JP4730461B2 - Magnetic core manufacturing method - Google Patents

Description

  The present invention relates to an armature magnetic core and a method of manufacturing the magnetic core. The armature magnetic core is used particularly in an armature used in an axial gap type rotating electric machine.

  An axial gap type rotating electrical machine includes a rotor provided to be rotatable about a rotation axis, and a stator that faces the rotor in a direction parallel to the rotation axis (hereinafter referred to as “axial direction”). . In most cases, the rotor and stator function as field elements and armatures, respectively.

  In the armature, an armature magnetic core (hereinafter also simply referred to as “magnetic core”) is annularly arranged in a circumferential direction perpendicular to the axial direction.

  In the axial gap type rotating electrical machine, the magnetic flux flowing through the magnetic core has a circumferential component because it flows in and out between a plurality of magnetic cores arranged annularly in the circumferential direction. The circumferential component of the magnetic flux causes the generation of eddy currents in the plane perpendicular to the circumferential direction, and consequently increases the iron loss. In order to suppress the generation of the eddy current, it is proposed that the magnetic core is formed of electrical steel sheets laminated in a radial direction with respect to the rotation axis (which is perpendicular to the axial direction and the circumferential direction of the magnetic core). Has been.

  The shape of the magnetic core as viewed from the opposing direction of the field element and the armature (hereinafter referred to as “the shape of the magnetic core in a plan view of the opposing direction” etc.) increases as the position in the radial direction increases (that is, the outer periphery). It is desirable that the width be increased in the circumferential direction. Such a shape brings about the advantage that it is easy to increase the space factor of the armature winding while increasing the area of the magnetic core in the plan view in the opposite direction. For example, the technique disclosed in Patent Document 1 can be used to manufacture such a magnetic core.

  Patent Document 2 exemplifies a technique in which two laminated structures of electromagnetic steel sheets are provided in one magnetic core that is wider in the circumferential direction toward the outer periphery.

JP 2007-252064 A JP 2009-11086 A

  However, the magnetic flux flowing through the magnetic core tends to have a radial component. This is because the magnitude of the magnetic flux tends to be non-uniform in the radial direction. In particular, as described above, this tendency becomes prominent when the circumferential dimension of the magnetic core depends on the radial position.

  The magnetic core can flow more magnetic flux in the axial direction as the circumferential dimension is larger. On the other hand, the distribution in the radial direction of the magnetic flux amount of the field magnetic flux flowing between the field element and the magnetic core and the distribution in the radial direction of the circumferential dimension of the magnetic core are not necessarily proportional to each other. . Therefore, the radial distribution of the magnetic flux in the magnetic core becomes non-uniform as it gets closer to the field element, and becomes uniform as it gets away from the field element. Such a variation in the radial distribution of the magnetic flux in the axial direction indicates that the magnetic flux flowing through the magnetic core has a radial component.

  When the above two distributions are proportional, the magnetic flux flowing in the axial direction has a distribution in the radial direction, and the magnetic flux flows more as the circumferential dimension of the magnetic core is larger. On the other hand, inflow and outflow of magnetic flux between the plurality of magnetic cores is guided by the yoke, but the magnetic flux distribution in the yoke is uniform. Therefore, the magnetic flux flowing in the magnetic core in the vicinity of the yoke tends to have a radial component. The radial component of the magnetic flux causes the generation of eddy currents in a plane perpendicular to the radial direction.

  However, each of the electromagnetic steel sheets laminated in the radial direction extends in parallel to a plane perpendicular to the radial direction, and thus it is difficult to suppress the generation of eddy currents due to the radial component of the magnetic flux.

  Accordingly, an object of the present invention is to provide a magnetic core that suppresses not only the generation of eddy currents due to the circumferential component of magnetic flux but also the generation of eddy currents due to radial components. Another object is to improve the yield in manufacturing the magnetic core.

  In the first aspect of the method for manufacturing a magnetic core according to the present invention, the raw material (8), which is an electromagnetic steel sheet, is conveyed every predetermined length (P) in the conveying direction (K). And (a) when the conveyance of the raw material is stopped, the step of punching out the raw material using the first punch (92), (b) left on the raw material in the step (a) Punching the electromagnetic steel sheet into a rectangle (Q) whose dimension in the transport direction is equal to or less than the predetermined length to obtain steel sheets for lamination (101 to 106, 201 to 206); (c) the step (b) Step of laminating the steel plates for lamination (101 to 106) obtained on one side with respect to the first punch in the width direction perpendicular to the transport direction among the steel plates for lamination obtained in step 1 in the punched order. With. However, in the step (a), in the width direction, the first punch reciprocates between the first position (92a, 92f; 90g, 90l) and the second position (92c, 92d; 90i, 90j). The position of the first punch is updated and repeated, and in the step (c), the laminated steel plates (101, 106) punched at the first position and the second position The laminated steel plates are laminated with the punched laminated steel plates (103, 104) as a boundary to obtain a plurality of laminated bodies (10a, 10b). And (d) It further has the process of forming the magnetic core (1) by making the laminated bodies in the said process (c) adjoin, making the position punched out by the said 1st punch into the other side.

