JP4472386B2 - Manufacturing method of laminated iron core - Google Patents

Description

    The present invention relates to a method for manufacturing a laminated core in which a laminated core is manufactured by punching iron core pieces from a laminated plate in which a plurality of thin metal plates are stacked, and laminating these predetermined number of iron core pieces together.

    For example, in a laminated core such as a stator core that is a component of an electric motor, each core piece is made of a thin plate in order to improve the output and efficiency of the electric motor or to reduce the size as much as possible. The formation of a metal plate (such as a magnetic steel sheet) having a thickness (for example, 0.20 mm or less) has been studied.

  However, in the configuration as described above, for example, when manufacturing a laminated core having the same height (stack thickness), a larger number than the conventional laminated core using a metal plate having a thick plate thickness (for example, 0.30 to 0.35 mm). Since an iron core piece is required and the man-hour for punching and forming the iron core piece is increased, the productivity is lowered.

  Therefore, in order to suppress the reduction in productivity as described above, there is provided a method for manufacturing a laminated core in which a core piece is formed in a state where a plurality of thin metal plates are overlapped (see, for example, Patent Document 1). ).

Specifically, before stacking a plurality of thin metal plates such as electromagnetic steel sheets and punching them with a press, there is a step of bringing the plurality of metal plates into close contact with half-cutting calamase. A method of manufacturing a laminated core by punching and forming iron core pieces from a plurality of metal plates stacked in this manner and then caulking and laminating them to each other. According to this, it is possible to reduce the number of stamping processes required to form the required number of iron core pieces, thereby achieving improvement in productivity.
JP 2003-153503 A

    By the way, in the method of manufacturing a laminated core as described above, when a plurality of thin metal plates (for example, 0.15 to 0.20 mm) are overlapped, half-cut Karamase is formed in a region that does not form a core piece. Even if the metal plates are combined, it is inevitable that a gap of about 0.01 to 0.005 mm is formed between the stacked metal plates.

  For this reason, a gap remains between the core pieces formed by punching from a laminated plate in which a plurality of metal plates are stacked.In a laminated core manufactured by caulking and stacking these iron core plates, the occupancy rate ( The ratio of the volume occupied by the metal to the total volume of the laminated core decreases, and when the motor is configured, it is not possible to achieve an increase in output or an increase in efficiency.

  An object of the present invention is to provide a method of manufacturing a laminated core capable of manufacturing a laminated core having a high space factor by punching out an iron core piece from a laminated plate in which a plurality of thin metal plates are stacked in view of the above-described actual situation. Is to provide.

    In order to achieve the above object, a method for manufacturing a laminated core according to the first aspect of the present invention includes punching out core pieces from a laminated plate in which a plurality of thin metal plates are stacked, and caulking and laminating a predetermined number of the core pieces together. A laminated core manufacturing method for manufacturing a laminated core by: forming a core piece forming portion of a laminated plate and a united locking part around the core piece forming unit, and forming a plurality of metal thin plates by the united locking unit A step of fixing them together, a step of removing all or part of the laminated plate other than the core piece forming portion in the core piece forming region, a step of forming a crimped portion in the core piece forming portion of the laminated plate, and a crimped portion The step of pushing the united locking part before or after the formation, the step of punching and forming the core pieces from the laminate, and the step of caulking and stacking the core pieces are characterized.

  According to a second aspect of the present invention, there is provided a laminated core manufacturing method according to the first aspect of the invention, wherein the united locking portion is formed by a punch having a convex end. Yes.

  A method for manufacturing a laminated iron core according to the invention of claim 3 is the method for producing a laminated iron core according to claim 1, wherein three directions in the plane of the laminated plate are provided in the central part of the core piece forming region of the laminated plate. It is characterized by forming a combined locking portion having a shape that exerts a uniform combined locking force as described above.

    According to the method for manufacturing a laminated iron core according to the invention of claim 1, when pushing back the united locking part before or after forming the crimping part, a plurality of metal thin plates constituting the laminated plate are subjected to pressure caused by pushback. Therefore, the thin metal plates are brought into close contact with each other without gaps, and the occupancy rate of the laminated core formed by caulking and laminating the core plates punched from the laminated plate is greatly improved. In an electric motor having a laminated iron core manufactured as a component, it is possible to improve output, improve efficiency, and achieve miniaturization as much as possible.

  According to the method for manufacturing a laminated iron core according to the invention of claim 2, the tip end portion of the coalesced locking portion protruding from the bottom surface of the laminated plate is formed by forming the united locking portion with a punch whose tip portion has a convex shape. In addition, since a convex shape is formed and a large pressure with a long stroke is required when pushing back the united engagement portion, the thin metal plates are surely pressed and brought into close contact with each other.

  According to the method for manufacturing a laminated core according to the invention of claim 3, the uniting mechanism of the shape that exerts a uniform uniting locking force in three or more directions in the plane of the laminate at the central part of the core piece forming region of the laminate. By forming the stop portion, the thin metal plates constituting the laminated plate are surely united by the combined locking portion, and by pushing back the combined locking portion, the thin metal plates of the stacked plate can be securely connected. It becomes possible to close.

