JP4484616B2 - Manufacturing method of laminated iron core - Google Patents

Description

The present invention relates to a method for manufacturing a laminated core, in which a stator piece is taken from a strip-shaped steel plate, laminated, and bonded to produce a laminated core.

Conventionally, in the stator core, as disclosed in Patent Document 1, the connecting unit plates 105a and 105b are punched out from the rolled steel plate w shown in FIG.

When this outer shape punching is performed, the die attached to the rotary die 128 is rotated 180 degrees for each predetermined number of sheets so that one connection unit plate 105a and the other connection unit plate 105b are stacked.

By laminating in this way, the thickness deviation generated along the width direction of the rolled steel sheet w is offset, and the unit laminated body 100 having a uniform stacked thickness shown in FIG. 12A is manufactured.

Since this unit laminated body 100 is arranged in a straight line through the connecting portions 104, each connecting portion 104 is bent into the annular stator core 200 shown in FIG.
Japanese Patent Laid-Open No. 9-2106020

By the way, since the connecting unit plates 105a and 105b constituting the above-described stator core 200 are usually taken along the width direction of the rolled steel sheet w as a material as shown in FIG. There is a problem that production must be performed, productivity is low, and production costs including mold costs are soaring.

Further, in this stator core 200, as shown in FIG. 11, in order to eliminate the plate thickness deviation that occurs in the production of the material, the outer die is removed by 180 in the outer shape removing process every predetermined number of the connecting unit plates 105a and 105b. However, a large die rotation mechanism is required to rotate the linear iron core.

Further, in the above-described annular stator core 200, it is difficult to form a skew.

In view of the above, the present invention is capable of stripping both the stator piece and the rotor piece from the strip-shaped steel plate, and can eliminate the thickness deviation by rotating and laminating (rolling) the core pieces, and the skew. An object of the present invention is to provide a method for manufacturing a laminated iron core that can be formed.

A method for manufacturing a laminated iron core according to claim 1 of the present invention comprises a predetermined number of core pieces being caulked and laminated, and includes a ring-shaped yoke portion and a predetermined number of teeth portions projecting inwardly of the yoke portion. The coil-shaped winding to each of the tooth portions has a cutting portion for separating the ring-shaped yoke portion so as to be developed into an arbitrary shape, and the teeth portion protrudes and connects between the adjacent yoke portions. A method for producing a laminated core for producing a laminated core comprising a predetermined number of bendable connecting parts that develop a yoke part that is sometimes separated by the cutting part into an arbitrary shape,
After punching and forming the rotor core piece from the thin plate material, a small hole punching step of punching and forming a small hole continuous to the connecting portion in the yoke portion forming region of the annular core piece having the ring shape on the thin plate material. When,
After punching and forming the small hole in the yoke portion forming region, the cutting line continuous to the small hole and the cutting line of the cutting portion are sheared and the portion formed by the two cutting lines is bent, and the bending is performed. Cutting and pushing back process to push back the processed part,
A slotting step for forming a predetermined number of teeth by punching a predetermined number of slots in the thin plate material;
An inner diameter punching process for punching and forming tooth tips in the predetermined number of teeth portions;
The outer shape of the annular core piece is punched into a ring shape to form individual annular core pieces separately,
The annular core piece is punched and formed 1) annular core piece or 2) a tooth portion corresponding to each tooth portion of the annular core piece, and a yoke corresponding to each yoke portion from which the tooth portion of the annular core piece projects. And a caulking laminating step for laminating and joining the divided core pieces separated by each yoke part for each tooth part ,
In addition, the cutting line that continues to the small hole in the cutting and bending process forms a connecting convex portion and a connecting concave portion that can be contacted by the yoke portion that is adjacent to the annular shape. The cutting line of the cutting part in the bending and pushback process forms a cutting convex part and a cutting concave part where the adjacent yoke part abuts across the cutting part,
In the caulking laminating step, rotational lamination that cancels out the plate thickness deviation with respect to the annular core piece is performed.

