. The constant width of the iron plate is set to be approximately equal to the total width of the predetermined number of iron plate pieces. For this reason, a predetermined number of strip-shaped iron plates are formed from the said iron plate, without producing scrap in the width direction of the iron plate which has the said fixed width.

In addition, since the crimping portion is formed before one iron plate is broken into the strip iron plate, the position accuracy of the crimping portion formed on each strip-shaped iron plate is high. As a result, it is possible to easily manufacture an accurate cylindrical coil iron core. In addition, it is possible to easily stack and fix a predetermined number of arranged strip-shaped iron plates.

In the second step, a predetermined number of strip-shaped iron plates formed in the first step are arranged as follows. That is, the narrow strip-shaped iron plates are arranged in a line in sequence toward both outer sides in the direction in which the front and back surfaces face each other centering on the wide strip-shaped iron plate. Thereby, each strip | belt-shaped iron plate is arrange | positioned in order to form the cylindrical cross section of the iron core for cylindrical coils. A predetermined number of strip-shaped iron plates arranged in a row are laminated and fixed by caulking in the third step. Thereby, the rod-shaped laminated body whose cross section is substantially circular is obtained. In the fourth step, the laminated body is cut at a predetermined interval in the axial direction to form an iron core for a cylindrical coil.

(2) The iron plate having the constant width may be a grain-oriented electrical steel sheet.

( 3 ) A method for manufacturing an iron core for a cylindrical coil according to the present invention is a method for manufacturing an iron core for a cylindrical coil composed of a predetermined number of iron plate pieces having different widths, and is substantially the same as the total width of the iron plate pieces. A first convex portion projecting to the first surface side which is one of the front and back surfaces of the iron plate having the same constant width and a second convex portion projecting to the second surface side which is the other of the front and rear surfaces are in the width direction of the iron plate. A forming step of forming the iron plate so that the width of each first protrusion and the width of each second protrusion have an uneven shape corresponding to the width of each band-shaped iron plate, and the formed iron plate Each of the first protrusions and the second protrusions is pressed to break each boundary between the first protrusions and the second protrusions to form a predetermined number of strips corresponding to the iron plate pieces. Breaking step of forming a crimped portion on each belt-shaped iron plate in a state where the belt-shaped iron plate is fixed, A first step including, first arranged in a row towards both outer directions front and back surfaces of each other successively narrow strip steel plate about a wide band steel plate to form a cylindrical cross section of the core for the cylindrical coil is opposed A second step, a third step of laminating and fixing the predetermined number of the strip-shaped iron plates arranged by caulking between each other, and a step of cutting the laminated body obtained by the laminating and fixing at predetermined intervals in the axial direction 4 steps.

  The iron core for cylindrical coils manufactured by this manufacturing method is composed of a predetermined number of iron plate pieces having different widths. Here, the predetermined number of iron plate pieces having different widths include the case where the predetermined number of iron plate pieces have the same width in addition to the case where all the iron plate pieces have different widths. . When manufacturing the iron core for cylindrical coils, the iron plate which has a fixed width is parted in the width direction in a 1st process. Thereby, a predetermined number of strip-shaped iron plates having different widths are formed. The predetermined number of strip-shaped iron plates respectively correspond to the predetermined number of iron plate pieces. In other words, a predetermined number of strip-shaped iron plates having a predetermined length and cut in the width direction correspond to a predetermined number of iron plate pieces, respectively. The constant width of the iron plate is set to be approximately equal to the total width of the predetermined number of iron plate pieces. For this reason, a predetermined number of strip-shaped iron plates are formed from the said iron plate, without producing scrap in the width direction of the iron plate which has the said fixed width.

  In the forming step, the iron plate having a certain width is formed into a concavo-convex shape in which the first protrusions and the second protrusions are alternately arranged in the width direction. Here, a 1st convex part is the part which protruded in the 1st surface side which is one of the front and back surfaces of the said iron plate, and a 2nd convex part is the part which protruded in the 2nd surface side which is the other of the front and back surfaces of the said iron plate. It is. The iron plate formed into a concavo-convex shape is pressed in the breaking process. By this pressing, an external force relatively acts so as to press each first convex portion to the second surface side and press each second convex portion to the first surface side. For this reason, each boundary between each 1st convex part and each 2nd convex part is fractured | ruptured. Here, since the width of each 1st convex part and the width | variety of each 2nd convex part respond | correspond to the width | variety of each said strip | belt-shaped iron plate, each 1st convex part and each 2nd convex part are a predetermined number strip | stripe by the said fracture | rupture. It becomes a strip-shaped iron plate.

Further , the crimped portion is formed before the iron plate is divided in the width direction. For this reason, compared with the case where a crimping part is formed in each strip | belt-shaped iron plate obtained by dividing an iron plate, the position accuracy of a crimping part is high. As a result, an accurate cylindrical coil iron core is easily manufactured .

  In the second step, a predetermined number of strip-shaped iron plates formed in the first step are arranged as follows. That is, the narrow strip-shaped iron plates are arranged in a line in sequence toward both outer sides in the direction in which the front and back surfaces face each other centering on the wide strip-shaped iron plate. Thereby, each strip | belt-shaped iron plate is arrange | positioned in order to form the cylindrical cross section of the iron core for cylindrical coils. A predetermined number of strip-shaped iron plates arranged in a row are laminated and fixed by caulking, an adhesive, or the like in the third step. Thereby, the rod-shaped laminated body whose cross section is substantially circular is obtained. In the fourth step, the laminated body is cut at a predetermined interval in the axial direction to form an iron core for a cylindrical coil.

( 4 ) The first protrusions and the second protrusions are arranged so that the width of each of the first protrusions and the width of each of the second protrusions gradually decreases from the center in the width direction toward both ends. It is preferable to arrange.

  In this structure, each boundary between each 1st convex part and each 2nd convex part is fractured | ruptured by a fracture | rupture process, The 1st convex part and 2nd convex part which are located in the center of the width direction of an iron plate are wide. It becomes a strip-shaped iron plate, and the first convex portion and the second convex portion located at both ends are narrow strip-shaped iron plates. Therefore, it becomes easy to arrange the strip-shaped iron plates in a row in the direction in which the front and back surfaces face each other.

  (5) In the first step, a shearing force is applied to each strip-shaped iron plate to form a stepped portion that is half-cut in the thickness direction, and in the fourth step, the laminate is pressed to form a step in each strip-shaped iron plate. The part may be broken.

  In the first step, a shearing force is applied to each strip-shaped iron plate. Thereby, a level | step difference part is formed in the thickness direction of each strip | belt-shaped iron plate. Each strip-shaped iron plate is laminated and fixed so that the stepped portions are arranged in a row in the direction of the front and back surfaces. The step portion of each belt-shaped iron plate is in a half-cut state that is easily broken by being pressed in the front and back direction. By pressing the laminate in the fourth step, the laminate is easily cut.

  (6) The first step includes a partial dividing step of dividing the partial region in the iron plate where the stepped portion is formed in the width direction, and forming the stepped portion in the partial region divided in the width direction. A half-cutting process.

  The step portion is formed in a state where only a partial region of the iron plate is divided in the width direction. For this reason, the positional accuracy of the step part formed in each strip-shaped iron plate is high, and as a result, it becomes possible to easily manufacture an accurate cylindrical core for a cylindrical coil.

(7) In the first step, a caulking portion may be formed before the step portion is formed on the iron plate.

Thereby, since a crimping part is formed ahead of a level difference part, a level difference part is not fractured when forming a crimping part.

  (8) The iron plate having the constant width may be a grain-oriented electrical steel sheet.

According to the method for manufacturing a cylindrical coil iron core according to the present invention, almost no scrap is generated. Therefore, compared with the conventional manufacturing method in which slits are provided in the width direction and the longitudinal direction of an iron plate and an iron plate piece is punched from the iron plate, the material yield is reduced. Can be improved. In addition, since the core for a cylindrical coil is formed by cutting a laminate obtained by laminating and fixing a predetermined number of strip-shaped iron plates, a plurality of iron plate pieces having different widths are laminated and fixed in order. As compared with the case of manufacturing, the iron core for cylindrical coils can be efficiently manufactured with simpler equipment. Therefore, the iron core for cylindrical coils can be manufactured at low cost. In addition, since the crimping portion is formed before one iron plate is broken into the strip iron plate, the position accuracy of the crimping portion formed on each strip-shaped iron plate is high. As a result, it is possible to easily manufacture an accurate cylindrical coil iron core. In addition, it is possible to easily stack and fix a predetermined number of arranged strip-shaped iron plates.

  Hereinafter, a first embodiment of the present invention will be described with reference to the drawings as appropriate. In addition, this Embodiment is only one aspect | mode of the manufacturing method of the iron core for cylindrical coils which concerns on this invention, and it cannot be overemphasized that an embodiment can be changed in the range which does not change the summary of this invention.

  FIG. 1 is a perspective view showing an appearance of a cylindrical coil core 1 manufactured by the method for manufacturing a cylindrical coil core according to the present embodiment. FIG. 2 is a longitudinal sectional view showing the laminated structure of the cylindrical coil iron core 1. 3 is a plan view of the cylindrical coil core 1 as viewed from the direction of arrow III in FIG.

  The iron core 1 for cylindrical coils is an iron core (core) used for an ignition coil etc., for example. The iron core 1 for cylindrical coils is composed of 28 pieces (an example of a predetermined number) of iron plate pieces 2 (iron plate pieces 11 to 29) having different widths in the present embodiment. The iron plate pieces 11 to 29 are flat and have a rectangular shape in plan view. As shown in FIGS. 1 to 3, the iron plate pieces 11 to 29 have the same length in the long side direction and different widths.

  As shown in FIG. 2, the iron plate pieces 11 to 29 have eight wide iron plate pieces 20 arranged at the center in the direction in which the front and back surfaces face each other (vertical direction in FIG. 2), The narrow iron plate pieces 2 are arranged so that the width becomes narrower sequentially toward both ends in the front and back direction. Specifically, four iron plate pieces 19 and 21 having the next widest width after the iron plate piece 20 are arranged above and below the eight wide iron plate pieces 20. And the width | variety of the iron plate piece 2 becomes narrow gradually toward the both ends of an up-down direction, and the width | variety of the two iron plate pieces 11 and 29 arrange | positioned at both ends is the narrowest.

  As described above, the cylindrical coil iron core 1 has a structure in which the iron plate pieces 11 to 29 having different widths are stacked and fixed so that they are arranged in a row in the direction of the front and back surfaces of each iron plate piece 2. It is substantially circular (see FIG. 2). It should be noted that the 28 iron plate pieces 2 having different widths (an example of a predetermined number) have the same 28 iron plate pieces 2 as in this embodiment in addition to the case where all the iron plate pieces 2 have different widths. The case of having the width iron plate piece 2 (the iron plate piece 20 or the like) is also included. Further, the number (a predetermined number) of the iron plate pieces 2 constituting the cylindrical coil iron core 1 is not limited to 28, and may be, for example, about 10 as long as the number is 3 or more.

  As shown in FIGS. 1 and 2, the iron plate pieces 11 to 28 are formed with three concave portions 3 (caulking portions in the present invention) in the longitudinal direction. The recessed part 3 is deformed so that each of the steel plate pieces 11 to 28 is recessed from one of the front and back surfaces to the other. As shown in FIGS. 2 and 3, the iron plate piece 29 is formed with three through holes 4 (caulking portions in the present invention) in the longitudinal direction. The through hole 4 is formed so as to penetrate in the front and back direction of the iron plate piece 29. The iron plate pieces 11 to 28 are fixed to each other by engagement of the recessed portions 3, and the iron plate pieces 28 and 29 are fixed to each other by fitting the recessed portion 3 of the iron plate piece 28 into the through hole 4 of the iron plate piece 29. That is, the iron plate pieces 11 to 29 are laminated and fixed to the cylindrical coil iron core 1 by so-called caulking.

  FIG. 4 is a schematic view showing the iron core manufacturing apparatus 30.

  The iron core manufacturing apparatus 30 is an apparatus for continuously manufacturing the iron core 1 for a cylindrical coil by performing the first to fourth steps in the present invention. The iron core manufacturing apparatus 30 includes an iron plate guide 31, half-cut rollers 40a and 40b, a press machine 50, sensors 32a and 32b, a strip-shaped iron plate guide 33, a rolling machine 70, a vise 34, a cutting machine 35, a chute 36, and a collection box 37. Is provided.

  5 is a front view of the half-cut rollers 40a and 40b as viewed from the direction of the arrow V in FIG. FIG. 6 is a side view of the half-cut rollers 40a and 40b. FIG. 7 is an enlarged view of a portion VII in FIG. FIG. 8 is an enlarged view of a portion VIII in FIG.

  The iron core 1 for cylindrical coils is manufactured from the iron plate 6 (refer FIG.6 and FIG.14) which has a fixed width substantially equivalent to the sum total of the width | variety of each iron plate piece 11-29. As the iron plate 6, a grain-oriented electrical steel plate that can easily magnetize a steel plate only in one direction is preferably used. However, the iron plate 6 is not limited to this, and may be a non-oriented electrical steel plate that is not biased in a specific direction of the steel plate. In addition, the width dimension of the iron plate 6 is suitably changed according to the sum total of the width | variety of the iron plate pieces 11-29. In other words, the width dimension of the iron plate 6 is changed according to the width and the number of the iron plate pieces 2 constituting the iron core 1 for a cylindrical coil.

  As will be described later, the iron plate 6 is conveyed by the half-cut rollers 40a and 40b, and is formed on the concavo-convex plate 7 by the half-cut rollers 40a and 40b (see FIGS. 6, 14, and 15). As shown in FIG. 5 to FIG. 8, the half-cut roller 40 a and the half-cut roller 40 b are arranged to face each other vertically with a predetermined distance d (see FIG. 8) across the conveyance path of the iron plate 6. This distance d is set within a range of 20 to 50% of the thickness of the iron plate 6 fed between the half-cut roller 40a and the half-cut roller 40b. The half-cut roller 40a is provided to be rotatable about a shaft 41 with a direction (perpendicular to the paper surface in FIG. 4) substantially orthogonal to the conveying direction of the iron plate 6 (right direction in FIG. 4) as an axial direction ( (See FIG. 6). The half-cut roller 40b is provided to be rotatable about a shaft 42 with the same direction as the half-cut roller 40a being the axial direction. Although not shown in the drawing, the half-cut roller 40a and the half-cut roller 40b rotate when the driving force of the drive source is transmitted to the shafts 41 and 42 via a drive transmission mechanism in which a plurality of gears are engaged. .