  The 2nd aspect of the manufacturing method of the magnetic core concerning this invention is the 1st aspect, Comprising: Among the said steel plates for lamination obtained by the said process (b), it is perpendicular | vertical to the said conveyance direction. The laminated steel plates (201, 206) punched at the first position in the punched order (201-206) obtained on the other side with respect to the first punch in the width direction which is the direction; A step of laminating the laminating steel plates with the laminating steel plates (203, 204) punched out at the second position as a boundary to obtain a plurality of laminates (20a, 20b), and (f) the step A step of forming the magnetic core (1) by adjoining the stacked bodies in (e) with the positions punched by the first punches opposite to each other.

  A third aspect of the method for manufacturing a magnetic core according to the present invention is the second aspect or the third aspect, wherein (g) the step (a) is performed before the step (c) is performed. When the conveyance of the raw material (8) is stopped, the raw material is transferred using the second punch (91) that maintains the position (91a to 91f) in the width direction. A punching process is further provided.

According to a first aspect of the method for manufacturing a magnetic core according to the present invention, an armature facing the field element (4) in the axial direction (Z) is annularly arranged in a circumferential direction (θ) perpendicular to the axial direction. Magnetic core (1) A magnetic core for an armature can be manufactured. Each of the magnetic cores includes a first portion (1a) on one side in the circumferential direction and a second portion (1b) on the other side in the circumferential direction. Each of the first part and the second part includes a plurality of electromagnetic steel sheets (100) stacked in a radial direction (R) perpendicular to both the axial direction and the circumferential direction. The first portion has a first winding portion (11a) and a first boundary surface (110a), and the second portion has a second winding portion (11b) and a second boundary surface (110b). The first boundary surface and the second boundary surface are parallel to the axial direction and the radial direction, and the first boundary surface and the second boundary surface are disposed adjacent to each other, and the first winding surface The part and the second winding part form a winding part (11) around which the armature winding (15) around the axial direction is wound.

  According to a second aspect of the method for manufacturing a magnetic core according to the present invention, the steel sheet for lamination used in the magnetic core is obtained from the raw material with less waste, and the use efficiency of the raw material is increased, and as a result, the magnetic core is manufactured. Improve the yield in

  According to the third aspect of the method for manufacturing a magnetic core according to the present invention, a magnetic flux guide part and an embedded part of the magnetic core having dimensions in the width direction that do not depend on the position in the radial direction can be formed.

It is a perspective view which illustrates the structure of the armature core employ | adopted as an axial gap type rotary electric machine. It is a perspective view which shows the external appearance of a magnetic core. It is a perspective view which shows the external appearance of the 1st part of a magnetic core. It is a perspective view which shows the external appearance of the 2nd part of a magnetic core. It is a perspective view which shows the external appearance of a magnetic core. It is a top view which shows the external appearance of the magnetic core in opposing direction planar view. It is a top view which shows the position of the fixed punch with respect to a raw material. It is a top view which shows the position of the movable punch with respect to a raw material. It is a top view which shows the raw material after punching with the fixed punch and the movable punch. It is a schematic diagram which shows the planar shape of the steel plate for lamination punched out. It is a schematic diagram which shows lamination | stacking of the steel plate for lamination punched out. It is a schematic diagram which shows lamination | stacking of the steel plate for lamination punched out. It is a schematic diagram which shows the planar shape of the steel plate for lamination punched out. It is a schematic diagram which shows lamination | stacking of the steel plate for lamination punched out. It is a schematic diagram which shows lamination | stacking of the steel plate for lamination punched out. Is a plan view showing an original material after being punched by a variable dynamic punch. It is a perspective view which shows the external appearance of a magnetic core. Is a plan view showing an original material after being punched by a variable dynamic punch. It is a perspective view which shows the external appearance of a magnetic core. It is a perspective view which shows a magnetic core and an insulator. It is a disassembled perspective view which shows the assembly of a magnetic core and an insulator. It is a perspective view which shows a magnetic core and an insulator. It is a disassembled perspective view which shows the assembly of a magnetic core and an insulator. It is sectional drawing which shows the structure of an axial gap type rotary electric machine.