According to the method for manufacturing a laminated core according to claim 1 of the present invention, it is easy to manufacture a mold for producing the laminated core.

Further, the stator iron piece and the rotor iron piece from the thin plate material can be taken together, and the production cost can be reduced.

Moreover, it is possible to rotate and laminate the iron core pieces. If the rotation is laminated, the thickness deviation of the thin plate material of the iron core pieces can be eliminated, and a laminated iron core having a desired shape can be obtained.

In addition, a skew angle can be given when the iron core pieces are laminated, and the laminated iron core can be skewed. If the skew is given, an impact due to the torque of the electric motor can be prevented.

Embodiments of the present invention will be described below with reference to the accompanying drawings.

As shown in FIG. 1A of the plan view, a laminated iron core 1 constituting a stator of an electric motor manufactured by using the present invention has yoke portions 2, 2... , And a predetermined number of teeth portions 3, 3... Around which coils (not shown) are wound.

As shown in FIG. 1B of the side view, this laminated iron core 1 has an annular core piece 1t formed with yoke portions 2, 2,... And teeth portions 3, 3,. A predetermined number of annular core pieces 1t each having a ring-shaped iron core piece having teeth portions 3 and teeth portions 3 are laminated and crimped using crimping portions k, k.

The laminated core 1 has a cutting portion c for expanding the yoke portions 2, 2... Into an arbitrary shape and a predetermined number of flexible connecting portions r, r..., And these connecting portions r, r. The yoke portions 2 are connected to each other in a ring shape via the.

Therefore, during the winding process of the coil to each tooth portion 3, as shown in FIG. 2, which is a development view thereof, the yoke portions 2, 2,... For example, it can be developed linearly.

As shown in FIG. 1, each of the annular core pieces 1 t constituting the laminated iron core 1 is provided with a circular half-cut crimped portion k for joining to each other, and connects the yoke portion 2. Continuing from the connecting portion r, a connecting small hole r1 is perforated, and further from the connecting small hole r1, a connecting convex portion r2 and a connecting concave portion r3 meeting the connecting convex portion r2 are formed. A cutting line rc is formed.

These corresponding connecting projections r2 and connecting recesses r3 are in contact with each other, so that the yoke portions 2 are adjacent to each other and have an annular shape.

The annular core piece 1t has a cutting line cl that forms a cutting projection c1 and a cutting recess c2 that meets the cutting projection c1 as a cutting portion c that separates the yoke portions 2 and 2. In the radial direction. When the cutting projection c1 and the cutting recess c2 come into contact with each other, the adjacent yoke portions 2 and 2 are adjacent to each other with the cutting portion c interposed therebetween.

By forming such cut portions c and a predetermined number of connecting portions r in each annular core piece 1t, when winding the coil to each tooth portion 3 of the laminated core 1 in which the annular core pieces 1t are laminated, As shown in FIG. 2, the laminated core 1 can be developed into an arbitrary shape by separating the laminated core 1 at the cutting portion c and bending each connecting portion r, and the winding process can be performed smoothly and easily. .

Next, a method for manufacturing the laminated core 1 having the above-described configuration will be described with reference to FIGS.

3 to 5 are plan views of the strip steel plate (thin plate material) W in the processing step, and the progressive die apparatus for manufacturing the laminated core 1 includes a small hole punching station S1, a cutting and pushback station S2, A cutting and bending surface beating station S3, a slot removing station S4, a first caulking part forming station S5, a second caulking part forming station S6, an inner diameter punching station S7, and a blank punching and rolling station S8 are provided.

In this progressive die apparatus, a processing station for manufacturing a rotor core (not shown) by sequentially forming rotor core pieces (not shown) prior to the above-described stations S1 to S8. And the rotor core and the stator core are manufactured by a common progressive mold apparatus.

That is, the material of the rotor core piece formed by stacking the rotor cores and the annular core piece 1t constituting the stator core 1 is taken on the same strip steel plate W.

First, prior to each step, a strip steel plate W is prepared, and as a previous step, a rotation that constitutes the rotor core in the central region of the annular core pieces 1t, 1t,... The material of the core iron piece is taken, and a round hole-shaped opening O is formed.