  As shown in FIGS. 5 to 8, the half-cut roller 40 a is provided with a concave peripheral surface 45 and a convex peripheral surface 46 on the outer peripheral surface of the roller body 43. The concave peripheral surface 45 constitutes the same peripheral surface as the outer peripheral surface of the roller body 43 in this embodiment (see FIG. 5). The convex peripheral surface 46 is provided so as to protrude outward in the radial direction of the roller body 43 from the concave peripheral surface 45. The concave peripheral surface 45 and the convex peripheral surface 46 are provided so as to extend in the rotation direction of the half-cut roller 40a. Further, the concave peripheral surface 45 and the convex peripheral surface 46 are alternately provided in the direction of the axis 41 (the left-right direction in FIG. 5). The concave peripheral surface 45 and the convex peripheral surface 46 are provided so that the width is gradually reduced from the center in the direction of the shaft 41 toward both ends (see FIG. 5). That is, the width of the concave peripheral surface 45 and the convex peripheral surface 46 positioned at the center in the direction of the shaft 41 is the widest, and the width of the concave peripheral surface 45 and the convex peripheral surface 46 positioned at both ends in the direction of the shaft 41 is the narrowest. The width of each concave peripheral surface 45 and each convex peripheral surface 46 is set. The widths of the concave peripheral surfaces 45 and the convex peripheral surfaces 46 are set so as to correspond to (approximately equal to) the widths of the iron plate pieces 11 to 29, respectively. Therefore, in the present embodiment, the widths of the eight concave peripheral surfaces 45 and the convex peripheral surfaces 46 located at the center in the direction of the axis 41 are both set to substantially the same value as the width of the iron plate piece 20 (see FIG. 2). ing. Further, the widths of the concave peripheral surface 45 and the convex peripheral surface 46 located at both ends in the direction of the axis 41 are set to be substantially the same as the widths of the iron plate pieces 11 and 29. Therefore, the total width in the direction of the axis 41 of each concave peripheral surface 45 and each convex peripheral surface 46 is substantially equal to the total width of the iron plate pieces 11 to 29. In addition, when the width | variety of each iron plate piece 11-29 is changed, the width | variety of each concave peripheral surface 45 and each convex peripheral surface 46 is also changed according to it.

  The half-cut roller 40b is configured to be rotatable about a shaft 42. A concave peripheral surface 47 and a convex peripheral surface 48 are provided on the outer peripheral surface of the roller main body 44 of the half-cut roller 40b. The concave peripheral surface 47 constitutes the same peripheral surface as the outer peripheral surface of the roller body 44 (see FIG. 5). The convex peripheral surface 48 is provided so as to protrude further outward in the radial direction of the roller body 44 than the concave peripheral surface 47. The concave peripheral surface 47 and the convex peripheral surface 48 are provided so as to extend in the rotation direction of the half-cut roller 40b. Further, the concave peripheral surface 47 and the convex peripheral surface 48 are alternately provided in the direction of the axis 42 (left and right direction in FIG. 5). The concave circumferential surfaces 47 and the convex circumferential surfaces 48 are alternately arranged in the direction of the shaft 42 such that the concave circumferential surface 47 faces the convex circumferential surface 46 and the convex circumferential surface 48 faces the concave circumferential surface 45. (See FIGS. 5 and 7). The width of each concave peripheral surface 47 is set to be substantially equal to the width of the convex peripheral surface 46 facing each other. Further, the width of each convex peripheral surface 48 is set to be approximately equal to the width of the concave peripheral surface 45 facing each other.

  The iron plate guide 31 (see FIG. 4) regulates the movement of the iron plate 6 conveyed by the half-cut rollers 40a and 40b in the width direction (direction perpendicular to the paper surface in FIG. 4). The iron plate guide 31 is provided on the upstream side (left side in FIG. 4) of the iron plate 6 in the conveying direction of the half-cut rollers 40a and 40b. By providing the iron plate guide 31, the iron plate 6 is fed between the half-cut rollers 40a and 40b without being displaced in the width direction. Specifically, the iron plate 6 does not pass through the outer sides in the directions of the shafts 41 and 42 rather than the concave peripheral surfaces 45 and 47 and the convex peripheral surfaces 46 and 48 located on both side edges of the half-cut rollers 40a and 40b. The iron plate 6 is conveyed.

  The distance between the convex peripheral surface 46 of the half-cut roller 40a and the convex peripheral surface 48 of the half-cut roller 40b is the distance d. Since the interval d is set within a range of 20 to 50% of the thickness of the iron plate 6 as described above, when the iron plate 6 enters between the half-cut roller 40a and the half-cut roller 40b, the iron plate 6 is moved to the half-cut roller 40a and the half-cut roller 40a. It is held in the thickness direction by the half-cut roller 40b. Thereby, the rotational force of the half-cut roller 40a and the half-cut roller 40b is reliably transmitted to the iron plate 6, and the iron plate 6 is conveyed. At that time, the iron plate 6 receives a pressing force in the thickness direction from the half-cut roller 40a and the half-cut roller 40b, and is formed into the concave-convex plate 7 having a concave-convex shape in the width direction (see FIGS. 14 and 15). Therefore, the iron plate 6 is sent to the press machine 50 as the concavo-convex plate 7 while being formed into a concavo-convex shape by the half-cut roller 40a and the half-cut roller 40b.

  FIG. 9 is a schematic cross-sectional view showing the press machine 50. FIG. 10 is a perspective view showing the back plate 59. FIG. 11 is a perspective view showing the upper plate 60. FIG. 12 is a perspective view showing the back plate 65. FIG. 13 is a perspective view schematically showing the base 54.

  The press machine 50 shown in FIG. 9 forms the strip-shaped iron plate 8 (see FIG. 22) by dividing the uneven plate 7 fed by the half-cut rollers 40a and the half-cut rollers 40b in the width direction. A lower mold 52 is provided.

  The base 53 of the upper mold 51 is provided with guide shafts 55 extending downward at both ends in the width direction (left and right direction in FIG. 9). The guide shaft 55 is inserted into a guide hole 56 provided in the lower mold 52 and supported so as to be movable up and down. Thereby, the upper mold | type 51 is comprised so that a movement to a horizontal direction is controlled and it can be moved up and down with respect to the lower mold | type 52. As shown in FIG. A plate housing portion 62 is provided on the lower surface side of the base portion 53. A back plate 59 (see FIG. 10) is housed in the plate housing portion 62 so as to be sandwiched between the base 53 and the upper plate 60 (see FIG. 11). A press plate 61 (see FIG. 9) is provided below the upper plate 60.

  The press plate 61 has a shaft hole 38 (see FIG. 9) through which the guide shaft 55 is inserted. The press plate 61 is supported so as to be movable up and down with respect to the base 53 via a pressure spring 58 with the guide shaft 55 inserted through the shaft hole 38. When an external force is applied upward with respect to the press plate 61, the pressure spring 58 contracts and the press plate 61 is pushed up toward the base 53. At this time, an elastic force (repulsive force) is generated in the pressurizing spring 58, and the elastic force and the weight of the press plate 61 act on the press plate 61 as a pressing force that pushes the press plate 61 downward. As will be described later, this pressing force presses the concavo-convex plate 7 (see FIG. 15) at a constant pressure, thereby forming 28 strips of iron plates 91 to 109 (see FIG. 22).

  As shown in FIG. 10, a press pin 68, a cut pin 69, and a half-cut plate 64 are provided on the lower surface of the back plate 59. The press pin 68 is for forming the recessed portion 3 (crimped portion) in the belt-shaped iron plates 91 to 108 (see FIG. 25), and on the lower surface of the back plate 59, the width direction of the back plate 59 (in FIG. 9). 27 press pins 68 are suspended in the horizontal direction. The cut pin 69 is for forming the through hole 4 (crimped portion) in the belt-shaped iron plate 109 (see FIG. 25), and is adjacent to the right end press pin 68 of the 27 press pins 68. It is suspended from the lower surface of the back plate 59 (see FIGS. 9 and 10). That is, 27 press pins 68 and one cut pin 69 are arranged on the lower surface of the back plate 59 in the width direction of the back plate 59. These 28 pins are arranged in three rows in the depth direction of the back plate 59.

  The half-cut plate 64 is suspended from the lower surface of the back plate 59 so as to extend in the width direction of the back plate 59. The half-cut plate 64 is for forming the half-cut portion 39 (see FIG. 25) in the belt-like iron plates 91-109. Therefore, the half-cut plate 64 is configured such that the length in the width direction of the back plate 59 is slightly longer than the total width of the strip-shaped iron plates 91 to 109. 9 schematically shows the structure of the press machine 50 as viewed from the direction of the arrow V in FIG. 4, the half-cut plate 64 is not shown in FIG. That is, the half-cut plate 64 is positioned on the downstream side in the conveying direction of the concavo-convex plate 7 with respect to the press pin 68 and the cut pin 69 in the state where the back plate 59 is housed in the plate housing portion 62 of the base 53 (right side in FIG. 4). As shown in FIG.

  As shown in FIGS. 9 and 11, the upper plate 60 is provided with insertion holes 77, 80, 81. The insertion hole 77 is through which the press pin 68 is inserted. The insertion hole 80 is for inserting the half-cut plate 64. In addition, the insertion hole 80 is not represented in FIG. 9 like the half-cut plate 64. The insertion hole 81 is for the cut pin 69 to be inserted therethrough. Thus, since the insertion holes 77, 80, 81 are formed in the upper plate 60, the press pin 68, the cut pin 69, and the half-cut plate 64 protrude downward from the lower surface of the upper plate 60, respectively. The back plate 59 is accommodated in the plate accommodating portion 62 of the base portion 53.

  As shown in FIG. 9, the press plate 61 is provided with insertion holes 78 and 82. The insertion hole 78 is for the press pin 68 to be inserted therethrough. The insertion hole 82 is where the cut pin 69 is inserted. Although not shown in the drawing, the press plate 61 is provided with a plate insertion hole through which the half-cut plate 64 is inserted. The press pin 68 is inserted through the insertion hole 78 of the press plate 61 through the insertion hole 77 of the upper plate 60. The cut pin 69 is inserted through the insertion hole 82 of the press plate 61 through the insertion hole 81 of the upper plate 60. The half-cut plate 64 is inserted through the plate insertion hole of the press plate 61 through the insertion hole 80 of the upper plate 60.

  As shown in FIGS. 9 and 13, the base 54 of the lower mold 52 is provided with a guide hole 56 that supports the guide shaft 55 so as to be movable up and down. By inserting the guide shaft 55 through the guide hole 56, the upper mold 51 can move up and down with respect to the base 54. On both sides in the width direction (left and right direction in FIG. 9) of the table 54, material guides 57 extending in the conveying direction of the uneven plate 7 (direction perpendicular to the paper surface in FIG. 9) are provided (see FIG. 13). The material guide 57 guides the concavo-convex plate 7 sent from the half-cut rollers 40a and 40b to a predetermined position in the width direction. The material guide 57 is disposed opposite to the direction perpendicular to the conveying direction of the concavo-convex plate 7 (left and right direction in FIG. 9) with a distance substantially equal to the width of the concavo-convex plate 7. Thereby, the uneven plate 7 is guided to a predetermined position of the press plate 61.

  As shown in FIGS. 9 and 13, a back plate 65 is accommodated in the accommodating portion 49 provided on the lower surface side of the base 54. As shown in FIG. 12, lift pins 67 are provided on the upper surface of the back plate 65. The lift pins 67 push up the strip-shaped iron plates 91 to 108 upward. These lift pins 67 are provided at positions corresponding to the press pins 68. In other words, the lift pins 67 are erected on the back plate 65 so as to be positioned directly below the press pins 68 in a state where the back plate 65 is housed in the housing portion 49 of the base 54. Therefore, the lift pins 68 are arranged on the upper surface of the back plate 65 so that 27 rows are arranged in the width direction of the back plate 65 and three rows are arranged in the conveying direction of the belt-like iron plate 8.

  The base 54 is provided with an insertion hole 79 and a recovery hole 63 (see FIG. 13). The insertion hole 79 allows the lift pin 68 to be inserted from below the table 54 to the upper surface of the table 54. The insertion hole 79 is provided at a position corresponding to each lift pin 68 in the base 54. The back plate 54 is accommodated in the accommodating portion 49 of the base 54 by being urged upward by the pressure spring 66 in a state where the lift pins 68 are supported in the corresponding insertion holes 79 so as to be movable up and down. The recovery hole 63 is a hole for recovering the punched piece 86 (see FIG. 23) of the strip-shaped iron plate 109 punched by the cut pin 69. The collection hole 63 is formed in the base 54 so as to be close to one material guide 57 (the right material guide 57 in FIG. 13) (see FIG. 19). Therefore, in FIG. 13, the recovery hole 63 is shown by a broken line so as to overlap the material guide 57, but the recovery hole 63 is not provided in the material guide 57.

  As will be described in detail later, the concavo-convex plate 7 conveyed by the half-cut rollers 40a and 40b is pressed from above by the press plate 61 in the press 50, and the boundary 87 (see FIG. 15) of the concavo-convex portion is broken. Thereby, the strip | belt-shaped iron plate 8 (refer FIG. 22) of 28 items (an example of a predetermined number of items) is formed. Furthermore, the press pin 68 protruding from the lower surface of the press plate 61 in a state in which the 28 strips of the iron plate 8 (band iron plates 91 to 109) are fixed between the press plate 61 and the base 54 by pressing of the press plate 61, cut The pin 69 and the half-cut plate 64 form a crimped part (the recessed part 3 or the through hole 4) and the half-cut part 39 (see FIG. 25).

  Therefore, the length from the lower surface of the back plate 59 to the tip (lower end) of the press pin 68 is set slightly longer than the total thickness of the upper plate 60 and the press plate 61. As a result, the tip of the press pin 68 slightly protrudes from the lower surface of the press plate 61 in a state where the press plate 61 is in contact with the upper plate 60, and the strip-shaped iron plates 91 to 108 are pressed by the protruding portion to form the recessed portion 3. The The length from the lower surface of the back plate 59 to the tip (lower end) of the cut pin 69 is set longer than the total of the thickness of the upper plate 60, the thickness of the press plate 61, and the thickness of the strip-shaped iron plate 8. ing. As a result, the tip of the cut pin 69 protrudes from the lower surface of the press plate 61 in a state where the press plate 61 is in contact with the upper plate 60, and a part of the strip-shaped iron plate 109 is punched out by the protruding portion to form the through hole 4. The Further, the length from the lower surface of the back plate 59 to the lower end of the half-cut plate 64 is slightly longer than the total thickness of the upper plate 60 and the press plate 61, and is a length obtained by adding the thickness of the strip-shaped iron plate 109 to this total. Is also set short. Thus, the lower end of the half-cut plate 64 slightly protrudes from the lower surface of the press plate 61 in a state where the press plate 61 is in contact with the upper plate 60, and the strip-shaped iron plates 91 to 109 are pressed by the protruding portion to form the half-cut portion 39. Is done.

  As shown in FIG. 4, a strip-shaped iron plate guide 33 is provided on the upstream side (left side in FIG. 4) of the strip-shaped iron plate 8 in the transport direction from the compactor 70. The strip-shaped iron plate guide 33 is a direction in which the front and back surfaces of the narrow strip-shaped iron plate 8 face each other in the order of the width (in the vertical direction in FIG. 4). Are arranged in a row toward both outer sides. In this embodiment, the strip-shaped iron plates 91 to 109 are guided by the strip-shaped iron plate guide 33 so as to be aligned in a vertical direction (see FIGS. 25 and 32).