First embodiment.
Referring to FIG. 1, the core of the armature is roughly composed of a magnetic core 1, a back yoke 2, and a support member 3. However, in order to show the fitting relationship between the magnetic core 1, the back yoke 2, and the fixed plate 3, one magnetic core 1 is shown separately from the back yoke 2 and the fixed plate 3. Of course, when the armature is configured, the separation is not performed.

FIG. 24 shows a cross section of the rotating electrical machine at position XX in FIG. 1 and 24, the armature is employed in an axial gap type rotating electrical machine together with a field element 4 that rotates about an axis J as a rotational axis. The axial direction Z is adopted parallel to the axis J. The armature faces the field element 4 in the axial direction Z.

  The field element 4 includes a base body 41 and a field generator 42. The base body 41 is fixed to the rotatable shaft 40, and the field generating section 42 is fixed to the base body 41 and generates a field magnetic flux. In order to cause the field magnetic flux to efficiently flow through the armature, it is desirable that the base body 41 employs a magnetic material so as to function as a so-called back yoke.

The armature core is employed in an armature together with an armature winding 15 (not shown in FIG. 1) wound around the magnetic core 1 around the axial direction Z. Note that “winding” includes not only an aspect involving an operation of winding a conducting wire around the magnetic core 1 but also an aspect in which an armature winding having a shape formed in advance as a coil is fitted to the magnetic core 1. . The coil is a so-called concentrated winding method in which the coil is wound around each of the magnetic cores 1 .

  The magnetic core 1 is annularly arranged in the circumferential direction θ with the axis J as the central axis. In each of the magnetic cores 1, electromagnetic steel plates (not shown: described in detail later) are laminated in the radial direction R. That is, when the magnetic core 1 is employed as the core of the armature, the radial direction R for any of the magnetic cores 1 is annularly arranged so as to be perpendicular to the axial direction Z. Accordingly, as shown in FIG. 1, the radial directions R1 and R2 of different magnetic cores 1 are different from each other when viewed as a whole core.

Similarly, the circumferential directions θ1 and θ2 for different magnetic cores 1 are different from each other when viewed as a whole core. However, the circumferential directions θ1 and θ2 can be regarded as common directions when viewed as the annular direction θ (FIG. 24) .

  The back yoke 2 is provided with an opening 21 that opens in the axial direction Z side according to the magnetic core 1, and each opening 21 is also opened radially inwardly. The magnetic core 1 has a winding part 11 around which the armature winding 15 is wound, and a magnetic flux guide part 12 positioned on the back yoke 2 side with respect to the winding part 11. The magnetic flux guide 12 is magnetically coupled to the magnetic core 1 and the back yoke 2 by fitting with the opening 21. Specifically, the magnetic flux guide 12 guides the magnetic flux flowing through the magnetic core 1 to the back yoke 2 or guides the magnetic flux flowing through the back yoke 2 to the magnetic core 1.

  When the opening 21 is also opened radially inward, an eddy current due to the axial component of the magnetic flux flowing in the magnetic core 1 having the magnetic flux guide 12 fitted to the opening 21 is generated in the back yoke 2. To suppress. A plurality of openings 21 are combined to form an opening 20.

  The magnetic core 1 also has an embedded portion 13 located on the opposite side of the winding portion 11 with respect to the magnetic flux guide portion 12. Correspondingly, the fixing plate 3 is provided with a groove 31. The groove 31 may penetrate in the axial direction Z.

  Here, an example in which an odd number (9) of magnetic cores 1 are provided is illustrated. In FIG. 24, the winding portion 11, the magnetic flux guide portion 12, the embedded portion 13, and the flange portion 14 of the magnetic core 1 appear on the left side in the drawing. However, the armature winding 15 appears instead on the right side in the figure.

The embedded portion 13 is fitted with the groove 31, and the fixed plate 3 mechanically holds the magnetic core 1. On the other hand, the back yoke 2 and the magnetic core 1 are magnetically coupled, and the back yoke 2 does not necessarily need to mechanically hold the magnetic core 1. Therefore, if both the back yoke 2 and the fixed plate 3 are fixed to each other, the back yoke 2 and the fixed plate 3 can be formed with materials in view of the functions to be secured by the magnetic coupling and the mechanical coupling. For example, the back yoke 2 is mainly formed of electromagnetic steel plates laminated along the axial direction Z , or is formed of a dust core. An example of the material of the fixing plate 3 is a metal lump.

  The fixing between the fixing plate 3 and the magnetic core 1 does not necessarily require the fitting between the groove 31 and the embedded portion 13. For example, both can be fixed by adhesion or welding.