Subsequently, the process proceeds to the manufacturing process of the laminated iron core 1, and first, in the small hole punching station S1, the connecting portions r, r,... A predetermined number (seven in the embodiment) of connecting small holes r1, r1,. (Small hole extraction process)
Next, in the cutting and pushback station S2, between the adjacent yoke portion 2 forming regions in each annular core piece 1t forming region, a connecting convex portion r2 and a connecting concave portion r3 meeting the connecting convex portion r2 are provided. , And a predetermined number of cutting lines rc,..., And one cutting line cl that forms the cutting convex part c1 and the cutting concave part c2 associated with the cutting convex part c1 are shear-separated and connected convex part .., r2 and the cutting projection c1 are bent.

That is, a shearing process and a bending process are performed on the connecting convex part r2,..., And the cutting convex part c1 of the cutting part c shown by the hatched part in FIG.

Subsequently, the bent connecting projections r 2,... And the cutting projection c 1 are pushed back so as to be flush with the strip steel plate W.

That is, in the cutting and pushing back station S2, the strip steel plate W is sheared and separated by the lowering of the punch along the cutting lines rc, rc,... After r2, ... and the cutting projection c1 are bent downward, the bent connecting projections r2, ... and the cutting projection c1 are joined to the strip steel plate W by a pushback slider (not shown). Push back to be flush. (Cutting and pushback process)
The shapes of the cutting lines rc, rc,... And the cutting line rc of the cutting part c can be appropriately set without being limited to the embodiment as long as they can be sheared and bent. Needless to say.

At the cut-bending portion beating station S3, the strip steel plate W is sandwiched between the die and the stripper plate, and the bent connecting convex portion r2, ... and the cut convex portion c1 are faced from above with the lower surface of the stripper plate. Thus, the connecting convex portions r2, ... and the cut convex portion c1 are formed so as to be flush with the belt-like steel plate W.

Thereafter, a predetermined number of slots S, S,... Are punched out around the opening O at the slot removal station S4 shown in FIG. (Slot removal process)
Next, in the first caulking part forming station S5 and the second caulking part forming station S6, caulking parts k, k,.

That is, in the first caulking part forming station S5, only the lowermost annular core piece 1t constituting one laminated iron core 1 is drilled with a round hole k1 as a caulking part k in order to fit the caulking meat. In the second crimping portion forming station S6, a circular half punching k2 is performed as the crimping portion k on the annular core piece 1t other than the lowermost layer.

Thereafter, at the inner diameter punching station S7 shown in FIG. 5, the tooth tips 3t in the respective tooth portions 3 are formed by punching. (Inner diameter removal process)
Next, in the blank punching and rolling station S8, the outer diameter of the yoke portion 2 in each annular core piece 1t is punched to form individual annular core pieces 1t.

And each cyclic | annular core piece 1t, 1t ... formed in the predetermined | prescribed shape is laminated | stacked by rotating 180 degree | times to the cyclic | annular core pieces 1t, 1t ... which were previously formed, and each crimping part Caulking and coupling to each other via k, k.

That is, in the blank punching and stacking station S8, the individual annular core pieces 1t, 1t,... Are punched and formed, and each annular core piece 1t is rotated and stacked by a predetermined number of 180.degree. The laminated iron core 1 shown in FIG. 1 is manufactured by caulking with. (Caulking lamination process)
In the station S8, it is also possible to give a skew angle when laminating each of the annular core pieces 1t, 1t. In this case, the configuration of the crimping portion k needs to be a configuration corresponding to skew (described later).

In addition, in the station S8, it is possible to stack only by giving a skew angle without rotating and stacking each of the annular core pieces 1t, 1t, etc. Also, each of the annular core pieces 1t, 1t,. The layers may be simply laminated and crimped without giving a skew angle.

Then, as shown in FIG. 2, the laminated core 1 taken out from the progressive die apparatus is expanded at an arbitrary shape by separating at the cutting portion c and bending each connecting portion r, for example, in a straight line shape. The coil winding process to each tooth portion 3 is performed.