  The compactor 70 stacks and fixes the strip-shaped iron plates 8 arranged by the strip-shaped iron plate guide 33 and conveys the laminate 9 (see FIGS. 4 and 33) obtained by the stacking and fixing to the cutting machine 35. . The compacting machine 70 includes compacting rollers 71 to 76, and compacting rollers 71, 73, and 75 are disposed on the upper side of the conveying path of the belt-shaped iron plate 8, so as to face these compacting rollers, respectively. In addition, rolling rollers 72, 74, and 76 are disposed below the conveyance path of the belt-shaped iron plate 8. The rolling rollers 71, 73, and 75 are supported so as to be movable up and down, and are urged downward by their own weight and springs. The strip-shaped iron plates 8 arranged in a line by the strip-shaped iron plate guide 33 are fed between the rolling roller 71 and the rolling roller 72. Thereby, the rolling roller 71 is pushed upward. Since the rolling roller 71 is urged downward by a spring or the like, the arranged strip-shaped iron plates 8 (band-shaped iron plates 91 to 109) are pressed against the rolling roller 72. Thereby, the belt-like iron plates 91 to 109 are laminated and fixed so as to be sandwiched from the rolling rollers 71 and 72. The band-shaped iron plates 91 to 108 have a recessed portion 3 formed by a press pin 68, and the band-shaped iron plate 109 has a through hole 4 formed by a cut pin 69 (see FIG. 25). Therefore, the strip-shaped iron plates 91 to 109 arranged in a row are stacked and fixed by caulking. The compacting machine 70 is provided with compacting rollers 73 and 74 and compacting rollers 75 and 76 configured in the same manner as the compacting rollers 71 and 72. The laminated body 9 obtained by rolling the belt-shaped iron plates 91 to 109 with the rolling rollers 71 and 72 is more firmly fixed with the rolling rollers 73 and 74 and the rolling rollers 75 and 76.

  Sensors 32a and 32b are provided between the half-cut rollers 40a and 40b and the rolling rollers 71 to 76 in the path along which the belt-shaped iron plate 8 (91 to 109) is conveyed. The sensor 32a and the sensor 32b detect the belt-shaped iron plate 8 conveyed. When the speed at which the laminated body 9 is carried out from the rolling rollers 71 to 76 is faster than the speed at which the belt-like iron plate 8 is carried out from the press 50 by the half-cut rollers 40a and 40b, the amount of slackness of the belt-like iron plate 8 gradually decreases. To do. As a result, there arises a problem that the belt-like iron plate 8 is pulled by the rolling rollers 71 to 76. On the contrary, when the speed at which the belt-like iron plate 8 is carried out from the press 50 by the half-cut rollers 40a and 40b is faster than the speed at which the laminated body 9 is carried out from the rolling rollers 71 to 76, the amount of slack of the belt-like iron plate 8 is reduced. As a result, there is a problem that the strip-shaped iron plates 8 are not correctly arranged in a row by the strip-shaped iron plate guide 33. Since the sensors 32a and 32b are provided at predetermined positions in the vertical direction as in the present embodiment, the strip-shaped iron plate 8 whose slack amount has decreased excessively is detected by the sensor 32a, and conversely the slack amount increases. The band-shaped iron plate 8 that has passed is detected by the sensor 32b. Therefore, in the iron core manufacturing apparatus 30, the rotational speeds of the half-cut rollers 40a and 40b and the rolling roller are set based on the detection results of the sensors 32a and 32b so that the slack amount of the belt-shaped iron plate 8 is within a predetermined range. The rotational speed of 71 to 76 is controlled.

  The vise 34 is sandwiched so that the laminated body 9 carried out from the compactor 70 is sandwiched from above and below. The cutting machine 35 presses the downstream side in the transport direction of the laminate 9 from the upper side with respect to the half-cut portion 39 with the vice 34 holding the upstream side in the transport direction of the laminate 9 with respect to the half-cut portion 39. . Thereby, the pressed laminated body 9 is cut | disconnected from the upstream laminated body 9 so that it may be bent. A sensor for detecting the half-cut portion 39 of the laminated body 9 is provided in the vicinity of the vise 34 and the cutting machine 35, and the operation timing of the vise 34 and the cutting machine 35 is controlled based on the detection result of the sensor. It is like that.

  Hereinafter, the manufacturing method of the iron core 1 for cylindrical coils is demonstrated. The cylindrical coil iron core 1 is manufactured using the iron core manufacturing apparatus 30 described above.

  FIG. 14 is a plan view showing the half-cut roller 40a. FIG. 15 is a perspective view showing the uneven plate 7. FIG. 16 is a longitudinal sectional view of the uneven plate 7 in the width direction. FIG. 17 is an enlarged view of a portion XVII in FIG.

 When manufacturing the iron core 1 for cylindrical coils, the iron plate 6 which has a fixed width as mentioned above is used. The iron plate 6 is divided in the width direction to form 28 strip-shaped iron plates 91 to 109 (see FIG. 25) corresponding to the iron plate pieces 11 to 29 (see FIG. 2), respectively. This step corresponds to the first step of the present invention. In the present embodiment, the first step is a forming step of forming the iron plate 6 into the concavo-convex plate 7 (see FIGS. 14 to 17), and the boundary 87 of the concavo-convex plate 7 is broken to form the strip-shaped iron plates 91 to 109 (FIG. 25). A rupture step to form a reference). The forming process is executed by the half-cut rollers 40 a and 40 b, and the breaking process is executed by the press machine 50.

  As shown in FIGS. 5 and 7, the half-cut roller 40 a and the half-cut roller 40 b are such that the concave peripheral surface 45 and the convex peripheral surface 48 face each other, and the convex peripheral surface 46 and the concave peripheral surface 47 face each other. Is arranged. The distance d between the convex peripheral surface 46 and the convex peripheral surface 48 is set within a range of 20 to 50% of the thickness of the iron plate 6. Therefore, the iron plate 6 fed between the half-cut roller 40a and the half-cut roller 40b has a space between the convex peripheral surface 46 and the concave peripheral surface 47 and a space between the convex peripheral surface 48 and the concave peripheral surface 45. It is deformed to be pushed into. Such deformation is also referred to as half-cutting. Therefore, as shown in FIG. 15, the iron plate 6 having a certain width is formed into an uneven shape in which the first protrusions 84 and the second protrusions 85 are alternately arranged in the width direction. The iron plate 6 formed into a concavo-convex shape is the concavo-convex plate 7 (see FIGS. 14 to 17). Here, the 1st convex part 84 is the part which protruded to the 1st surface side (this embodiment upper surface side) which is one of the front and back of the iron plate 6, and the 2nd convex part 85 is the front and back of the iron plate 6. This is a portion protruding to the second surface side (the lower surface side in the present embodiment) which is the other side. By the way, the concave peripheral surfaces 45, 47 and the convex peripheral surfaces 46, 48 are formed on the roller bodies 43, 44 so that the widths in the directions of the shafts 41, 42 are gradually narrowed from the center of the shafts 41, 42 toward both ends. It is provided on the outer peripheral surface. Therefore, the first protrusions 84 and the second protrusions 85 are arranged so that the widths of the first protrusions 84 and the widths of the second protrusions 85 are gradually reduced from the center in the width direction toward both ends. Has been. As described above, the iron plate 6 is formed into a concavo-convex shape in which the first convex portions 84 and the second convex portions 85 are alternately arranged by the rotation of the half-cut rollers 40 a and 40 b, and is sent to the press machine 50 as the concavo-convex plate 7. This step corresponds to the molding step in the present invention.

  The iron plate 6 (uneven plate 7) formed into a concavo-convex shape is guided to the upper surface of the table 54 with both side edges in the width direction being supported by the material guide 57. When the concavo-convex plate 7 is guided onto the table 54, the base 53 of the upper mold 51 is lowered.

  FIG. 18 is a schematic cross-sectional view of the press machine 50 showing how the upper mold 51 descends. FIG. 19 is an enlarged view of the XIX portion in FIG.

  Since the press plate 61 is connected to the base 53 via the pressurizing spring 58, the press plate 61 descends together with the base 53. The concavo-convex plate 7 is guided on the upper surface of the table 54, and the lower surface of the lowered press plate 61 contacts the first convex portion 84 of the concavo-convex plate 7 (see FIGS. 18 and 19).

  FIG. 20 is a schematic cross-sectional view of the press machine 50 showing a state where the boundary 87 is broken by pressing the press plate 61. FIG. 21 is an enlarged view of the XXI portion in FIG. FIG. 22 is a perspective view showing strip-shaped iron plates 91 to 109 formed by breaking the boundary 87 of the uneven plate 7.

  The base 53 is further lowered from the state shown in FIGS. An external force acts upward on the press plate 61, and the pressure spring 58 is contracted. Thereby, the elastic force of the pressure spring 58 acts on the press plate 61, and the first convex portion 84 of the concavo-convex plate 7 is pressed downward by the press plate 61. The uneven plate 7 is pushed down toward the base 54. Since the tip of the lift pin 67 protrudes from the upper surface of the base 54, the lift pin 67 is pressed downward by the second convex portion 85 of the concavo-convex plate 7. By this pressing force, the pressure spring 66 is contracted, the back plate 65 is pushed down together with the lift pin 67, the lift pin 67 is immersed in the insertion hole 79 of the base 54, and the second convex portion 85 of the concave and convex plate 7 is the base. 54 abuts on the upper surface of 54. That is, the concavo-convex plate 7 is sandwiched from above and below by the press plate 61 and the base 54.

  When the base 53 is further lowered from this state, the uneven plate 7 is pressed by the press plate 61 so as to be pressed against the base 54. By this pressing, each first convex portion 84 is pressed to the second surface side (the lower surface side in the present embodiment), and each second convex portion 85 is pressed to the first surface side (the upper surface side in the present embodiment). As described above, an external force acts on the concavo-convex plate 7 relatively. For this reason, each boundary 87 (refer FIGS. 15-17) between each 1st convex part 84 and each 2nd convex part 85 is fractured | ruptured (refer FIG.20 and FIG.21). Here, since the width of each 1st convex part 84 and the width of each 2nd convex part 85 respond | correspond to the width | variety of each strip | belt-shaped iron plates 91-109, each 1st convex part 84 and each 2nd convex by the said fracture | rupture. The part 85 becomes the strip | belt-shaped iron plates 91-109 (refer FIG. 22).

  FIG. 23 is a schematic cross-sectional view of the press machine 50 showing a state in which the recessed portion 3 and the through hole 4 are formed by the press pin 68 and the cut pin 69. FIG. 24 is an enlarged view of the XXIV part in FIG. FIG. 25 is a perspective view showing the strip-shaped iron plate 91 to the strip-shaped iron plate 109 sent out from the press machine 50.

  The 28 strip-shaped iron plates 91 to 109 formed by pressing the press plate 61 are fixed by the press of the press plate 61. In other words, the strip-shaped iron plates 91 to 109 are supported by the press plate 61 and the base 54 so as to be sandwiched from above and below (see FIGS. 20 and 21). The base 53 provided above the press plate 61 is further lowered from this state. As a result, the pressure spring 58 is further contracted to lower the upper plate 60 relative to the press plate 61, and the lower ends of the press pin 68, the cut pin 69, and the half-cut plate 64 from the lower surface of the press plate 61. The part protrudes. Since the lower surface of the press plate 61 is in close contact with the strip-shaped iron plates 91 to 109, the center portion in the width direction of the strip-shaped iron plates 91 to 108 is pushed down by the press pins 68, thereby forming the recessed portions 3 (FIG. 23 to FIG. 25). At the same time, the central portion in the width direction of the strip-shaped iron plate 109 is punched by the cut pin 69, thereby forming the through hole 4 (see FIGS. 23 to 25). The punched piece 86 (see FIG. 23) punched by the cut pin 69 falls below the table 54 through the recovery hole 63 and is recovered in a recovery box (not shown). In this way, crimped portions (recessed portions 3 or through-holes 4) are formed in the respective strip-shaped iron plates 91 to 109 in a state where the 28 strip-shaped iron plates 91 to 109 are fixed by pressing the press plate 61. In addition, a caulking portion (the recessed portion 3 or the through hole 4) is formed in each of the belt-like iron plates 91 to 109, and at the same time, a half-cut portion 39 (see FIG. 28-31) are formed. The half cut portion 39 is a cut formed in each of the belt-like iron plates 91 to 109, whereby each of the belt-like iron plates 91 to 109 can be easily cut in the longitudinal direction. This step corresponds to the breaking step in the present invention.

  FIG. 26 is a schematic cross-sectional view of the press machine 50 showing a state in which the belt-like iron plate 91 to the belt-like iron plate 108 are pushed up by the lift pins 67. FIG. 27 is an enlarged view of a portion XXVII in FIG.

  The band-shaped iron plates 91 to 108 on the table 54 are formed with the recessed portions 3 so that the upper surface side is recessed and the lower surface side protrudes. These recessed portions 3 are formed by being deformed so that the upper surfaces of the iron plate pieces 91 to 108 are pushed downward by the press pins 68. Since the insertion hole 79 formed in the base 54 is provided below the press pin 68, the protruding portion of each iron plate piece 91 to 108 enters the insertion hole 79 due to the formation of the recessed portion 3. In this state, it is placed on the table 54 (see FIG. 24). If the recessed part 3, the through-hole 4, and the half cut part 39 are formed with respect to the strip | belt-shaped iron plates 91-109, the base 53 will raise. Since the base 53 and the press plate 1 that are in contact with each other are separated from each other, the contracted pressure spring 58 is restored to its original shape. Since the press plate 61 is provided on one end side of the pressurizing spring 58, the press plate 61 is also lifted together with the base 53 when the pressurizing spring 58 is completely restored to the original state. Thereby, the pressing force with respect to the strip | belt-shaped iron plates 91-109 is removed. When the pressing force is removed, the pressure spring 66 extends. The back plate 65 and the lift pin 67 are raised by the elastic force of the pressure spring 66, and the belt-like iron plates 91 to 108 are pressed upward by the lift pin 67. Thereby, each protrusion part of each strip | belt-shaped iron plates 91-108 is pushed up above the stand 54 from the inside of the penetration hole 79 (refer FIG.26 and FIG.27). Thus, when the belt-like iron plates 91 to 108 are pushed upward by the lift pins 67, the belt-like iron plates 91 to 109 can move toward the compactor 70.