  It is desirable that a flange portion 14 is provided at a position closest to the field element 4 in the magnetic core 1. In order to increase the efficiency of the magnetic interaction between the armature and the field element, the flange portion 14 is set wider than the winding portion 11. Here, since the electromagnetic steel sheets are laminated along the radial direction R, in order to simplify the lamination, the flange portion 14 does not expand from the winding portion 11 in the radial direction R, and expands only along the circumferential direction θ. The structure is illustrated. Of course, you may employ | adopt the magnetic core 1 of the structure which does not provide the collar part 14. FIG.

2 to 4, the magnetic core 1 includes a first portion 1a on one side in the circumferential direction θ (arrowhead side in the drawing) and a second portion 1b on the other side in the circumferential direction θ (arrowhead side in the drawing). Prepare. 3 and 4, the electromagnetic steel sheets 100 laminated in the radial direction are partially drawn while exaggerating their thickness.
In the magnetic core 1 exemplified here, the shape of the magnetic flux guide portion 12 and the embedded portion 13 does not depend on the radial direction R, and thus exhibits a rectangular parallelepiped. The circumferential dimensions W2 and W3 of the magnetic flux guide portion 12 and the embedded portion 13 do not depend on the position in the radial direction R. On the other hand, the winding part 11 becomes wide on the outer peripheral side (radial direction R side) for reasons such as increasing the space factor of the armature winding 15.

  An example of a technique for ensuring the bonding between the laminated magnetic steel sheets 100 will be given. The electromagnetic steel sheet 100 is locally deformed in the thickness direction to form a coupling portion, and the coupling portions are fitted to each other between the adjacent electromagnetic steel plates 100. The coupling portion may be simple irregularities, or the electromagnetic steel sheet 100 may be partially broken and deformed in the thickness direction. A technique for obtaining a bond between laminated electromagnetic steel sheets 100 using the latter modification is a well-known technique commonly referred to as “Karamase”.

  It is desirable that the coupling between the laminated magnetic steel sheets 100 is applied individually to the first portion 1a and the second portion 1b. Usually, since the magnetic core 1 is elongated in the axial direction Z, a plurality of coupling portions are provided along the axial direction Z for each electromagnetic steel sheet 100. However, since the coupling portion deteriorates the magnetic properties of the electrical steel sheet, it is also desirable to provide the coupling portion in a place where the magnetic properties are less likely to be a problem, for example, the flange portion 14.

  The first portion 1a and the second portion 1b are adjacent to each other through the boundary surface 110. The first portion 1a includes a first winding portion 11a, a first magnetic flux guide portion 12a, a first embedded portion 13a, and a first flange portion 14a. The second portion 1b includes a second winding portion 11b, a second magnetic flux guide portion 12b, a second embedded portion 13b, and a second flange portion 14b. The first winding part 11a and the second winding part 11b together with the winding part 11, the first magnetic flux guiding part 12a together with the second magnetic flux guiding part 12b, and the first embedded part 13a as the second embedded part. The embedded portion 13 is formed together with 13b, and the first flange portion 14a and the second flange portion 14b constitute the flange portion 14 (see also FIG. 1).

  The first portion 1a has a first boundary surface 110a on the other side in the circumferential direction θ, and the second portion 1b has a second boundary surface 110b on one side in the circumferential direction θ. The first boundary surface 110a and the second boundary surface 110b are adjacent to each other. The boundary surface 110 can be grasped as an adjacent position between the first boundary surface 110a and the second boundary surface 110b. However, as will be described later, the first boundary surface 110a and the second boundary surface 110b are not necessarily in direct contact with each other, and an insulating material having a sufficiently small thickness in the circumferential direction may be interposed therebetween. .

Thus, the magnetic core 1 is formed by coupling the first portion 1a and the second portion 1b adjacent to each other via the boundary surface 110 (or the first boundary surface 110a and the second boundary surface 110b). Such binding can be achieved by employing a resin molding, for example.

As described above, in the magnetic core 1, any cross section perpendicular to the radial direction R is divided by the first boundary surface 110 a and the second boundary surface 110 b, so that an area in which the eddy current can be generated in the cross section. And the generation of eddy currents is reduced. That is, the generation of eddy current due to the radial component of the magnetic flux flowing through the magnetic core 1 can be suppressed.

And the surface perpendicular | vertical to the circumferential direction (theta) is parted by the boundary of the some electromagnetic steel plate 100 laminated | stacked on the radial direction R. FIG. Therefore, the area where eddy currents can be generated due to the circumferential component of the magnetic flux flowing in the magnetic core 1 is reduced, thereby reducing the generation of eddy currents. Moreover, since the boundary of the electromagnetic steel sheet 100 has a magnetic resistance and becomes a barrier, the magnetic flux flowing through the magnetic core is less likely to flow in the radial direction R , thereby contributing to the reduction of the radial component itself of the magnetic flux flowing through the magnetic core.