When this winding process is completed, as shown in FIG. 1 again, the cutting portions c are brought into contact with each other to complete the annular motor stator.

According to the above configuration, the laminated iron core of this type of stator has been conventionally formed by taking a straight material on a steel plate, but can be manufactured in the same manner as the laminated iron core in the circumferential direction, Mold production becomes easy.

Further, it is possible to take the material in a form in which a predetermined number of annular core pieces 1t constituting the laminated core 1 are connected in an annular shape as shown in FIGS. 3 to 5, and the same strip steel plate together with the rotor core pieces. The material can be taken on W, so that the laminated iron core 1 of the stator can be manufactured together with the rotor iron core using the same progressive die apparatus.

Therefore, the cost related to the production of the laminated core 1 such as the reduction of the material cost and the processing cost is reduced, and the production cost of the entire motor including the stator core and the rotor core can be greatly reduced.

Further, each of the annular core pieces 1t, 1t,... Formed in a predetermined shape is rotated and rotated at an arbitrary angle (for example, 180 °) to the previously formed annular core pieces 1t, 1t,. By joining together, the shape defect of the laminated core 1 caused by the thickness deviation of the material inherent in the strip steel plate W can be eliminated.

Further, if the laminated core 1 is skewed, it is possible to prevent the generation of a steep torque such as the starting torque of the electric motor, and it is possible to prevent the occurrence of an impact due to the electric motor torque.

FIG. 7 shows a laminated iron core (laminated iron core according to claim 2) 11 which is a modified example 1 of the laminated iron core 1 described above.

In the modified example 1, as shown in FIG. 7B in the side view, only the annular core pieces 11t1, 11t2, and 11t3 arranged in the uppermost layer, the middle layer, and the lowermost layer have the same configuration as that of the annular core piece 1t described above. As shown in FIG. 7 (a), the yoke portions 12, 12,... Are separated at the cutting portion c10 and connected in an annular shape via the connecting portions r10.

The core pieces other than the annular core pieces 11t1, 11t2, and 11t3 are divided core pieces 11t4, 11t4,... Each having a structure in which the yoke portions 12 having the tooth portions 13 are separated from each other.

These divided core pieces 11t4, 11t4,... And the upper, middle and lower annular core pieces 11t1, 11t2, 11t3 are caulked and joined by caulking portions k10,.

According to the above configuration, the connecting convex portions r12,... And the connecting portion r10 of the upper, middle, and lower annular core pieces 11t1, 11t2, and 11t3 are deformed to some extent by bending, and these annular core pieces. When only 11t1, 11t2, and 11t3 are laminated, a gap is generated between the laminated cores.

On the other hand, since the core pieces other than the upper, middle, and lower annular core pieces 11t1, 11t2, and 11t3 are the divided core pieces 11t4, 11t4,..., They are bent without the connecting convex portion r12 and the connecting portion r10. Will not be deformed.

Therefore, by laminating the annular core pieces 11t1, 11t2, 11t3 and the divided core pieces 11t4, 11t4,..., The flat structure of the strip steel plate W can be held as much as possible, and the occurrence of gaps between the laminated cores is obviated. Can be prevented.

In the first modification, the case where the annular core pieces 11t1, 11t2, and 11t3 are arranged in the uppermost layer, the middle layer, and the lowermost layer of the laminated iron core 11 is illustrated. However, the annular core pieces 11t1, 11t2, and 11t3 can be arranged only in the uppermost layer and the lowermost layer. Alternatively, it can be arranged only on one of the uppermost layer and the lowermost layer.

Also in this case, there is an effect that the generation of a gap between the laminated cores can be prevented in advance.

FIG. 8 shows a laminated iron core 21 which is a modified example 2 of the laminated iron core 1 described above.