Hereinafter, the present invention will be described in detail with reference to the drawings illustrating embodiments.
FIG. 1 shows an embodiment of a laminated stator core (laminated core) manufactured in accordance with the method for manufacturing a laminated core according to the present invention. The laminated stator core 1 includes a yoke 10Y having a ring shape, A predetermined number of magnetic poles 10T, 10T,... Extending from the yoke 10Y in the radially inward direction.

  The laminated stator core 1 is manufactured by punching out the core pieces 10 from a laminated plate in which a plurality of thin metal plates are stacked as will be described later, and caulking and laminating a predetermined number of the core pieces 10, 10,. The individual core pieces 10 constituting the laminated stator core 1 are formed with a combined locking portion 10A and a caulking portion 10C, which will be described in detail later.

  FIG. 2 shows a laminated plate 100 used for manufacturing the laminated stator core 1 described above. The laminated plate 100 having a strip shape is composed of three thin metal plates 101 made of electromagnetic steel plates or the like, It is configured by overlapping each other. Incidentally, the number of the thin metal plates 101 constituting the laminated plate 100 is not limited to the embodiment (three pieces), and is based on various conditions such as the number of the core pieces 10 constituting the laminated stator core 1. Needless to say, it can be set appropriately.

  Further, the laminated stator core 1 shown in FIG. 1 is manufactured by sequentially pressing the laminated plate 100 shown in FIG. 2 in a transfer press (a progressive die apparatus) as will be described later. It is.

Below, an example of the method of manufacturing the laminated stator core 1 mentioned above is demonstrated in detail following the manufacturing process shown in FIG.
Here, the laminated stator core 1 is caulked and laminated by core pieces 10, 10... Formed from the laminated plate 100 (metal thin plate 101) through processing stations S1 to S7 of a transfer press (not shown). Manufactured.

  First, in the processing station S1 and the processing station S2, a plurality of thin metal plates 101 constituting the stacked body 100 are shifted from each other by forming the combined locking portions 10A, 10A,. Connect and fix so that there is nothing.

  Here, the united locking portion 10A is formed by half-punching a part of the laminated plate 100 (the thin metal plate 101) by a punch P in a manner of pushing downward as shown in FIG. Yes.

  Further, the united locking portion 10A formed at the processing station S1 is formed around the iron core piece forming portion (the portion constituting the actual iron core piece 10) in the laminated plate 100, that is, at a portion that becomes scrap in the subsequent steps. ing.

  On the other hand, the united locking portion 10 </ b> A formed at the processing station S <b> 2 is formed at a portion corresponding to the iron core piece forming portion in the laminated plate 100, specifically the yoke portion 1 </ b> Y of the laminated stator core 1.

  Further, in the processing station S1, the unit formed in the central part of the core piece forming region of the laminated plate 100 (all the range inward from the outer peripheral line of the core piece 10 including the portion constituting the actual core piece 10). The locking portion 10A has a cross shape, that is, a shape that exerts a uniform combined locking force in three or more directions in the plane of the laminated plate 100.

  The shape of the united locking portion 10A is an appropriate shape other than the cross shape, for example, three directions or 5 as long as the shape exerts a uniform uniting locking force in three or more directions in the plane of the laminated plate 100. It goes without saying that various shapes such as a radial shape extending in a direction higher than the direction can also be adopted.

  In the processing stations S1 and S2, the unitary locking portions 10A, 10A,... Are formed at predetermined positions of the laminated plate 100, and then in the subsequent processing station S3, other than the core piece forming portion in the core piece forming region of the laminated plate 100. .., More specifically, the yoke portion 1Y of the laminated stator core 1 and the slots 10S, 10S... Surrounded by the adjacent magnetic poles 1T, 1T are separated.

  After the slots 10S, 10S,... Are removed at the processing station S3, the crimping portions 10C, 10C,... Are formed at predetermined positions of the core piece forming portion in the laminated plate 100 (metal thin plate 101) at the processing station S4.

Next, at the processing station S5, the united locking portions 10A, 10A... Formed on the laminated plate 100 are pushed back.
That is, as shown in FIG. 4 (b), the upper surface of the laminated plate 100 is supported by the back plate B, and the united locking portion 10A is pressed from below by the pushback punch A, and the united unit as shown in FIG. 4 (c). The front end surface 10Aa of the locking portion 10A is pushed back to the lower surface of the laminated plate 100.

  At this time, the plurality of metal thin plates 101, 101,... Constituting the laminated plate 100 are brought into pressure contact with each other due to the pressure accompanying the pushback, so that the respective metal thin plates 101 come into close contact with each other without any gap.