It is also desirable to sandwich an insulating material between the first boundary surface 110a and the second boundary surface 110b. This is because the insulating material improves the insulation between the first portion 1a and the second portion 1b, thereby ensuring the division in the plane perpendicular to the circumferential direction θ of the magnetic core 1. As an example, an insulating sheet is sandwiched between the first portion 1a and the second portion 1b. As another example , after the first portion 1a and the second portion 1b are individually coated with an insulating material, the first boundary surface 110a and the second boundary surface 110b are adjacent to each other, and both are coupled. Forming the core 1. This cuts off the current between the first part 1a and the second part 1b, and it is desirable to pass the magnetic flux. Therefore, it is sufficient if the thickness is enough to cut off the eddy current.

As a method for joining the first portion 1a and the second portion 1b, laser welding can be used in addition to the mold. However, it is desirable that the welds do not contact each other. This is because, when the welded portions are in contact with each other, the possibility that the extending directions of the electromagnetic steel sheets 100 of the first portion 1a and the second portion 1b are not perpendicular to the radial direction R increases. Specifically, the weld enters the range of the thickness of the electromagnetic steel sheet 100, preferably provided in each electromagnetic steel sheet 100.

  Further, instead of a mold, the periphery of the magnetic core 1 with the axial direction Z as an axis may be surrounded by a cylindrical insulator. As illustrated in FIGS. 20 and 21, the insulator 6 includes, for example, a pair of components 6 a and 6 b. The parts 6a and 6b are combined with each other along the circumferential direction θ to couple the first part 1a and the second part 1b. Alternatively, as illustrated in FIGS. 22 and 23, the insulator 6 includes, for example, a pair of components 6c and 6d. Then, the parts 6c and 6d are combined with each other along the radial direction R to couple the first part 1a and the second part 1b. In either case, the armature winding 15 (see FIG. 24) is wound around the magnetic core 1 via the insulator 6.

  The magnetic core 1 may not be symmetric with respect to the boundary surface 110. FIG. 5 shows a case where the boundary surface 110 is shifted from the center of the magnetic core 1 in the circumferential direction θ to the other side in the circumferential direction θ. Thereby, the cross section in the arbitrary positions of radial direction R can make the 2nd part 1b narrower than the 1st part 1a. The magnetic core 1 having such a configuration brings about a unique effect particularly in the following situation.

When the field element 4 rotates from the other side in the circumferential direction θ to one side, that is, when the field element 4 rotates in accordance with the direction of the arrow in the circumferential direction θ, the field element 4 is interposed between the field element 4 and the magnetic core 1. The amount of magnetic flux that flows is greater on the other side than on one side. This is because, in the field element, when the field generating portion 42 approaches the magnetic core 1, a magnetic attractive force acts between them, and when it moves away, a magnetic repulsive force acts. Therefore, the amount of magnetic flux contributing to eddy current is greater on the other side in the circumferential direction than on one side in the circumferential direction of the magnetic core 1. Therefore, the eddy current is more effectively reduced by making the cross-sectional area of the cross section perpendicular to the radial direction R of the second portion 1b smaller than that of the first portion 1a.

  Here, the case where both the first boundary surface 110a and the second boundary surface 110b extend parallel to the radial direction R and the axial direction Z (that is, perpendicular to the circumferential direction θ) is illustrated. However, if the laminated steel sheets extend perpendicular to the radial direction R when the first boundary surface 110a and the second boundary surface 110b are adjacent to form the magnetic core 1, the first boundary surface 110a. The second boundary surface 110b may be inclined with respect to the axial direction Z or the radial direction R.

  For example, the angle formed by the first boundary surface 110a with the radial direction R at the outer peripheral end of the first portion 1a is different from the angle formed by the second boundary surface 110b with the radial direction R at the outer peripheral end within the second portion 1b. A complementary angle relationship (the sum of the two is a flat angle) may be used. Or the angle which the 1st boundary surface 110a makes with the axial direction Z in the axial direction Z side (side near the field element 4) of the 1st part 1a, and the 2nd boundary surface 110b in the axial direction Z side of the 2nd part 1b. The angle formed with the radial direction R may be a complementary angle.

Furthermore, the first boundary surface 110a and the second boundary surface 110b may be curved surfaces, and in this case, they are fitted together to form the boundary surface 110.