In the second modification, as shown in FIG. 8A of the plan view, an annular core piece 21t1 constructed in the same manner as the annular core piece 1t of the laminated core 1, and each connecting projection r221 in the annular core piece 21t1. And a cutting line rc21, rc21,... Forming a connecting concave part r221 and a connecting concave part r232 formed opposite to the cutting line rc21, rc21,. As shown in the side view of FIG. 8 (b), the annular core pieces 21t2 having rc22, rc22,... are alternately stacked and crimped and joined by crimping portions k20,.

In addition, the cutting line cl which forms the cutting convex part c21 which is the cutting part c20, and the cutting concave part c22 which meets the cutting convex part c21 is formed in the same shape in both the annular core piece 21t1 and the annular core piece 21t2. .

Also in this laminated iron core 21, at the time of the coil winding process to the tooth part 23, the yoke part 22 can be separated by the cutting part c20 and developed into an arbitrary shape via the connecting parts r20, r20,. .

9 and 10 show a laminated core (laminated core of claim 3) 31 which is a modified example 3 of the laminated core 1 described above.

As shown in FIG. 9 (a) in the plan view and FIG. 9 (b) in the developed plan view, the laminated core 31 of Modification 3 is divided into the core pieces (split core pieces in claim 3) 31t2, 31t2,. An annular core piece (annular core piece of claim 3) 31t1 is laminated to form a skew angle, and crimped and joined by crimping portions k30,.

In this laminated core 31, the annular core piece 31t1 arranged in the lowermost layer has a configuration similar to the annular core piece 1t of the laminated core 1, and the yoke portion 32 is connected in a ring shape via a predetermined number of connecting portions r30. Has been.

As shown in FIGS. 9B and 10A, the core pieces other than the lowermost layer are divided core pieces 31t2, 31t2,..., Each having a yoke portion 32 having a teeth portion 33, each divided. Has been.

As shown in FIG. 9, the caulking portion k30 used for joining these iron core pieces forms a skew throwing hole k31, and the divided iron core pieces 31t2, 31t2,. Bending is performed and a hole for inserting the claw portion k32 is formed only in the lowermost annular core piece 31t1.

The laminated core 31 is manufactured by laminating a predetermined number of divided core pieces 31t2, 31t2,... Of a divided structure on the lowermost annular core piece 31t1 with a skew angle, and caulking and joining at a crimping portion k30. .

When winding a coil around the teeth portion 33 of the laminated core 31, the coil is developed from the state shown in FIG. 9A as shown in FIG. 9B to have an arbitrary shape such as a straight line shown in FIG. be able to.

According to the above configuration, since the laminated iron core 31 is skewed, it is possible to prevent the start-up torque of the motor from being sharply generated and to prevent the occurrence of an impact due to the torque of the motor.

In addition, in the laminated core 31 of the modification 3, although the case where the lowermost core piece was made into the connection structure was illustrated, it replaces with the lowermost core piece, and it is good also considering the uppermost layer core piece as a connection structure.

The present invention can be effectively used for components similar to the stator of an electric motor.

(a) And (b) is the top view and side view which show the laminated iron core of the Example in connection with this invention. The top view which shows the state which expand | deployed the laminated iron core of the Example in connection with this invention. The top view of the strip | belt-shaped steel plate which shows the manufacturing process in each station of the progressive die apparatus which manufactures the laminated iron core of the Example in connection with this invention. The top view of the strip | belt-shaped steel plate which shows the manufacturing process in each station of the progressive die apparatus which manufactures the laminated iron core of the Example in connection with this invention. The top view of the strip | belt-shaped steel plate which shows the manufacturing process in each station of the progressive die apparatus which manufactures the laminated iron core of the Example in connection with this invention. The enlarged plan view which shows the site | part by which the cutting bending in the annular core piece of the Example in connection with this invention is performed. (a) And (b) is the top view and side view which show the laminated iron core of the modification 1 of the Example in connection with this invention. (a) And (b) is the top view and side view which show the laminated iron core of the modification 2 of the Example in connection with this invention. (a) And (b) is a top view which shows the laminated iron core of the modification 3 of the Example in connection with this invention, and the top view which shows the state which expand | deployed this laminated iron core. (a) And (b) is the top view and side view which show the state which expand | deployed linearly the laminated core of the modification 3 of the Example in connection with this invention. The top view which shows the process of manufacturing the conventional unit laminated body. (a) And (b) is a perspective view which shows the shape of the unit laminated body shape | molded with the conventional progressive mold apparatus, and the perspective view which shows the shape of the cyclic | annular core product manufactured by winding the conventional unit laminated body Figure.