  Further, as shown in FIG. 4 (a), the union locking portion 10A is formed by a punch P having a tip end Pa having a convex shape, and the tip end surface 10Aa has a convex shape. Is pushed back to the lower surface of the laminated plate 100, a large pressure is applied over a long stroke, that is, a distance obtained by adding the protruding height of the tip portion 10Aa to the height s of the shearing portion. As the 101s are reliably pressed together, the effect of bringing them into close contact with each other without a gap is great.

  After the union locking portions 10A, 10A,... Are pushed back at the processing station S5, the center opening 10R surrounded by the magnetic poles 1T, 1T,.

  Further, in the processing station S7, the outer shape (outer periphery) of the iron core piece 10 is removed / caulked and laminated, and thus a laminated stator core 1 is manufactured which is formed by laminating a predetermined number of iron core pieces 10 together. The Rukoto.

  Here, as described above, since the metal thin plates 101 constituting the laminated plate 100 are in close contact with each other by being pushed back at the previous processing station S5, the core pieces 10 formed by punching from the laminated plate 100 are formed. In the laminated stator core 1 formed by caulking, the occupancy rate is greatly improved by bringing the core pieces 10 into close contact with each other without a gap.

  Thus, in the electric motor having the laminated stator core 1 manufactured through the processes as described above as constituent elements, it is possible to improve output, improve efficiency, and achieve miniaturization as much as possible.

  5 and 6 show a modified example of the combined locking portion formed in the laminated plate 100. The combined locking portion 10A 'in the embodiment of FIG. 5 has a convex surface with a gentle tip portion Pa'. The front end surface 10Aa ′ of the punch P ′ is a gentle convex surface following the front end portion Pa ′ of the punch P ′.

  Further, the unitary locking portion 10A ″ in the embodiment of FIG. 6 is formed by using a one-cut punch P ″, and its tip surface 10Aa ″ projects in a shape that follows the tip portion Pa ″ of the punch P ″. ing.

  As described above, even in the combined locking portions 10A ′ and 10A ″ having various shapes, the combined locking portions 10A ′ and 10A ″ are pushed back to the lower surface of the laminated plate 100 in the pushback process. It goes without saying that the metal thin plates 101 constituting the laminated plate 100 are brought into close contact with each other as in the embodiment, so that the occupation rate of the laminated stator core can be greatly improved.

  In addition, it cannot be overemphasized that the manufacture procedure of the lamination | stacking stator core 1 using a progressive die apparatus is not limited to the Example mentioned above, It can set suitably. For example, in the above-described embodiment, the slots 10S, 10S,... Are removed at the processing station S3 and the center opening 10R is punched out at the final processing station S7, but in the core piece forming region of the laminated plate 100 at the processing station S3. Can be formed by punching out all the portions other than the iron core piece forming portion, that is, the slots 10S, 10S... And the central opening 10R.

  Further, in the present embodiment described above, an example in which a laminated stator core of an electric motor is manufactured is shown, but the present invention can be applied even when manufacturing various laminated iron cores such as a laminated rotor core of an electric motor. Needless to say, it can be applied effectively.

The external appearance perspective view which shows an example of the lamination | stacking stator core manufactured by the manufacturing method of the lamination | stacking core concerning this invention. FIG. 2 is an external perspective view of a laminated plate used for manufacturing the laminated stator core shown in FIG. 1. The top view which shows the punching process of the laminated board in the case of manufacturing the laminated stator core shown in FIG. (a), (b) and (c) are principal part sectional drawings which show one Example of the united locking part in a laminated board. (a), (b) and (c) is principal part sectional drawing which shows the other Example of the uniting latching | locking part in a laminated board. (a), (b) and (c) is principal part sectional drawing which shows the further another Example of the uniting latching | locking part in a laminated board.

Explanation of symbols

1 ... Laminated stator core (laminated core),
10 ... Iron core piece,
10A, 10A ′, 10A ″.
10C ... crimping part,
100 ... laminate,
101 ... Metal thin plate,
P, P ', P "... Punch,
A ... Pushback punch,
B: Back plate.

Claims (3)

A method of manufacturing a laminated core, in which a laminated core is manufactured by punching out an iron core piece from a laminated plate in which a plurality of thin metal plates are stacked, and caulking and laminating a predetermined number of the iron core pieces to each other,
Forming a core piece forming portion of the laminated plate and a united locking portion around the core piece forming unit, and fixing the plurality of metal thin plates to each other by the united locking unit;
A step of pulling apart or all of the core plate other than the core piece forming portion in the core piece forming region from the laminated plate;
Forming a crimped portion in the core piece forming portion of the laminate;
A step of pushing back the union locking portion before or after the formation of the crimped portion;
Punching and forming an iron core piece from the laminate,
Caulking and laminating the iron core pieces to each other;
A method for producing a laminated iron core, comprising: 2. The method of manufacturing a laminated core according to claim 1, wherein the united locking portion is formed by a punch having a convex tip end portion. The union locking portion having a shape that exerts a uniform union locking force in three or more directions in the plane of the laminate plate is formed at a central portion of the core piece forming region of the laminate plate. Manufacturing method of laminated iron core.

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