  When the groove 31 is provided as described above, the opening 21 penetrates in the axial direction Z. However, there may be a case where the fixing plate 3 is not provided. In this case, the opening portion 21 does not need to penetrate in the axial direction Z, and in the axial direction Z, an opening for simply fitting with the magnetic flux guide portion 12 is provided. It's enough. In the case where the fixing plate 3 is not provided, the groove 31 is naturally not provided, and therefore the embedded portion 13 is not required to be provided in the magnetic core 1.

  Alternatively, the opening 21 and the groove 31 may have the same shape as viewed from the axial direction Z. In this case, the magnetic flux guide portion 12 and the embedded portion 13 have the same shape as viewed from the axial direction Z. Further, the magnetic flux guide portion 12, the embedded portion 13, and the winding portion 11 may have the same shape as viewed from the axial direction Z. The magnetic core 1 in such a case is shown in FIG.

  Or the magnetic core 1 may be employ | adopted as the armature pinched | interposed into a pair of rotor in the axial direction Z. In the magnetic core 1 employed in this case, a pair of winding portions 11 are provided and have a configuration in which the magnetic flux guide portion 12 is sandwiched in the axial direction Z. Of course, the collar part 14 can be provided in any winding part 11. FIG. 19 shows the magnetic core 1 in such a case. However, a mode in which the back yoke 2 and the fixed plate 3 are not provided may be employed. In this case, the magnetic core 1 does not require not only the embedded portion 13 but also the magnetic flux guide portion 12, for example, only the winding portion 11 extends between the pair of flange portions 14.

  Alternatively, even when the armature faces the field element only on one side in the axial direction Z, there are cases where advantages can be obtained by employing the magnetic core 1 shown in FIG. For example, when the groove 31 penetrates in the axial direction Z in the fixing plate 3, the collar portion 14 located on the other side in the axial direction Z may be provided with a function of locking the groove 31 in the axial direction Z. In such a case, the groove 31 also opens in the radial direction R in the same manner as the opening 21, and the magnetic core 1 is arranged from the inner peripheral side of the groove 31 and the opening 21.

Second embodiment.
Although the structure of the magnetic core 1 can be variously modified as described above, the first boundary surface 110a and the second boundary surface 110b are parallel to the axial direction Z and the radial direction R from the viewpoint of easy manufacture. Is desirable. That electrical steel sheet to form a first portion 1a and the second portion 1b is because can be laminated by aligning the position at the first boundary surface 110a and a second boundary surface 110b parallel to the stacking direction. In this respect, the magnetic steel sheet is more advantageous than the structure of Patent Document 2 in which the steel sheet is shifted with respect to the stacking direction.

  Furthermore, if the magnetic core 1 is symmetrical with respect to the boundary surface 110, the magnetic core 1 has two advantages in the process of punching out the magnetic steel sheet constituting the magnetic core 1 from the raw material. One is reduction of waste materials, and one is reduction of the number of movable punches. Hereinafter, it will be described that these advantages can be obtained by explaining a specific punching process.

Such a magnetic core 1 is shown in FIG. FIG. 6 is a plan view showing the appearance of the magnetic core 1 in plan view in the opposite direction. However, part of the radial direction R side of the first flux guides fraction 12a, first buried portion component 13a, both the first winding unit component 11a is hidden on the first flange portion component 14a, the first flux guide parts component 12a portion in the radial direction R side of the second buried portion component 13b, both the second winding portion component 11b is hidden on the second flange portion 14b.

  With reference to FIGS. 7 to 9, the raw material 8 that is an electromagnetic steel plate is conveyed in the conveying direction K. In general, the raw material 8 is long, and the longitudinal direction thereof is selected as the transport direction K. The raw material 8 is conveyed every predetermined length P, and when the conveyance of the raw material 8 is stopped, punching by a fixed punch or a movable punch, which will be described later, is executed.

  However, FIGS. 7 and 8 are drawn from the viewpoint of moving in accordance with the conveyance direction K of the raw material 8 for the sake of simplicity. Therefore, although the punching does not actually move in the transport direction K, the punching is illustrated as being performed at a plurality of positions.

  In addition, here, for simplicity of explanation, the number of stacked layers is described as three, but the actual number of stacked layers is much larger.

  7 indicate the positions of the fixed punches. Hereinafter, these positions 91a to 91f may be collectively referred to as position 91, or the fixed punch itself may be described as position 91.

Fixed punch (and its position) 91, the position of the vertical width direction is maintained in the transport direction K of the raw material 8. In the sense that the position 91 in the width direction is fixed, it is “fixed”. Of course, from the necessity of punching the raw material 8, in the punching direction (in the direction perpendicular to the paper surface in accordance with FIGS. 7 to 9), It becomes movable. Therefore, the positions in the width direction of the positions 91a to 91f are equal.