  As described above, in the first step including the forming step and the breaking step, the iron plate 6 having a certain width is divided in the width direction. Thereby, the 28 strip | belt-shaped iron plates 91-109 from which width differs are formed. The 28 strips of iron plates 91 to 109 correspond to the 28 iron plate pieces 11 to 29, respectively. In other words, 28 strip-shaped iron plates 91 to 109 having a predetermined length and cut in the width direction correspond to 28 iron plate pieces 11 to 29, respectively. The fixed width of the iron plate 6 is set to be substantially equal to the total width of the 28 iron plate pieces 11 to 29 as described above. For this reason, the strip | belt-shaped iron plates 91-109 of 28 strips are formed from the iron plate 6, without producing a scrap in the width direction of the iron plate 6. FIG. These band-shaped iron plates 91 to 109 are fixed by pressing the press plate 61 in the same state as a single plate, and a crimped portion (the recessed portion 3 and the through hole 4) is formed. Therefore, the position accuracy of the caulking portion formed on the belt-shaped iron plates 91 to 109 is high, and as a result, the accurate cylindrical coil core 1 for a cylindrical coil can be easily manufactured.

  FIG. 28 is a perspective view of the belt-like iron plate 91 passing between the sensors 32a and 32b. FIG. 29 is a longitudinal sectional view of the belt-like iron plate 91 viewed from the width direction. FIG. 30 is a perspective view of the belt-like iron plate 109 passing between the sensors 32a and 32b. FIG. 31 is a longitudinal sectional view of the belt-like iron plate 109 viewed from the width direction.

  As shown in FIG. 25, the 28 strip-shaped iron plates 91 to 109 formed by the press machine 50 are rolled from the press machine 50 by the rotation of the half-cut rollers 40 a and 40 b in a state of being aligned in the width direction (horizontal line). It is sent to the pressure machine 70. The strip-shaped iron plates 91 to 109 sent out from the press machine 50 are guided while being deformed to bend downward so as to pass between the sensors 32a and 32b (see FIGS. 28 and 30). The strip-shaped iron plates 91 to 108 are provided with three concave portions 3 and half-cut portions 39 alternately arranged in the longitudinal direction (see FIGS. 28 and 29). In addition, the strip-shaped iron plate 109 is provided with three through holes 4 and half-cut portions 39 alternately arranged in the longitudinal direction (see FIGS. 30 and 31).

  32 is a front view of the strip-shaped iron plate guide 33 as viewed from the direction of the arrow V in FIG.

  The strip-shaped iron plate guide 33 guides the strip-shaped iron plates 91 to 109, which have passed between the sensors 32a and 32b, in a line to form a column cross section (see FIG. 2) of the cylindrical coil iron core 1. The strip-shaped iron plate guide 33 has a flat plate shape, and as shown in FIG. 32, guide holes 111 to 129 are formed in the thickness direction (direction perpendicular to the paper surface in FIG. 32). The guide holes 111 to 129 and the strip-shaped iron plates 8 (91 to 109) have the same length in the width direction (the left-right direction in FIG. 32). For example, the length in the width direction of the belt-shaped iron plate 91 and the guide hole 111 is matched, the length in the width direction of the belt-shaped iron plate 99 and the guide hole 119 is matched, and the width direction of the strip-shaped iron plate 100 and the guide hole 120 is matched. The lengths match and the lengths in the width direction of the belt-like iron plate 109 and the guide hole 129 match. The strip-shaped iron plates 91 to 109 are formed from the iron plate 6 having a certain thickness, and the recessed portion 3 or the through hole 4 is formed. Therefore, the height of the strip-shaped iron plates 91 to 108 is larger than the thickness of the iron plate 6 by the amount of protrusion of the recessed portion 3. The width of the guide holes 111 to 128 (including the guide hole 129 in this embodiment) in the vertical direction in FIG. 32 is set sufficiently large with respect to the height of the strip iron plates 91 to 108.

  The strip-shaped iron plate guide 33 has a narrow strip shape with the wide strip-shaped iron plate 100 as the center by inserting the strip-shaped iron plates 91-109 through a plurality of guide holes 111-120 formed side by side in the vertical direction. The iron plates 8 are arranged in a row toward both outer sides in the direction in which the front and back surfaces face each other (vertical direction in FIG. 25). In the present embodiment, eight strip-shaped iron plates 100 are arranged in the vertical direction, and two strip-shaped iron plates 99, a strip-shaped iron plate 98, a strip-shaped iron plate 97, a strip-shaped iron plate 96, a strip-shaped iron plate 95, and a strip-shaped iron plate 94 are arranged upward. The strip-shaped iron plate 93, the strip-shaped iron plate 92, and the strip-shaped iron plate 91 are arranged in this order. Then, toward the lower side of the eight strip iron plates 100, two strip iron plates 101, strip iron plates 102, strip iron plates 103, strip iron plates 104, strip iron plates 105, strip iron plates 106, strip iron plates 107, strip iron plates 108, The strip-shaped iron plate 109 is arrange | positioned in order. Thereby, the column cross section of the iron core 1 for cylindrical coils is formed. This step corresponds to the second step in the present invention.

  FIG. 33 is a cross-sectional view showing the belt-like iron plate 91 to the belt-like iron plate 109 that are stacked and fixed. FIG. 34 is a perspective view showing the laminate 9.

  The 28 strip iron plates 91 to 109 arranged by the strip iron plate guide 33 are fed into the compactor 70 by the rotation of the compaction rollers 71 to 76 in the compactor 70. The strip-shaped iron plates 91 to 109 arranged in a line in the vertical direction are first pressed by the rolling rollers 71 and 72 so as to be sandwiched from above and below. The band-shaped iron plates 91 to 108 are formed with recesses 3, and the band-shaped iron plate 109 is formed with a through hole 4. Therefore, the belt-like iron plates 91 to 109 sandwiched between the rolling rollers 71 and 72 are stacked and fixed by caulking between the caulking portions (see FIG. 33). In other words, it is fixed by meshing the recessed portions 3 or by fitting the recessed portions 3 into the through holes 4. Thereby, the rod-shaped laminated body 9 (refer FIG. 34) whose cross section is substantially circular is obtained. Incidentally, on the downstream side in the conveying direction of the pressure rollers 71 and 72, pressure rollers 73 and 74 and pressure rollers 75 and 76 are provided. Therefore, the belt-like iron plates 91 to 109 are surely stacked and fixed by these three roller pairs. This step corresponds to the third step in the present invention.

  By repeating the first to third steps on the iron plate 6, the laminated body 9 is provided with half-cut portions 39 at predetermined intervals in the longitudinal direction (axial direction). Since the half-cut portions 39 are formed in all the strip-shaped iron plates 91 to 109 constituting the laminated body 9, they are provided so as to be aligned in a row in the front and back surfaces of each other (see FIG. 34). The laminated body 9 sent out from the compactor 70 is temporarily fixed so as to be sandwiched from above and below by the vise 34 at a predetermined timing. At that time, the laminated body 9 is sandwiched in a state where the half-cut portion 39 is positioned between the vise 34 and the cutting machine 35 by the vise 34 operating at a predetermined timing. In this state, the cutting machine 35 descends. Thereby, the laminated body 9 on the side not supported by the vise 34 (downstream in the transport direction) is folded at the half-cut portion 39 to obtain the cylindrical coil core 1. The cylindrical coil core 1 obtained in this way is stored in a collection box 37 via a chute 36. Thus, the cylindrical coil core 1 is continuously formed by cutting the laminated body 9 at predetermined intervals in the axial direction. This step corresponds to the fourth step in the present invention.

  As is clear from the above description, only the punched piece 86 becomes scrap in the process of manufacturing the cylindrical coil core 1. Therefore, according to the manufacturing method of the cylindrical coil core 1 according to the present embodiment, almost no scrap is generated, so that the material yield can be improved. Moreover, since the cylindrical coil iron core 1 is formed by cutting the laminate 9, the cylindrical coil iron core 1 is formed as compared with the case where the cylindrical coil iron core 1 is configured by laminating and fixing a plurality of iron plate pieces one by one. The iron core 1 can be efficiently manufactured with simple equipment. Therefore, the iron core 1 for cylindrical coils can be manufactured at low cost.

  In addition, this invention is not limited to the said embodiment, The following forms may be sufficient. That is, in the present embodiment, each first convex portion 84 and each second convex portion 84 and each second convex portion 85 have a width that gradually decreases from the center in the width direction toward both ends. Although the case where the convex part 85 was arranged was demonstrated, the arrangement | sequence of each 1st convex part 84 and each 2nd convex part 85 is not limited to this. For example, the first protrusions 84 and the second protrusions 85 are arranged so that the width of each first protrusion 84 and the width of each second protrusion 85 gradually increase from the center in the width direction toward both ends. May be. In addition, two regions are set with respect to the iron plate 6 with the center in the width direction as a boundary, and the width of each first protrusion 84 and each second protrusion 85 is from one end to the center in the width direction in one region. The first convex portions 84 and the second convex portions 85 may be arranged so as to be gradually widened toward the center and gradually narrowed from the end in the width direction toward the center in the other region.

  Moreover, in this embodiment, although the iron plate 6 was shape | molded into the uneven | corrugated plate 7, the boundary 87 of the uneven plate 7 was fractured | ruptured, and the strip | belt-shaped iron plates 91-109 were formed, the strip | belt-shaped iron plates 91-109 are other types. It may be formed by a method. For example, the iron plate 6 may be divided in the width direction without forming the iron plate 6 into the concavo-convex plate 7 to form the belt-like iron plates 91 to 109.

  Moreover, in this embodiment, although the concave part 3 was formed in the strip | belt-shaped iron plates 91-108 and the through-hole 4 was formed in the strip | belt-shaped iron plate 109 as a crimping part, the crimped part is the concave part 3. It may be only. That is, the recessed portion 3 may be formed on the belt-shaped iron plate 109 instead of the through hole 4. In this case, the cut pin 69 provided on the back plate 59 may be changed to the press pin 68, which is preferable because no scrap is generated in the process of manufacturing the cylindrical coil core 1.

  Further, the method of stacking and fixing the belt-like iron plates 8 (91 to 109) is not limited to the caulking described in the present embodiment. For example, the belt-like iron plates 8 may be bonded and fixed together with an adhesive, or may be stacked and fixed by welding.

  Moreover, the cutting method of the laminated body 9 is not limited to the method of this embodiment which folds the part of the half cut part 39 with the cutting machine 35. FIG. For example, the laminated body 9 may be cut by a discharge wire cutter, a circular saw, a grindstone-type cutting machine, a diamond wheel-type cutting machine or the like without forming the half-cut portion 39 in the laminated body 9 in advance.

  Hereinafter, the manufacturing method of the iron core for cylindrical coils which concerns on the 2nd Embodiment of this invention is demonstrated, referring drawings suitably. The cylindrical coil core 1 (see FIG. 1) manufactured by the cylindrical coil core manufacturing method according to this embodiment is partially the same as the cylindrical coil core manufacturing method according to the first embodiment. Manufactured using. For this reason, the same components as those in the first embodiment are denoted by the same reference numerals, description thereof is omitted, and different points are mainly described.

  FIG. 35 is a schematic view showing the iron core manufacturing apparatus 210.

  The iron core manufacturing apparatus 210 is an apparatus for continuously manufacturing the iron core 1 for cylindrical coils by performing the first to fourth steps in the present invention. The iron core manufacturing apparatus 210 includes an iron plate guide 89, a press machine 220, sensors 32a and 32b, a strip-shaped iron plate guide 33, a compactor 70, a breaker 215, a chute 36, and a collection box 37. In other words, the iron core manufacturing apparatus 210 has an iron plate guide 89 instead of the iron plate guide 31, has a press machine 220 instead of the half-cut rollers 40 a and 40 b and the press machine 50, and is replaced with the vise 34 and the cutting machine 35. Except for having a breaker 215, it is the same as the iron core manufacturing apparatus 30 (see FIGS. 4 and 35). In the present embodiment, a description will be given of a form in which the cylindrical coil core 1 manufactured by the core manufacturing apparatus 210 is composed of 28 strip-shaped iron plates 212 (see FIG. 68). The length of the cylindrical coil iron core 1 in the axial direction (vertical direction in FIG. 3) will be described as L.

  In order to manufacture the iron core 1 for cylindrical coils by the iron core manufacturing apparatus 210, the iron plate 6 is used in this embodiment. That is, a grain-oriented electrical steel sheet is used. In the iron core manufacturing apparatus 210, the iron plate 6 is conveyed by a distance L according to the operation of the press machine 220. The transport operation of the iron plate 6 is performed by a transport device (not shown).

  The iron plate guide 89 (see FIG. 35) regulates the movement of the iron plate 6 conveyed by the conveying device in the width direction (direction perpendicular to the paper surface in FIG. 35). The iron plate guide 89 is provided on the upstream side of the pressing machine 220 in the conveying direction of the iron plate 6 (left side in FIG. 35; hereinafter, simply referred to as “upstream side”). By this iron plate guide 89, the iron plate 6 is fed to a predetermined position of the press machine 220 (see FIG. 36) without being displaced in the width direction.

  FIG. 36 is a longitudinal sectional view of the press machine 220 as viewed from the width direction of the iron plate 6.

  The press machine 220 divides the iron plate 6 fed by the conveying device in the width direction (direction perpendicular to the paper surface in FIGS. 35 and 36) to form a belt-like iron plate 212 (see FIG. 68). That is, the press machine 220 performs the first step in the present invention. The press machine 220 includes an upper die 221 and a lower die 131. As shown in FIG. 36, the press machine 220 has a first region to a fourth region in the conveyance direction of the iron plate 6. The lengths of the first region to the third region are set substantially equal to the axial length L of the cylindrical coil core 1. In the press machine 220, the operation of conveying the iron plate 6 by the distance L by the conveying device and the operation of pressing the iron plate 6 by the upper die 221 are alternately repeated. As a result, the iron plate 6 is pressed four times in each region (first region to fourth region) of the press machine 220, and the strip-shaped iron plates 212 (171 to 189) are formed from the iron plate 6.

  FIG. 37 is a longitudinal sectional view showing a first region of the press machine 220 as seen from the direction of the arrow XXXVII in FIG. FIG. 38 is a longitudinal sectional view showing the second region and the third region of the press machine 220 as viewed from the direction of the arrow XXXVII in FIG.

  As shown in FIG. 37, a guide shaft 255 is provided on the base 222 of the upper mold 221. In the first region (see FIG. 36), the guide shaft 255 is provided to extend downward at both ends of the base portion 222 in the width direction of the iron plate 6 (direction perpendicular to the paper surface in FIG. 36). As shown in FIG. 38, a guide shaft 140 is provided on the base 222. The guide shaft 140 is provided so as to extend downward at both ends of the base 222 in the width direction of the iron plate 6 in the third region (see FIG. 36). As shown in FIGS. 37 and 38, guide holes 256 and 148 are provided in the base 139 of the lower mold 131. The guide hole 256 supports the guide shaft 255 so as to be movable up and down. The guide hole 148 supports the guide shaft 140 so as to be movable up and down. When the guide shaft 255 is inserted into the guide hole 256 and the guide shaft 140 is inserted into the guide hole 148, the base portion 222 is supported to be movable up and down while being restricted from moving in the horizontal direction with respect to the base 139. The

  As shown in FIGS. 36 to 38, a plate accommodating portion 227 is provided on the lower surface side of the base portion 222 so as to be recessed above the base portion 222. A back plate 223 is accommodated in the plate accommodating portion 227 so as to be sandwiched between the base portion 222 and the upper plate 224. A press plate 225 for pressing the iron plate 6 is provided below the upper plate 224.