1, 21 ... laminated iron core (laminated iron core according to claims 1 and 4),
11 ... laminated iron core (laminated iron core of claim 2),
31 ... laminated iron core (laminated iron core of claim 3),
2, 22 ... Yoke part (yoke part of claims 1 and 4),
12. The yoke part of claim 2,
3, 23 ... teeth part (the teeth part of claims 1 and 4),
13. The teeth part according to claim 2,
3t ... tooth tip,
1t, 2 1t1... Annular core pieces (iron pieces of claims 1 and 4),
11t1, 11t2, 11t3 ... annular core pieces (annular core pieces of claim 2),
11t4 ... split core piece (split core piece of claim 2),
31t1 ... annular core piece (annular core piece of claim 3),
31t2 ... split core piece (split core piece of claim 3),
c, c20 ... cutting part (the cutting part of claims 1 and 4),
c1 ... cutting convex part (part formed by the cutting line of the cutting part of claim 4),
c10 ... cutting part (cutting part of claim 2),
cl: a cutting line for forming a cutting convex part and a cutting concave part (the cutting line of the cutting part of claim 4),
r, r20 ... connecting part (the connecting part of claims 1 and 4),
r1 ... Small hole for connection (small hole),
r2 ... Convex protrusion (part formed by a cutting line continuous with the small hole of claim 4),
r10 ... connection part (connection part of claim 2),
rc ... cutting line (cutting line continuous to the small hole of claim 4) forming the connecting convex part and the connecting concave part,
S ... Slot,
W: Strip steel plate (thin plate material).

Claims (1)

In order to develop a ring-shaped yoke portion into an arbitrary shape, comprising a predetermined number of iron core pieces and a ring-shaped yoke portion and a predetermined number of teeth portions protruding inward of the yoke portion. In addition to having a cutting part to be separated, the tooth part protrudes and connects between the adjacent yoke parts, and the yoke part separated by the cutting part at the time of coil winding to each tooth part has an arbitrary shape A method for manufacturing a laminated iron core for producing a laminated iron core having a predetermined number of connecting portions that can be bent,
After punching and forming the rotor core piece from the thin plate material, a small hole punching step of punching and forming a small hole continuous to the connecting portion in the yoke portion forming region of the annular core piece having the ring shape on the thin plate material. When,
After punching and forming the small hole in the yoke portion forming region, the cutting line continuous to the small hole and the cutting line of the cutting portion are sheared and the portion formed by the two cutting lines is bent, and the bending is performed. Cutting and pushing back process to push back the processed part,
A slotting step for forming a predetermined number of teeth by punching a predetermined number of slots in the thin plate material;
An inner diameter punching process for punching and forming tooth tips in the predetermined number of teeth portions;
The outer shape of the annular core piece is punched into a ring shape to form individual annular core pieces separately,
The annular core piece is punched and formed 1) annular core piece or 2) a tooth portion corresponding to each tooth portion of the annular core piece, and a yoke corresponding to each yoke portion from which the tooth portion of the annular core piece projects. And a caulking laminating step for laminating and joining the divided core pieces separated by each yoke part for each tooth part ,
In addition, the cutting line that continues to the small hole in the cutting and bending process forms a connecting convex portion and a connecting concave portion that can be contacted by the yoke portion that is adjacent to the annular shape. The cutting line of the cutting part in the bending and pushback process forms a cutting convex part and a cutting concave part where the adjacent yoke part abuts across the cutting part,
And in the said crimping lamination process, the rotation lamination which cancels the plate | board thickness deviation with respect to the said annular core piece is performed, The manufacturing method of the laminated core characterized by the above-mentioned.

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