  Positions 92a to 92f in FIG. 8 indicate positions of the movable punch. Hereinafter, the positions 92a to 92f may be collectively referred to as the position 92, or the movable punch itself may be described as the position 92.

  The movable punch (and its position) 92 is movable in the width direction. Of course, it is also movable in the punching direction. The movable punch (and its position) 92 includes positions 92a and 92f (hereinafter also referred to as “first positions 92a and 92f”) existing at the leftmost position in the drawing, and positions 92c and 92d (hereinafter referred to as “second position” positioned at the rightmost position). 92c, 92d ") in the width direction.

  As described above, since the punching does not actually move in the transport direction K, the positions 91a to 91f and the positions 92a to 92f are illustrated in the order opposite to the transport direction K in this order. Since the raw material 8 is conveyed every predetermined length P and punching is performed when the conveyance of the raw material 8 is stopped, the positions 91a to 91f and the positions 92a to 92f are predetermined along the conveying direction K, respectively. It will be illustrated at intervals of length P.

  The punching with the fixed punch and the punching with the movable punch are executed as a pair (however, the prior relationship between the two is not important), and the punching holes 90a to 90f shown in FIG. 9 are formed.

  The rectangular region Q is a position where the raw material 8 is further punched after the punching holes 90a to 90f are formed, and the dimension in the transport direction K is equal to or less than the predetermined length P, and is set at an interval of the predetermined length P. The The punching holes 90a to 90f are preferably protruded from the rectangular region Q in the direction along the transport direction K.

  The punching hole 90a is obtained as a result of punching at the fixed punch position 91a and punching at the movable punch position 92a. The same applies to the other punched holes 90b to 90f. Positioning in the conveying direction K between the punching with the fixed punch and the punching with the movable punch is a well-known technique, and therefore details are not described here.

However, in the present embodiment, it is desirable that the punched portion at the fixed punch position 91a slightly overlaps the punched portion at the movable punch position 92a. The same applies to the positions 91b to 91f of the other fixed punches and the positions 92b to 92f of the movable punches. As a result, the punching holes 90a to 90f protrude from the rectangular region Q in the direction along the conveying direction K, so that the punching holes 90a to 90f allow the raw material 8 to be moved to the left and right sides in the rectangular region Q to which the punching holes 90a to 90f belong. And to separate.

Then, by punching the rectangular region Q, the steel plates 101 to 106 and the lamination steel plates 101 to 106 and the lamination are respectively formed from the raw material 8 on one side (here, the left side in the drawing) and the other side (here, the right side in the drawing) with respect to the punching holes 90a to 90f. Steel plates 201 to 206 are obtained. Since the positioning in the transport direction K between the punching of the rectangular area Q and the punching by the fixed punch or the movable punch is also a well-known technique, the details thereof are omitted. If the width dimension of the raw material 8 is exactly constant, the punching in the rectangular region Q may be replaced by a process of simply cutting the raw material 8 in the transport direction K.

  Taking the laminated steel plates 101 and 201 as an example, the positional relationship in the rectangular region Q will be roughly described. The narrow portion of the fixed punch (and its position) 91 is the magnetic flux guide portion 12, and the wide portion is the buried portion 13. Are complementary to each other. Further, the narrow portion of the movable punch (and its position) 92 has a complementary relationship with the flange portion 14 and the wide portion with the winding portion 11. In the pair of laminated steel plates that are simultaneously punched, if the total width dimension of the flange portion 14 and the total width dimension of the magnetic flux guide portion 12 are substantially the same, the use efficiency of the electromagnetic steel sheet is further increased.

  FIG. 10 shows the laminated steel plates 101 to 106 arranged in the order of punching. In order to make the shape easy to see, these are shown in an oblique arrangement in the punching order, but in practice it is not necessary to arrange them obliquely. Since the raw material 8 does not move in the direction (width direction) orthogonal to the conveyance direction K, the opposite side (the width direction end portion side of the raw material 8) is aligned by punching the rectangular region Q. In practice, it is desirable to be laminated in that way.

  The steel plates 101 to 106 for lamination are obtained on the left side of the punched holes 90b to 90f. The first positions 92a and 92f are located on the leftmost side in the drawing. Therefore, the laminating steel plates 101 and 106 obtained from the left side of the punched holes 90a and 90f corresponding to the first positions 92a and 92f have a width dimension at a position corresponding to the winding portion 11 and the flange portion 14 so that the laminating steel plates. The smallest of 101-106. On the contrary, since the second positions 92c and 92d are located on the rightmost side in the drawing, the steel plates 103 and 104 for lamination obtained from the left side of the punching holes 90c and 90d correspond to the winding part 11 and the flange part 14, respectively. The width dimension at the position is the largest among the steel plates 101 to 106 for lamination. The width dimension of the steel plates 102 and 105 for lamination is smaller than that of the steel plates 103 and 104 for lamination and larger than that of the steel plates 101 and 106 for lamination.