  37 and 38, the press plate 225 has a shaft hole 238 through which the guide shaft 255 is inserted and a shaft hole 142 through which the guide shaft 140 is inserted. The press plate 225 is supported so as to be movable up and down with respect to the base 222 via the pressure springs 258 and 143 in a state where the guide shaft 255 is inserted into the shaft hole 238 and the guide shaft 140 is inserted into the shaft hole 142. ing. When an external force is applied upward with respect to the press plate 225, the pressure springs 258 and 143 contract and the press plate 225 is pushed up toward the base 222. At this time, an elastic force (repulsive force) is generated in the pressure springs 258 and 143, and the elastic force and the weight of the press plate 225 act on the press plate 225 as a pressing force that pushes the press plate 225 downward. The iron plate 6 is pressed by this pressing force.

  As shown in FIGS. 36 to 38, a press pin 229, a cut pin 269, a cut punch 226, and a half-cut punch 228 are provided on the lower surface of the back plate 223. The press pin 229 is for forming the recessed part 3 (150-154) equivalent to the crimping part of this invention in the iron plate 6 (refer FIG. 47). As shown in FIG. 37, 27 press pins 229 are suspended from the lower surface of the back plate 223 in the width direction of the back plate 223 (the left-right direction in FIG. 37). The cut pin 269 is for forming the through-hole 4 (156-158) equivalent to the crimping part of this invention in the iron plate 6 (refer FIG. 47). The cut pin 269 is suspended from the lower surface of the back plate 223 so as to be adjacent to the rightmost press pin 229 among the 27 press pins 229 (see FIG. 37). That is, on the lower surface of the back plate 223, 27 press pins 229 and one cut pin 269 are arranged in the width direction of the back plate 223. These 28 pins are provided in the first region so as to be arranged in three rows in the depth direction of the back plate 223 (left and right direction in FIG. 36). In FIG. 36, the cut pin 269 is omitted.

  The cut punch 226 divides the iron plate 6 in the width direction to form a belt-like iron plate 212 (171 to 189) described later, and is provided over the second region and the third region (see FIG. 58). The cut punch 226 has a substantially rectangular parallelepiped shape that is long in the conveying direction of the iron plate 6 (right direction in FIG. 36) and thin in the width direction of the iron plate 6 (direction perpendicular to the paper surface in FIG. 36) (see FIGS. 36 and 38). ). This cut punch 226 is located behind the press pin 229 and the cut pin 269 in the conveyance direction of the iron plate 6 (the right side in FIG. 36. Hereinafter, simply referred to as “downstream side”), the back plate 223. Is arranged. Fourteen cut punches 226 are suspended from the lower surface of the back plate 223 in the width direction of the back plate 223 (see FIG. 38). Since the cut punch 226 is provided over the second region and the third region, the iron plate 6 is first divided by the cut punch 226 at a partial region 161 (see FIG. 51) located immediately below the cut punch 226. Then, after the iron plate 6 is conveyed by the distance L, the remaining area corresponding to the upstream side of the partial area 161 is divided by the press of the upper die 221.

  As shown in FIG. 36, an inclined portion 144 is provided on the upstream side of the lower end of the cut punch 226, and an inclined portion 145 is provided on the downstream side. The inclined portion 144 is formed by bending the upstream end at the lower end of the cut punch 226. The inclined portion 145 is formed by bending the downstream end at the lower end of the cut punch 226. Since the inclined portions 144 and 145 are provided in the cut punch 226, a gap is generated between the end portions 218 and 219 (see FIG. 36) and the cut punch 226 when the cut punch 226 is lowered (see FIG. 36). (See FIG. 55). Therefore, the iron plate 6 is prevented from being divided in the transport direction by the cut punch 226. The cut punch 226 has a length M in the conveyance direction (left and right direction in FIG. 36) of about 119% of the distance L, a length P of the inclined portion 144 in the conveyance direction is about 11% of the distance L, and a length in the conveyance direction of the inclined portion 145. Q is set to about 8% of the distance L. Therefore, when the cut punch 226 is lowered, the iron plate 6 is divided by a length MPQ (approximately the same as the distance L in the present embodiment) in the transport direction. Thereby, the strip | belt-shaped iron plates 171-189 (refer FIG. 58) are formed.

  FIG. 39 is a vertical cross-sectional view of the press machine 220 as seen from the width direction of the iron plate 6 and shows a boundary portion between the third region and the fourth region.

  The half-cut punch 228 forms step portions 130, 160, 170, and 190 (see FIGS. 44, 55, 62, and 67), which will be described later, on the belt-like iron plates 171 to 189. As will be described in detail later, these stepped portions are formed by receiving a shearing force from the half-cutting punch 228 and the half-cutting die 138 (see FIG. 64). The half-cut punch 228 has a substantially rectangular parallelepiped shape extending in the width direction of the press machine 220 (direction perpendicular to the paper surface in FIG. 36), and has a length substantially the same as the width of the iron plate 6. The half-cut punch 228 is located on the downstream side of the cut punch 226 and is disposed in the fourth region so as to be adjacent to the third region. The half-cut die 138 is provided in the third region so as to be adjacent to the fourth region.

  As shown in FIGS. 36 to 38, the upper plate 224 has insertion holes 230, 191, 194 and 200. A press pin 229 is inserted through the insertion hole 230 (see FIGS. 36 and 37). The cut pin 269 is inserted through the insertion hole 191 (see FIG. 37). The cut punch 226 is inserted through the insertion hole 194 (see FIGS. 36 and 38). The half-cut punch 228 is inserted through the insertion hole 200 (see FIG. 36). Thus, since the insertion holes 230, 191, 194, 200 are formed in the upper plate 224, the back plate 223 has the press pins 229, the cut pins 269, the cut punch 226, and the half-cut punch 228, respectively. The plate 224 is accommodated in the plate accommodating portion 227 so as to protrude downward from the lower surface of the plate 224.

  As shown in FIGS. 36 to 38, the press plate 225 has insertion holes 278, 282, 146, 202. The press pin 229 is inserted through the insertion hole 278 (see FIGS. 36 and 37). The cut pin 269 is inserted through the insertion hole 282 (see FIG. 37). The cut punch 226 is inserted through the insertion hole 146 (see FIGS. 36 and 38). The half-cut punch 228 is inserted through the insertion hole 202 (see FIG. 36). As shown in FIGS. 36 and 37, the press pin 229 is inserted into the insertion hole 278 of the press plate 225 through the insertion hole 230 of the upper plate 224. As shown in FIG. 37, the cut pin 269 is inserted into the insertion hole 282 of the press plate 225 through the insertion hole 191 of the upper plate 224. As shown in FIGS. 36 and 38, the cut punch 226 is inserted into the insertion hole 146 of the press plate 225 through the insertion hole 194 of the upper plate 224. As shown in FIG. 36, the half-cut punch 228 is inserted into the insertion hole 202 of the press plate 225 through the insertion hole 200 of the upper plate 224.

  As shown in FIGS. 37 and 38, material guides 257 extending in the conveying direction (right direction in FIG. 36) of the iron plate 6 are provided on both sides in the width direction (direction perpendicular to the paper surface in FIG. 36) of the table 139. Is provided. The material guide 257 guides the iron plate 6 fed to the press machine 220 to a predetermined position in the width direction of the press machine 220. The material guide 257 is disposed so as to face the direction perpendicular to the conveying direction of the iron plate 6 (the left-right direction in FIGS. 37 and 38) with a distance substantially equal to the width of the iron plate 6. The iron plate 6 is guided by the iron plate guide 89 (see FIG. 35) until it is fed into the press machine 220, and after being fed into the press machine 220, it is guided by this material guide 257.

  As shown in FIGS. 36 and 37, an accommodation portion 249 is provided on the lower surface side of the table 139. A back plate 265 is accommodated in the accommodating portion 249. Lift pins 147 are provided on the upper surface of the back plate 265. The lift pins 147 push up the iron plate 6 upward. The lift pins 147 are provided at positions corresponding to the press pins 229. In other words, each lift pin 147 is erected on the back plate 265 so as to be positioned directly below the press pin 229 in a state where the back plate 265 is housed in the housing portion 249. That is, the lift pins 147 are erected on the upper surface of the back plate 265 so that 27 are arranged in the width direction of the back plate 265 and 3 are arranged in the conveying direction of the iron plate 6.

  As shown in FIG. 37, the base 139 is provided with an insertion hole 279 and a recovery hole 263. The insertion hole 279 vertically penetrates the table 139, and the lift pin 147 is inserted therethrough. The back plate 265 is accommodated in the accommodating portion 249 in a state where the lift pins 147 are supported by the corresponding insertion holes 279 so as to be vertically movable and are urged upward by the pressure springs 266. The recovery hole 263 penetrates the table 139 up and down. When the iron plate 6 is punched by the cut pins 269, punched pieces 196 (see FIG. 45) are generated. The punched piece 196 falls below the table 139 through the collection hole 263 and is collected in a collection box (not shown).

  As shown in FIGS. 36 and 38, an accommodation portion 149 is provided on the lower surface side of the table 139. A back plate 141 is accommodated in the accommodating portion 149. Lift pins 136 are provided on the upper surface of the back plate 141. The lift pins 136 push up the strip-shaped iron plate 212 upward (see FIGS. 59 and 60). The lift pin 136 is provided at a position corresponding to the cut punch 226. In other words, each lift pin 136 is positioned immediately below the cut punch 226 in a state where the back plate 141 is accommodated in the accommodating portion 149. Therefore, the lift pins 136 are erected on the upper surface of the back plate 141 so that 14 lift pins 136 are arranged in the width direction of the back plate 141.

  As shown in FIG. 38, the base 139 is provided with an insertion hole 165. The insertion hole 165 allows the lift pin 136 to pass therethrough, and is formed so as to penetrate from the housing portion 149 to the upper surface of the table 139. The back plate 141 is accommodated in the accommodating portion 149 in a state where the lift pins 136 are supported by the corresponding insertion holes 165 so as to be movable up and down and are urged upward by the pressure spring 137.

  The half-cut die 138 (see FIG. 36) is for forming step portions 130, 160, 170, and 190 on the strip-shaped iron plates 171 to 189. The half-cut die 138 has a substantially rectangular parallelepiped shape extending in the width direction of the press machine 220, and has the same length as the width of the iron plate 6, similar to the half-cut punch 228. The half-cut die 138 is fixed to the upper surface of the table 139 so as to be adjacent to the fourth region.

  As shown in FIGS. 36 and 38, dimples 132 to 135 are provided on the upper surface side of the lower mold 131. The dimples 132 to 135 accommodate the recessed portions 150 to 154. The recessed portions 150 to 154 formed on the iron plate 6 move in order from the first region to the second region, the third region, and the fourth region as the iron plate 6 is conveyed. The dimples 132 to 135 are provided on the upper surface of the lower mold 131 so as to face the recessed portions 150 to 154 located in each region.

  The dimples 135 are provided on the upper surface of the table 139 so that 27 dimples 135 are arranged in the width direction of the press machine 220 (perpendicular to the paper surface in FIG. 36) and two dimples 135 are arranged in the conveying direction of the iron plate 6 (right direction in FIG. 36). Yes. The dimple 132 (see FIGS. 36 and 38) is provided on the upper surface of the lift pin 136. The dimple 133 (see FIGS. 36 and 38) is provided on a press surface 193 (see FIG. 38) which is a part of the upper surface of the table 139. The dimples 132 and the dimples 133 are arranged so as to be alternately arranged in the width direction of the press machine 220 (see FIG. 38). In the second region and the third region of the lower mold 131, these dimples 132 and 133 are arranged in three rows in the conveying direction of the iron plate 6. The dimples 134 are provided on the upper surface of the half-cut die 138 so that 27 dimples 134 are arranged in the width direction of the press machine 220. As will be described in detail later, the iron plate 6 is pressed by the press plate 225 and the table 139 when the upper die 221 is lowered. At that time, each protruding portion of the recessed portions 150 to 154 enters one of the dimples 132 to 135. Thereby, the iron plate 6 or the strip | belt-shaped iron plate 212, and the stand 139 contact | adhere, without producing a clearance gap mutually.

  The iron plate 6 is fixed between the press plate 225 and the table 139 by pressing the press plate 225 (see FIG. 44). In this state, recesses 150 to 154 are formed in the iron plate 6 by the tips of the press pins 229 protruding from the lower surface of the press plate 225 corresponding to the first region (see FIG. 36) (see FIG. 46). Therefore, the length from the lower surface of the back plate 223 to the tip (lower end) of the press pin 229 is set slightly longer than the total thickness of the upper plate 224 and the press plate 225. Thus, the tip of the press pin 229 slightly protrudes from the lower surface of the press plate 225 in a state where the press plate 225 is in contact with the upper plate 224, and the iron plate 6 is pressed by the protruding portion to form the recessed portions 150 to 154. .

  The iron plate 6 is fixed between the press plate 225 and the base 139 as described above (see FIG. 44), and the through hole 156 is formed by the cut pin 269 protruding from the lower surface of the press plate 225 corresponding to the first region. ˜158 are formed (see FIG. 46). Therefore, the length from the back plate 223 to the tip (lower end) of the cut pin 269 is set longer than the total of the thickness of the upper plate 224, the thickness of the press plate 225, and the thickness of the iron plate 6. Accordingly, the tip of the cut pin 269 protrudes from the lower surface of the press plate 225 in a state where the press plate 225 is in contact with the upper plate 224, and a part of the iron plate 6 is punched out by the protruding portion to form through holes 156 to 158. Is done.

  The iron plate 6 is divided in the width direction by the cut punch 226 protruding from the lower surface of the press plate 225 while being fixed between the press plate 225 and the base 139 as described above (see FIG. 44). As a result, 28 strips (an example of a predetermined number of strips) of strip-shaped iron plates 212 (see FIG. 58) are formed downstream from the partial region 161 of the iron plate 6. Therefore, the length from the back plate 223 to the tip (lower end) of the cut punch 226 is set longer than the total of the thickness of the upper plate 224, the thickness of the press plate 225, and the thickness of the iron plate 6. In this embodiment, the length of the cut punch 226 is about 110 to 150% of the thickness of the iron plate 6 with the iron plate 6 fixed between the press plate 225 and the base 139. Is set to As a result, the tip of the cut punch 226 protrudes from the lower surface of the press plate 225 beyond the thickness of the iron plate 6 while the press plate 225 is in contact with the upper plate 224, and the iron plate 6 is pressed by the protruding portion and the press surface 193 of the table 139. Is sheared in the width direction (see FIG. 56).

  As shown in FIG. 38, the cut punches 226 and the press surfaces 192 of the press plates 225 are alternately provided in the width direction of the press machine 220 (the left-right direction in FIG. 38). The cut punch 226 and the press surface 192 are provided so that the width is gradually reduced from the center in the width direction toward both ends. That is, the cut punch 226 and the press surface 192 located at the center in the width direction have the widest width, and the cut punch 226 and the press surface 192 located at both ends in the axial direction have the smallest width. The width of the press surface 192 is set. The widths of the cut punches 226 and the press surface 192 are set so as to correspond to (approximately equal to) the widths of the iron plate pieces 11 to 29 (see FIG. 2). Therefore, in the present embodiment, the widths of the eight cut punches 226 and the press surface 192 positioned at the center in the width direction are both set to substantially the same value as the width of the iron plate piece 20 (see FIG. 2). Further, the widths of the cut punch 226 and the press surface 192 located at both ends in the axial direction are set to substantially the same values as the widths of the iron plate pieces 11 and 29. Therefore, the sum of the widths of the cut punches 226 and the press surfaces 192 in the axial direction is substantially equal to the sum of the widths of the iron plate pieces 11 to 29 (the width of the iron plate 6). In addition, when the width | variety of each iron plate piece 11-29 is changed, the width | variety of each cut punch 226 and the press surface 192 is also changed according to it.

  As shown in FIG. 38, the insertion holes 165 and the press surfaces 193 of the table 139 are provided alternately in the width direction of the press machine 220 (the left-right direction in FIG. 38). The insertion holes 165 and the press surfaces 193 are alternately provided in the width direction so that the insertion holes 165 face the cut punch 226 and the press surface 193 faces the press surface 192. The width of each insertion hole 165 is set substantially equal to the width of the opposing cut punch 226. The width of each press surface 193 is set to be approximately equal to the width of the press surface 192 facing each other.

  FIG. 40 is a schematic view of the breaker 215 viewed from the width direction of the laminate 199.

  The breaker 215 presses the laminate 199 (see FIG. 74) to break the step portions 130, 160, 170, and 190 of the respective strip-shaped iron plates 171 to 189. As shown in FIG. 40, the breaking machine 215 has an upper mold 216 and a lower mold 217. On the lower surface of the upper mold 216, a press plate 167 is provided that comes into contact with the upper surface of the laminated body 199 fed into the space between the upper mold 216 and the lower mold 217 (in this embodiment, a belt-shaped iron plate 171). On the upper surface of the lower mold 217, a press plate 168 is provided that contacts the lower surface of the laminate 199 (in this embodiment, a belt-like iron plate 189). Dimples 163 and 164 are provided on the upper surface of the press plate 168. As shown in FIG. 75, the dimples 163 and 164 are recessed portions 3 (in FIG. 75, recessed portions) projecting downward from the laminated body 199 from the through holes 4 (through holes 156 and 157 in FIG. 75) of the belt-shaped iron plate 189. Part 150, 151). By providing these dimples 163 and 164 on the upper surface of the press plate 168, the lower surface of the laminate 199 is in close contact with the upper surface of the press plate 168. The breaker 215 is provided with sensors that detect the step portions 130, 160, 170, and 190 of the laminated body 199, and the lowering timing of the upper mold 216 is controlled based on the detection results of the sensors. It is like that. Further, when the recessed portion 3 does not protrude from the through hole 4, it is not necessary to provide the dimples 163 and 164 on the press plate 168.

  Hereinafter, the manufacturing method of the iron core 1 for cylindrical coils is demonstrated. In this embodiment, the iron core 1 for cylindrical coils is manufactured using the iron core manufacturing apparatus 210 described above.

  When manufacturing the iron core 1 for cylindrical coils with the iron core manufacturing apparatus 210, the iron plate 6 is used similarly to 1st Embodiment. A directional electromagnetic steel sheet is used for the iron plate 6. The iron plate 6 is divided in the width direction by the press machine 220 to form 28 strip-shaped iron plates 171 to 189 (see FIG. 68) corresponding respectively to the iron plate pieces 11 to 29 (see FIG. 2). This step corresponds to the first step of the present invention.

  The first step includes a caulking portion forming step in which the recessed portions 150 to 154 and the through holes 156 to 158 are formed in the iron plate 6, and a partial region 161 in which the step portions 130, 160, 170, and 190 are formed in the iron plate 6. 51), and a half-cutting step for forming stepped portions 130, 160, 170, and 190 in a partial region 161. All of these processes are performed by the press machine 220.

  As shown in FIG. 36, the iron plate 6 is guided by the iron plate guide 89 and is transported by a transport device (not shown), and is fed between the upper mold 221 and the lower mold 131 of the press machine 220. The fed iron plate 6 is guided to the upper surface of the table 139 in a state where both side edges in the width direction are supported by the material guide 257. When the iron plate 6 is guided onto the table 139, the base 222 of the upper mold 221 is lowered.

  FIG. 41 is a longitudinal sectional view of the press machine 220 as seen from the width direction of the iron plate 6 and shows a state in which the upper die 221 is lowered. FIG. 42 is a longitudinal sectional view of the press machine 220 as seen from the width direction of the iron plate 6 and shows a state where the iron plate 6 is sandwiched. FIG. 43 is a longitudinal sectional view showing a first region of the press machine 220 as viewed from the arrow XXXVII in FIG. 35, and shows a state where the iron plate 6 is sandwiched.

  Since the press plate 225 is connected to the base 222 via the pressure springs 258 and 143 (FIGS. 37 and 38), the press plate 225 descends together with the base 222. The iron plate 6 is guided on the upper surface of the table 139, and the lower surface of the lowered press plate 225 contacts the upper surface of the iron plate 6 (see FIG. 41).

  The base 222 is further lowered from the state shown in FIG. Thereby, the iron plate 6 is pushed down toward the base 139. Since the tip of the lift pin 147 protrudes from the upper surface of the table 139 in the first region, the lift pin 147 is pressed downward by the iron plate 6. The pressing spring 266 is contracted by this pressing force. The lift pin 147 and the back plate 265 are pushed downward, the lift pin 147 is immersed in the insertion hole 279, and the lower surface of the iron plate 6 contacts the upper surface of the table 139 (see FIGS. 42 and 43). That is, the iron plate 6 is sandwiched from above and below by the press plate 225 and the base 139. The base 222 is further lowered from the state shown in FIGS. The pressure springs 258 and 143 are contracted by an external force acting upward on the press plate 225. Thereby, the elastic force of the pressure springs 258 and 143 acts on the press plate 225, and the iron plate 6 is pressed downward by the press plate 225.

  FIG. 44 is a longitudinal sectional view of the press machine 220 as viewed from the width direction of the iron plate 6, and shows a state where the iron plate 6 is half-punched by the press pin 229. FIG. 45 is a longitudinal sectional view showing the first region of the press machine 220 as viewed from the arrow XXXVII in FIG. 35, and shows a state where the iron plate 6 is half-cut by the press pin 229. FIG. 46 is an enlarged view of the XXXXVI portion in FIG. FIG. 47 is a perspective view of the iron plate 6 in which the recessed portion 151 and the through hole 157 are formed.

  The iron plate 6 is fixed by pressing a press plate 225. In other words, the iron plate 6 is supported by the press plate 225 and the base 139 so as to be sandwiched from above and below (see FIGS. 42 and 43). The base 222 provided above the press plate 225 is further lowered from this state. As a result, the pressure springs 258 and 143 are further contracted, the upper plate 224 is lowered relative to the press plate 225, and the tips of the press pin 229 and the cut pin 269 protrude from the lower surface of the press plate 225. (See FIGS. 44 and 45). Since the lower surface of the press plate 225 is in close contact with the iron plate 6, a part of the iron plate 6 is pushed down by the press pin 229, thereby forming a recess 151 in the iron plate 6 (see FIGS. 44 to 47). . As shown in FIG. 47, the concave portions 151 are formed so that 27 pieces are arranged in the width direction of the iron plate 6 and three pieces are arranged in the conveying direction of the iron plate 6. At the same time, the iron plate 6 is punched by the cut pins 269 to form the through holes 157 (see FIGS. 45 to 47). As shown in FIG. 47, three through holes 157 are formed so as to be lined up in the conveying direction of the iron plate 6. In this way, the caulking portion (here, the recessed portion 151 and the through hole 157) is formed before the step portion 170 described later is formed on the iron plate 6. As shown in FIG. 45, each punched piece 196 punched by the cut pin 269 falls below the table 139 through the recovery hole 263 and is recovered in a recovery box outside the drawing. In addition, each recessed part 151 is each formed in the position corresponding to the strip | belt-shaped iron plates 171-188 in the iron plate 6, and each through-hole 157 is formed in the position corresponding to the strip | belt-shaped iron plate 189 in the iron plate 6 (FIG. 47). And FIG. 63). This step corresponds to the crimped portion forming step.

  FIG. 48 is a longitudinal sectional view showing a first region of the press machine 220 as viewed from the arrow XXXVII in FIG. 35, and shows a state where the iron plate 6 is pushed up by the lift pins 147. 49 is an enlarged view of a portion XXXXIX in FIG.

  The iron plate 6 located in the first region on the table 139 is formed with a recess 151 so that the upper surface side is recessed and the lower surface side protrudes (see FIG. 46). Each recessed portion 151 is formed by being deformed so that the iron plate 6 is pushed downward by the press pin 229. Since the insertion hole 279 is provided below the press pin 229, the iron plate 6 is placed on the table 139 in a state where the protruding portion of the recessed portion 151 is press-fitted into the insertion hole 279 (see FIG. 46). ). When the recess 151 and the through hole 157 are formed in the iron plate 6, the base 222 is raised as shown in FIG. Since the base 222 and the press plate 225 that are in contact with each other are separated, the compressed pressure springs 258 and 143 are restored to their original shapes. Since the press plate 225 is provided on one end side of the pressure springs 258 and 143, the press plate 225 rises together with the base portion 222 when the pressure springs 258 and 143 are completely restored to the original state. Thereby, the pressing force with respect to the iron plate 6 is removed. When the pressing force is removed, the pressure spring 266 extends. The back plate 265 and the lift pin 147 are raised by the elastic force of the pressure spring 266, and the iron plate 6 is pressed upward by the lift pin 147. Thereby, each recessed part 151 of the iron plate 6 is pushed up from the inside of the insertion hole 279 to the upper side of the stand 139 (refer FIG.48 and FIG.49). Thus, when the iron plate 6 is pushed upward by the lift pins 147, the recessed portion 151 and the through hole 157 can move from the first region to the second region.

  FIG. 50 is a longitudinal sectional view of the press machine 220 as seen from the width direction of the iron plate 6 and shows a state in which the recessed portion 151 is located in the first region. FIG. 51 is a longitudinal sectional view of the press machine 220 as seen from the width direction of the iron plate 6 and shows a state in which the recessed portion 151 has moved to the second region. FIG. 52 is a longitudinal sectional view of the press machine 220 as viewed from the width direction of the iron plate 6 and shows a state where the iron plate 6 is sandwiched. FIG. 53 is a longitudinal sectional view showing the second region and the third region of the press machine 220 as viewed from the arrow XXXVII in FIG. 35, and shows a state where the iron plate 6 is sandwiched. 54 is an enlarged view of a portion XXXXXIV in FIG.

  If the recessed part 151 and the through-hole 157 are formed in the iron plate 6 in the 1st area | region, the iron plate 6 will be conveyed only the distance L by the conveying apparatus. Thereby, the recessed part 151 and the through-hole 157 move from a 1st area | region to a 2nd area | region (refer FIG.50 and FIG.51). 50 and 51, the through hole 157 is omitted. The base 222 is lowered from the state shown in FIG. The iron plate 6 is pushed down toward the table 139 and comes into contact with the upper surface of the table 139 (see FIGS. 52 and 53). Since the dimples 132, 133, and 135 are provided on the upper surface of the lower mold 131 in the second region, the protruding portions of the recessed portions 151 are accommodated in the corresponding dimples 132, 133, and 135 (FIGS. 52 to FIG. 54). For this reason, the iron plate 6 is sandwiched between the press plate 225 and the table 139 without a gap between the iron plate 6 and the upper surface of the table 139 in the second region.

  FIG. 55 is a longitudinal sectional view of the press machine 220 as seen from the width direction of the iron plate 6 and shows a state where a partial region 161 is divided by the cut punch 226. FIG. 56 is a longitudinal sectional view showing the second region and the third region of the press machine 220 as viewed from the arrow XXXVII in FIG. 35, and shows a state where the partial region 161 is divided. FIG. 57 is an enlarged view of a portion XXXXXVII in FIG. FIG. 58 is a perspective view showing the strip-shaped iron plate 212 formed in the partial region 161.

  The base 222 is further lowered from the state shown in FIGS. An external force acts upward on the press plate 225, and the pressure springs 258 and 143 are contracted. The elastic force of the pressure springs 258 and 143 acts on the press plate 225, and the iron plate 6 is pressed downward by the press plate 225. As the base 222 is lowered, this pressing force increases. The iron plate 6 is fixed by the press surface 192 of the press plate 225 and the press surface 193 of the table 139. The base 222 is lowered relative to the press plate 225, and the tip of each cut punch 226 protrudes from the lower surface of the press plate 225 (see FIGS. 55 to 57). Each cut punch 226 protrudes from the lower surface of the press plate 225 in a state where the iron plate 6 is sandwiched between the press surface 192 of the press plate 225 and the press surface 193 of the table 139. For this reason, an external force acts on the iron plate 6 relatively so as to press the iron plate 6 downward by the cut punch 226 and press the iron plate 6 upward by the press surface 193. As a result, the iron plate 6 positioned immediately below the cut punch 226 is pushed down so as to enter the insertion hole 165, and the iron plate 6 is divided (sheared here) in the width direction (see FIGS. 55 to 58). As described above, the widths of the cut punches 226 and the press surfaces 192 correspond to the widths of the strip-shaped iron plates 171 to 189. Therefore, the iron plate 6 divided in the width direction becomes 28 strip-shaped iron plates 171 to 189 (see FIG. 58). In addition, inclined portions 144 and 145 are provided on the upstream side and the downstream side in the transport direction at the lower end of the cut punch 226. Since the iron plate 6 positioned immediately below the inclined portions 144 and 145 is not divided, in this embodiment, a partial region 161 (see FIGS. 51 and 55) of the iron plate 6 is divided in the width direction. The partial region 161 is a region including a portion where a later-described stepped portion 170 (see FIG. 63) is formed, and a two-dot chain line in FIG. 58 indicates a position where the stepped portion 170 is formed. As shown in FIG. 58, only a part of the region 161 is divided, so that the distance from the iron plate 6 in a single plate state to the position where the stepped portion 170 is formed is sufficiently larger than the length L. Shorter. Therefore, the stepped portion 170 can be formed in a state where the position where the stepped portion 170 is formed in each of the belt-shaped iron plates 171 to 189 is aligned in the width direction of the iron plate 6. Compared with the case where the distance from the iron plate 6 to the position where the stepped portion 170 is formed is L, the positional accuracy of the stepped portion 170 formed on the belt-like iron plates 171 to 189 is higher. As a result, the length of each of the iron plate pieces 11 to 29 becomes more uniform, and it becomes possible to easily manufacture an accurate cylindrical coil core 1 for a cylindrical coil. This step corresponds to the partial cutting step of the present invention.

  Since the cut punch 226, the press pin 229, and the cut pin 269 are all suspended from the back plate 223, when the cut punch 226 is lowered, the press pin 229 and the cut pin 269 are also lowered. For this reason, the recessed part 152 and the through-hole 158 are formed in the iron plate 6 in a 1st area | region by performing the above-mentioned partial parting process (refer FIG. 58). The recessed portion 152 and the through hole 158 are formed in the iron plate 6 in the same manner as the recessed portion 151 and the through hole 157.

  FIG. 59 is a longitudinal sectional view showing the second region and the third region of the press machine 220 as viewed from the arrow XXXVII in FIG. 35, and shows a state where the upper die 221 is raised. 60 is an enlarged view of a portion XXXXXX in FIG.

  In the second region and the third region, the iron plate 6 and each belt-like iron plate 212 extending from the iron plate 6 are placed on the table 139 in a state where a part of the belt-like iron plate 212 is press-fitted into the insertion hole 165 (FIG. 55 to FIG. 55). FIG. 57). When the iron plate 6 is divided and the belt-like iron plates 171 to 189 are formed, the base 222 is raised as shown in FIG. Along with this, each cut punch 226 rises, so that the pressing force from the cut punch 226 against the strip-shaped iron plate 212 located in the insertion hole 165 gradually decreases. As a result, the pressure spring 137 extends. The back plate 141 and the lift pin 136 are raised by the elastic force of the pressure spring 137, and the belt-like iron plate 212 positioned in the insertion hole 165 is pushed up from the insertion hole 165 to the upper side of the table 139 by the lift pin 136 (FIGS. 59 and 60). reference). 59 and 60 show a state where the strip-shaped iron plate 212 located in the insertion hole 165 is being pushed up. Since the strip-shaped iron plate 212 located on the press surface 193 of the table 139 is connected to the strip-shaped iron plate 212 on the lift pin 136 via the iron plate 6, it is pushed upward together with the strip-shaped iron plate 212 on the lift pin 136.

  FIG. 61 is a longitudinal sectional view of the press machine 220 viewed from the width direction of the iron plate 6 and shows a state in which the recessed portion 151 has moved to the third region. FIG. 62 is a longitudinal sectional view of the press machine 220 as viewed from the width direction of the iron plate 6 and shows a state in which a stepped portion 170 is formed on the downstream side of the recessed portion 151. FIG. 63 is a perspective view of the strip-shaped iron plate 212 on which the stepped portion 170 is formed. 64 is an enlarged view of a portion XXXXXXIV in FIG.

  When the partial area 161 of the iron plate 6 is divided in the width direction, the iron plate 6 is conveyed by the distance L by the conveying device. Thereby, the recessed part 151 and the through-hole 157 move from a 2nd area | region to a 3rd area | region (refer FIG.51 and FIG.61). The base 222 is lowered from the state shown in FIG. Thereby, the strip | belt-shaped iron plates 171-189 are fixed so that it may be pinched | interposed into the press plate 225 and the stand 139. When the base 222 is further lowered from this state, an external force acts on the press plate 225 in the upward direction, and the pressure springs 258 and 143 (see FIGS. 37 and 38) are contracted. The elastic force of the pressure springs 258 and 143 acts on the press plate 225, and the iron plate 6 is pressed downward by the press plate 225. As a result, in the third region, the strip-shaped iron plates 212 (171 to 189) are formed on the press surface 192 (see FIG. 38), the press surface 197 (see FIG. 62) of the press plate 225, the press surface 193 (see FIG. 38), and The upper surface of the half-cut die 138 is fixed so as to be sandwiched from above and below. In that case, the strip | belt-shaped iron plates 171-189 are fixed in the state located in a line with the width direction. When the base 222 is further lowered, the lower end portion of the half-cut punch 228 protrudes from the lower surface of the press plate 225 (see FIGS. 62 and 64). For this reason, the strip-shaped iron plates 171 to 189 are pressed so that the strip-shaped iron plate 212 located in the fourth region is pressed downward by the half-cutting punch 228 and the strip-shaped iron plate 212 positioned in the third region is pressed upward by the half-cutting die 138. External force acts relative to That is, a shearing force is applied to each of the belt-like iron plates 171 to 189. As a result, a stepped portion 170 (see FIGS. 62 to 64) in a half cut state is formed in the thickness direction (vertical direction in FIG. 62) of each of the strip-shaped iron plates 171 to 189. This process corresponds to the half-cutting process of the present invention.

  Since the half-cut punch 228, the cut punch 226, the press pin 229, and the cut pin 269 are all suspended from the back plate 223, when the half-cut punch 228 is lowered, the cut punch 226 and the press pin 229 are provided. , And the cut pin 269 are also lowered. For this reason, by performing the above-described half-cutting process, the upstream side of the partial area 161 (see FIG. 51) in the iron plate 6 in the second area, that is, the remaining area of the partial area 161 is cut in the width direction by the cut punch 226. (See FIG. 63). At the same time, a recess 153 (see FIG. 62) is formed in the first region.

  FIG. 65 is an enlarged cross-sectional view of the stepped portion 170.

  As shown in FIG. 65, the gap g in the thickness direction (vertical direction in FIG. 65) of the strip-shaped iron plate 212 in the stepped portion 170 is set to about 30% of the thickness of the iron plate 6. That is, the half-cut punch 228 has a lower end portion that protrudes downward from the press plate 225 by about 70% of the thickness of the iron plate 6 when the upper plate 224 and the press plate 225 are in contact with each other (see FIG. 62). Its length is set. The stepped portion 170 is formed in a half-cut state in which the belt-like iron plate 212 located in the third region is pushed up and the belt-like iron plate 212 located in the fourth region is pushed down. Since the gap g between the stepped portions 170 is sufficiently smaller than the thickness of the belt-like iron plate 212, the stepped portion 170 is easily broken when pressed from above and below. The step portions 130, 160, and 190 are the same as the step portion 170.

  FIG. 66 is a longitudinal sectional view of the press machine 220 as viewed from the width direction of the iron plate 6 and shows a state in which the recessed portion 151 has moved to the fourth region. FIG. 67 is a longitudinal sectional view of the press machine 220 as viewed from the width direction of the iron plate 6 and shows a state in which the stepped portion 190 is formed on the upstream side of the recessed portion 151 and the through hole 157. FIG. 68 is a perspective view of the strip-shaped iron plate 212 in which the stepped portion 190 is formed.

  When the stepped portion 170 is formed on the downstream side as shown in FIG. 63, the recessed portion 151 and the through hole 157 of the belt-shaped iron plate 212 move from the third region to the fourth region after the upper die 221 is lifted ( 62 and 66). The upper mold 221 is lowered toward the lower mold 131 from the state shown in FIG. As a result, as shown in FIGS. 67 and 68, the band-shaped iron plate 212 has a stepped portion 190 formed on the upstream side of the recessed portion 151 and the through hole 157. The strip-shaped iron plate 212 in which the step portions 170 and 190 are formed on both sides in the longitudinal direction is transported by the transport device in a state where the upper mold 221 is raised, and is unloaded from the press machine 220.

  Thus, in the 1st process which has the above-mentioned partial cutting process and the above-mentioned half cutting process, iron plate 6 which has a fixed width is cut in the width direction. Thereby, 28 strip-shaped iron plates 171 to 189 having different widths are formed. The strip-shaped iron plates 171 to 189 correspond to the 28 iron plate pieces 11 to 29, respectively. In other words, 28 strip-shaped iron plates 171 having a predetermined length and cut in the width direction correspond to 28 iron plate pieces 11 to 29, respectively. The constant width of the iron plate 6 is set substantially equal to the total width of the 28 iron plate pieces 11 to 29. For this reason, the strip | belt-shaped iron plates 171-189 of 28 strips are formed from the iron plate 6, without producing a scrap in the width direction of the iron plate 6. FIG.

  Further, each of the belt-like iron plates 171 to 189 is formed with a stepped portion 170 in a state where a partial region 161 (see FIG. 51) is divided in the width direction. Thereby, the level | step-difference part 170 is formed in the position close enough compared with the distance L from the iron plate 6 in each strip | belt-shaped iron plates 171-189 (refer FIG.58 and FIG.63). Therefore, the stepped portion 170 is formed in a state where the position where the stepped portion 170 is formed in each of the belt-shaped iron plates 171 to 189 is aligned in the width direction of the iron plate 6. Therefore, compared with the case where the stepped portion 170 is formed in a state where the strip-shaped iron plates 171 to 189 are completely divided, the positional accuracy of the stepped portion 170 is higher, and as a result, the accurate cylindrical coil core 1 can be easily manufactured. It becomes possible.

  FIG. 69 is a perspective view of the strip-shaped iron plate 171 passing between the sensors 32a and 32b. FIG. 70 is a longitudinal sectional view of the strip-shaped iron plate 171 as viewed from the width direction. FIG. 71 is a perspective view of a strip-shaped iron plate 189 that passes between the sensors 32a and 32b. FIG. 72 is a longitudinal sectional view of the belt-like iron plate 189 as seen from the width direction.

  As shown in FIG. 68, the 28 strip-shaped iron plates 171 to 189 formed by the press machine 220 are sent from the press machine 220 to the compactor 70 in a state of being arranged in the width direction (one horizontal example). The strip-shaped iron plates 171 to 189 sent out from the press machine 220 are guided while being deformed so as to bend downward so as to pass between the sensors 32a and 32b (see FIGS. 35, 69, and 71). The strip-shaped iron plates 171 to 188 are provided with three concave portions 3 (150 to 152 in FIG. 69) and step portions 130, 160, 170, and 190 alternately arranged in the longitudinal direction. The strip-shaped iron plate 189 is provided with three through-holes 4 (156 to 158) and stepped portions 130, 160, 170, and 190 alternately arranged in the longitudinal direction.

  In the strip-shaped iron plate guide 33 (see FIG. 32), the respective strip-shaped iron plates 171 to 189 are inserted through a plurality of guide holes 111 to 120 formed side by side in the vertical direction. The strip-shaped iron plate guide 33 has the narrow strip-shaped iron plate 212 (refer to FIG. 68) as the center, and the narrow strip-shaped iron plate 212 is directed to both outer sides in the direction in which the front and back surfaces face each other (vertical direction in FIG. 68). Arranged in a row. In the present embodiment, eight strip-shaped iron plates 180 are arranged in the vertical direction, and two strip-shaped iron plates 179, strip-shaped iron plates 178, strip-shaped iron plates 177, strip-shaped iron plates 176, strip-shaped iron plates 175, strip-shaped iron plates 174 are directed upward. The strip-shaped iron plate 173, the strip-shaped iron plate 172, and the strip-shaped iron plate 171 are arranged in this order. Then, toward the lower side of the eight strip-shaped iron plates 180, the two strip-shaped iron plates 181, the strip-shaped iron plate 182, the strip-shaped iron plate 183, the strip-shaped iron plate 184, the strip-shaped iron plate 185, the strip-shaped iron plate 186, the strip-shaped iron plate 187, the strip-shaped iron plate 188, the strip-shaped Iron plates 189 are arranged in order. Thereby, the column cross section of the iron core 1 for cylindrical coils is formed. This step corresponds to the second step in the present invention.

  FIG. 73 is a longitudinal sectional view of the laminate 199. FIG. 74 is a perspective view showing the laminate 199. FIG.

  The 28 strip-shaped iron plates 171 to 189 arranged by the strip-shaped iron plate guide 33 are fed into the compactor 70 by the rotation of the compaction rollers 71 to 76 in the compactor 70. The strip-shaped iron plates 171 to 189 arranged in a line in the vertical direction are first pressed by the rolling rollers 71 and 72 so as to be sandwiched from above and below. The band-shaped iron plates 171 to 188 are formed with recesses 3 (150 to 154), and the band-shaped iron plate 189 is formed with through holes 4 (156 to 158). Therefore, the belt-like iron plates 171 to 189 held between the rolling rollers 71 and 72 are stacked and fixed by caulking between the caulking portions (see FIG. 73). In other words, it is fixed by meshing the recessed portions 3 or by fitting the recessed portions 3 into the through holes 4. Thereby, the rod-shaped laminated body 199 (refer FIG. 74) whose cross section is substantially circular is obtained. Incidentally, on the downstream side in the conveying direction of the pressure rollers 71 and 72, pressure rollers 73 and 74 and pressure rollers 75 and 76 are provided. Therefore, the belt-like iron plates 171 to 189 are securely stacked and fixed by these three roller pairs. This step corresponds to the third step in the present invention.

  Steps 130, 160, 170, 190 (FIG. 73 and FIG. 73) are formed at predetermined intervals in the longitudinal direction (axial direction) of the laminate 199 by repeating the first to third steps on the iron plate 6. In step 74, a step 170) is provided. The step portions 170 are formed on all the strip-shaped iron plates 171 to 189 constituting the laminated body 199, and are provided so as to be aligned in a row in the front and back surfaces of each other (see FIGS. 73 and 74). In other words, the strip-shaped iron plates 171 to 189 are arranged by the strip-shaped iron plate guides 33 so that the stepped portions 170 of the respective strip-shaped iron plates 171 to 189 are arranged in a line in the front and back surfaces of each other.

  FIG. 75 is a longitudinal sectional view of the breaker 215 viewed from the width direction of the laminate 199. FIG. 76 is a longitudinal sectional view of the breaker 215 viewed from the width direction of the laminated body 199, and shows a state where the laminated body 199 is sandwiched. FIG. 77 is a longitudinal sectional view of the breaker 215 viewed from the width direction of the laminate 199 and shows a state where the stepped portions 170 of the respective strip-shaped iron plates 212 constituting the laminate 199 are broken.

  The laminated body 199 sent out from the compactor 70 is sent between the upper mold 216 and the lower mold 217 included in the breaking machine 215 (see FIG. 75). When the sensor detects that the stepped portion 170 of the stacked body 199 has reached between the dimple 163 and the dimple 164, the upper mold 216 is lowered to press the stacked body 199. As a result, as shown in FIG. 76, the lower surface of the press plate 167 contacts the upper surface of the laminate 199, and the lower surface of the laminate 199 contacts the upper surface of the press plate 168. At this time, the recessed portion 150 exposed from the through hole 156 is accommodated in the dimple 164, and the recessed portion 151 exposed from the through hole 157 is accommodated in the dimple 163. For this reason, the lower surface of the laminated body 199 adheres closely to the upper surface of the press plate 168 without a gap. As a result, the pressing force from the press plates 167 and 168 is correctly transmitted in the stacking direction of the stacked body 199 (vertical direction in FIG. 76), and the stepped portions 170 of the respective strip-shaped iron plates 171 to 189 are broken (see FIG. 77). Thereby, the laminated body 199 on the downstream side is folded at the stepped portion 170 to obtain the cylindrical coil core 1. The cylindrical coil core 1 obtained in this way is stored in a collection box 37 via a chute 36. In this way, the cylindrical coil core 1 is continuously formed by cutting the laminated body 199 at predetermined intervals in the axial direction. This step corresponds to the fourth step in the present invention.

  As described above, in the second embodiment of the present invention, the stepped portion 170 is formed by applying a shearing force to each of the belt-like iron plates 171 to 189 in the first step (see FIG. 68). In the third step, these band-shaped iron plates 171 to 189 are laminated and fixed so that the respective stepped portions 170 are arranged in a line in the front and back surfaces of each other (see FIGS. 73 and 74). The laminated body 199 obtained by the lamination fixing is pressed in the fourth step (see FIG. 76). The step portions 170 of the respective strip-shaped iron plates 171 to 189 constituting the laminated body 199 are in a half-cut state that is easily broken when pressed in the front and back direction. For this reason, the laminated body 199 can be cut | disconnected easily.

  In addition, this invention is not limited to the said embodiment, The following forms may be sufficient. That is, the 1st process in this embodiment is not limited to what includes a partial cutting process and a half cutting process. That is, when the axial length L of the cylindrical coil core 1 is short, the partial area 161 and other areas may be divided at a time and then the half-cutting process may be performed. However, in this case, there is a possibility that the positional accuracy of the stepped portion 170 formed on the belt-like iron plates 171 to 189 may be lowered. Therefore, it is preferable to divide only the partial area 161 in the iron plate 6 and perform the half-cutting process in a state close to a single plate.

  Moreover, in this embodiment, although the form which forms the recessed part 3 and the through-hole 4 before forming the level | step-difference part 170 in the iron plate 6 was demonstrated, after forming the level | step-difference part 170 in each strip | belt-shaped iron plates 171-189, it is recessed. The part 3 and the through hole 4 may be formed. However, in this case, since the recessed portion 3 and the through hole 4 are formed in a state where the iron plate 6 is divided in the width direction, the positional accuracy of the recessed portion 3 and the through hole 4 may be lowered. Therefore, it is preferable to form the stepped portion 170 after forming the recessed portion 3 and the through hole 4 in the iron plate 6 in a single plate state.

  Moreover, in this embodiment, although the iron plate 6 demonstrated the form which is a grain-oriented electrical steel plate, the iron plate 6 may be a non-oriented electrical steel plate.

FIG. 1 is a perspective view showing an appearance of a cylindrical coil core 1 manufactured by the method for manufacturing a cylindrical coil core according to the present embodiment. FIG. 2 is a longitudinal sectional view showing the laminated structure of the cylindrical coil iron core 1. 3 is a plan view of the cylindrical coil core 1 as viewed from the direction of arrow III in FIG. FIG. 4 is a schematic view showing the iron core manufacturing apparatus 30. 5 is a front view of the half-cut rollers 40a and 40b as viewed from the direction of the arrow V in FIG. FIG. 6 is a side view of the half-cut rollers 40a and 40b. FIG. 7 is an enlarged view of a portion VII in FIG. FIG. 8 is an enlarged view of a portion VIII in FIG. FIG. 9 is a schematic cross-sectional view showing the press machine 50. FIG. 10 is a perspective view showing the back plate 59. FIG. 11 is a perspective view showing the upper plate 60. FIG. 12 is a perspective view showing the back plate 65. FIG. 13 is a perspective view schematically showing the base 54. FIG. 14 is a plan view showing the half-cut roller 40a. FIG. 15 is a perspective view showing the uneven plate 7. FIG. 16 is a longitudinal sectional view of the uneven plate 7 in the width direction. FIG. 17 is an enlarged view of a portion XVII in FIG. FIG. 18 is a schematic cross-sectional view of the press machine 50 showing how the upper mold 51 descends. FIG. 19 is an enlarged view of the XIX portion in FIG. FIG. 20 is a schematic cross-sectional view of the press machine 50 showing a state where the boundary 87 is broken by pressing the press plate 61. FIG. 21 is an enlarged view of the XXI portion in FIG. FIG. 22 is a perspective view showing the strip-shaped iron plate 91 to the strip-shaped iron plate 109 formed by breaking the boundary 87 of the uneven plate 7. FIG. 23 is a schematic cross-sectional view of the press machine 50 showing a state in which the recessed portion 3 and the through hole 4 are formed by the press pin 68 and the cut pin 69. FIG. 24 is an enlarged view of the XXIV part in FIG. FIG. 25 is a perspective view showing the strip-shaped iron plate 91 to the strip-shaped iron plate 109 sent out from the press machine 50. FIG. 26 is a schematic cross-sectional view of the press machine 50 showing a state in which the belt-like iron plate 91 to the belt-like iron plate 108 are pushed up by the lift pins 67. FIG. 27 is an enlarged view of a portion XXVII in FIG. FIG. 28 is a perspective view of the belt-like iron plate 91 passing between the sensors 32a and 32b. FIG. 29 is a longitudinal sectional view of the belt-like iron plate 91 viewed from the width direction. FIG. 30 is a perspective view of the belt-like iron plate 109 passing between the sensors 32a and 32b. FIG. 31 is a longitudinal sectional view of the belt-like iron plate 109 viewed from the width direction. 32 is a front view of the strip-shaped iron plate guide 33 as viewed from the direction of the arrow V in FIG. FIG. 33 is a cross-sectional view showing the belt-like iron plate 91 to the belt-like iron plate 109 that are stacked and fixed. FIG. 34 is a perspective view showing the laminate 9. FIG. 35 is a schematic view showing the iron core manufacturing apparatus 210. FIG. 36 is a longitudinal sectional view of the press machine 220 as viewed from the width direction of the iron plate 6. FIG. 37 is a longitudinal sectional view showing a first region of the press machine 220 as seen from the direction of the arrow XXXVII in FIG. FIG. 38 is a longitudinal sectional view showing the second region and the third region of the press machine 220 as viewed from the direction of the arrow XXXVII in FIG. FIG. 39 is a vertical cross-sectional view of the press machine 220 as seen from the width direction of the iron plate 6 and shows a boundary portion between the third region and the fourth region. FIG. 40 is a schematic view of the breaker 215 viewed from the width direction of the laminate 199. FIG. 41 is a longitudinal sectional view of the press machine 220 as seen from the width direction of the iron plate 6 and shows a state in which the upper die 221 is lowered. FIG. 42 is a longitudinal sectional view of the press machine 220 as seen from the width direction of the iron plate 6 and shows a state where the iron plate 6 is sandwiched. FIG. 43 is a longitudinal sectional view showing a first region of the press machine 220 as viewed from the arrow XXXVII in FIG. 35, and shows a state where the iron plate 6 is sandwiched. FIG. 44 is a longitudinal sectional view of the press machine 220 as viewed from the width direction of the iron plate 6, and shows a state where the iron plate 6 is half-punched by the press pin 229. FIG. 45 is a longitudinal sectional view showing the first region of the press machine 220 as viewed from the arrow XXXVII in FIG. 35, and shows a state where the iron plate 6 is half-cut by the press pin 229. FIG. 46 is an enlarged view of the XXXXVI portion in FIG. FIG. 47 is a perspective view of the iron plate 6 in which the recessed portion 151 and the through hole 157 are formed. FIG. 48 is a longitudinal sectional view showing a first region of the press machine 220 as viewed from the arrow XXXVII in FIG. 35, and shows a state where the iron plate 6 is pushed up by the lift pins 147. 49 is an enlarged view of a portion XXXXIX in FIG. FIG. 50 is a longitudinal sectional view of the press machine 220 as seen from the width direction of the iron plate 6 and shows a state in which the recessed portion 151 is located in the first region. FIG. 51 is a longitudinal sectional view of the press machine 220 as seen from the width direction of the iron plate 6 and shows a state in which the recessed portion 151 has moved to the second region. FIG. 52 is a longitudinal sectional view of the press machine 220 as viewed from the width direction of the iron plate 6 and shows a state where the iron plate 6 is sandwiched. FIG. 53 is a longitudinal sectional view showing the second region and the third region of the press machine 220 as viewed from the arrow XXXVII in FIG. 35, and shows a state where the iron plate 6 is sandwiched. 54 is an enlarged view of a portion XXXXXIV in FIG. FIG. 55 is a longitudinal sectional view of the press machine 220 as seen from the width direction of the iron plate 6 and shows a state where a partial region 161 is divided by the cut punch 226. FIG. 56 is a longitudinal sectional view showing the second region and the third region of the press machine 220 as viewed from the arrow XXXVII in FIG. 35, and shows a state where the partial region 161 is divided. FIG. 57 is an enlarged view of a portion XXXXXVII in FIG. FIG. 58 is a perspective view showing the strip-shaped iron plate 212 formed in the partial region 161. FIG. 59 is a longitudinal sectional view showing the second region and the third region of the press machine 220 as viewed from the arrow XXXVII in FIG. 35, and shows a state where the upper die 221 is raised. 60 is an enlarged view of a portion XXXXXX in FIG. FIG. 61 is a longitudinal sectional view of the press machine 220 viewed from the width direction of the iron plate 6 and shows a state in which the recessed portion 151 has moved to the third region. FIG. 62 is a longitudinal sectional view of the press machine 220 as viewed from the width direction of the iron plate 6 and shows a state in which a stepped portion 170 is formed on the downstream side of the recessed portion 151. FIG. 63 is a perspective view of the strip-shaped iron plate 212 on which the stepped portion 170 is formed. 64 is an enlarged view of a portion XXXXXXIV in FIG. FIG. 65 is an enlarged cross-sectional view of the stepped portion 170. FIG. 66 is a longitudinal sectional view of the press machine 220 as viewed from the width direction of the iron plate 6 and shows a state in which the recessed portion 151 has moved to the fourth region. FIG. 67 is a longitudinal sectional view of the press machine 220 as viewed from the width direction of the iron plate 6 and shows a state in which the stepped portion 190 is formed on the upstream side of the recessed portion 151 and the through hole 157. FIG. 68 is a perspective view of the strip-shaped iron plate 212 in which the stepped portion 190 is formed. FIG. 69 is a perspective view of the strip-shaped iron plate 171 passing between the sensors 32a and 32b. FIG. 70 is a longitudinal sectional view of the strip-shaped iron plate 171 as viewed from the width direction. FIG. 71 is a perspective view of a strip-shaped iron plate 189 that passes between the sensors 32a and 32b. FIG. 72 is a longitudinal sectional view of the belt-like iron plate 189 as seen from the width direction. FIG. 73 is a longitudinal sectional view of the laminate 199. FIG. 74 is a perspective view showing the laminate 199. FIG. FIG. 75 is a longitudinal sectional view of the breaker 215 viewed from the width direction of the laminate 199. FIG. 76 is a longitudinal sectional view of the breaker 215 viewed from the width direction of the laminated body 199, and shows a state where the laminated body 199 is sandwiched. FIG. 77 is a longitudinal sectional view of the breaker 215 viewed from the width direction of the laminate 199 and shows a state in which the stepped portion 170 of each strip-shaped iron plate 212 constituting the laminate 199 is broken.

DESCRIPTION OF SYMBOLS 1 ... Iron core for cylindrical coils 3 ... Recessed part (crimping part)
4 ... Through hole (crimped part)
6 ... Iron plate 8 ... Band-shaped iron plate 9 ... Laminate 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27 , 28, 29 ... iron plate piece 33 ... strip-shaped iron plate guide 84 ... first convex part 85 ... second convex part 87 ... boundaries 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109 ... strip-shaped iron plates 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129... Guide holes 150, 151, 152, 153, 154... Recessed portions (caulking portions)
156, 157, 158 ... through hole (crimped area)
161... Partial regions 130, 160, 170, 190... Step portions 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186 , 187, 188, 189 ... strip-shaped iron plate 199 ... laminated body 212 ... strip-shaped iron plate

Claims (8)

A method for manufacturing an iron core for a cylindrical coil composed of a predetermined number of iron plate pieces having different widths,
After pressing one iron plate having a constant width substantially equal to the total width of each iron plate piece to form a crimped portion at each position corresponding to each iron plate piece, the one iron plate is A first step of forming a predetermined number of strip-shaped iron plates corresponding to each of the iron plate pieces by dividing in a direction;
A second step of sequentially arranging narrow strip-shaped iron plates in a row toward both outer sides in a direction in which the front and back surfaces face each other, with a wide strip-shaped iron plate as a center to form a cylindrical cross section of the cylindrical coil iron core;
A third step of laminating and fixing the above-mentioned predetermined number of strip-shaped iron plates arranged by caulking between the caulking parts ;
And a fourth step of cutting the laminated body obtained by the lamination fixing at a predetermined interval in the axial direction. The method for manufacturing an iron core for a cylindrical coil according to claim 1, wherein the iron plate having the certain width is a grain-oriented electrical steel sheet. A method for manufacturing an iron core for a cylindrical coil composed of a predetermined number of iron plate pieces having different widths,
The first protrusion protruding to the first surface side which is one of the front and back surfaces of the iron plate having a constant width substantially equal to the total width of the iron plate pieces, and the second protrusion protruding to the second surface side which is the other of the front and back surfaces. The iron plate is formed so that the two convex portions are alternately arranged in the width direction of the iron plate, and the width of each first convex portion and the width of each second convex portion have an uneven shape corresponding to the width of each belt-like iron plate. And forming a predetermined number of strip-shaped iron plates respectively corresponding to the iron plate pieces by pressing the formed iron plate and breaking the boundaries between the first and second convex portions. And a breaking step of forming a caulking portion on each strip-shaped iron plate in a state where the predetermined number of strip-shaped iron plates are fixed by the press ,
A second step of sequentially arranging narrow strip-shaped iron plates in a row toward both outer sides in a direction in which the front and back surfaces face each other, with a wide strip-shaped iron plate as a center to form a cylindrical cross section of the cylindrical coil iron core;
A third step of stacking and fixing the above-mentioned predetermined number of strip-shaped iron plates arranged by caulking between each other ,
And a fourth step of cutting the laminated body obtained by the lamination fixing at a predetermined interval in the axial direction. Claims above widths and the respective second convex portions of the first convex portions are arranged the respective first protrusions and each of the second protrusions such that successively narrower toward both ends from the center of the width direction Item 4. A method for manufacturing an iron core for a cylindrical coil according to Item 3 . In the first step, a shearing force is applied to each band-shaped iron plate to form a stepped portion that is half cut in the thickness direction,
The manufacturing method of the iron core for cylindrical coils of Claim 3 or 4 which presses the said laminated body and fracture | ruptures the level | step-difference part of each strip | belt-shaped iron plate in the said 4th process.   The first step includes a partial dividing step of dividing the partial region where the stepped portion is formed in the iron plate in the width direction, and a half cutting step of forming the stepped portion in the partial region divided in the width direction. The manufacturing method of the iron core for cylindrical coils of Claim 5 containing these. The manufacturing method of the iron core for cylindrical coils of Claim 5 or 6 which forms a crimp part before forming the said level | step-difference part in the said iron plate in the said 1st process. The method for manufacturing an iron core for a cylindrical coil according to any one of claims 3 to 7 , wherein the iron plate having the constant width is a grain-oriented electrical steel plate.

Images