As shown in FIG. 11, the laminated steel plates 101 to 106 are stacked in the order of punching, specifically, the ones punched first are stacked below. At this time, as described above, the opposite sides of the punched holes 90b to 90f are aligned, and the steel plates 101 to 106 for lamination are laminated. In addition, although the steel plates 103 and 104 for lamination | stacking are shown laminated | stacked in the figure, they may not actually be laminated | stacked. The method for determining the unit of lamination can be realized by a known method.

  Laminating steel plates 101 to 106 are laminated with the laminating steel plates 101 and 106 punched at the first positions 92a and 92f and the laminating steel plates 103 and 104 punched at the second positions 92c and 92d as a boundary. Laminates 10a and 10b are obtained. Specifically, the laminated body 10a is composed of laminating steel plates 101 to 103, and the laminated body 10b is composed of laminating steel plates 104 to 106. In FIG. 10, for easy explanation, the steel plates 101 to 106 constituting the laminates 10 a and 10 b are shown separately.

  Then, the stacked bodies 10a and 10b are adjacent to each other with the positions punched by the movable punch 92 opposite to the punched holes 90b to 90f, that is, the stacked bodies 10a and 10b are adjacent to each other. It will function as the second portion 1b.

  Referring to FIG. 13 to FIG. 15, the laminated steel plates 201 to 206 are laminated downward as they are punched first, similarly to the laminated steel plates 101 to 106. A plurality of laminating steel plates 201 to 206 are laminated with the laminating steel plates 201 and 206 punched at the first positions 92a and 92f and the laminating steel plates 203 and 204 punched at the second positions 92c and 92d as boundaries. The laminates 20a and 20b are obtained. Specifically, the laminated body 20a is composed of steel plates 204 to 206 for laminating, and the laminated body 20b is composed of steel plates 201 to 203 for laminating. In FIG. 13, the steel plates for laminating 201 to 206 constituting the laminated bodies 20a and 20b are shown separately.

  And the laminated bodies 20a and 20b function as the first part 1a and the second part 1b, respectively, by making the positions punched by the movable punch 92 opposite to each other and adjoining each other. .

  Thus, the movable punch positions 92a to 92f reciprocate in the width direction, whereby the steel plates 101 to 106 and 201 to 206 for lamination are obtained from the raw material 8 on both sides in the width direction. Therefore, one movable punch is enough. Since the conventional technique required a pair of movable punches that move symmetrically according to the width of the laminated steel sheet to be punched, this embodiment reduced the number of movable punches compared to the conventional technique. become.

  Further, in the raw material 8, the portions not corresponding to the laminated steel plates 101 to 106 and 201 to 206 are the outside of the rectangular region Q and the portions corresponding to the punched holes 90 b to 90 f. In view of the fact that the area of the punched holes 90b to 90f can be reduced by reducing the number of movable punches in the present embodiment as described above, and that the outside of the rectangular region Q has become waste material in the prior art, In the embodiment, waste materials are reduced as compared with the conventional technique.

  Of course, only one of the laminated steel plates 101 to 106 and the laminated steel plates 201 to 206 can be used for forming the magnetic core 1. If it considers except a viewpoint of waste material reduction, even if it is such a manufacturing process, there exists an effect that the magnetic core demonstrated in 1st Embodiment can be obtained.

  In the present embodiment, since the width dimensions of the magnetic flux guide portion 12 and the embedded portion 13 of the magnetic core 1 are constant regardless of the radial position, punching by the fixed punch 91 is necessary. However, this embodiment can also be applied to punching using only a movable punch.

  When the winding part 11, the magnetic flux guide part 12, and the embedded part 13 have the same shape as seen from the axial direction Z as shown in FIG. 17, punched holes 90g to 90l shown in FIG. These holes are obtained only by a movable punch. The punching holes 90g to 90l are all the same shape, and only the position in the width direction in the rectangular region Q is different.

A punching hole is formed at a position in the width direction of the movable punch that is updated by reciprocating the movable punch in the width direction each time the raw material 8 is conveyed in the conveyance direction K by a predetermined length P and the conveyance is stopped. 90g-90l is punched out. As for the laminated steel plates obtained from both sides of the punched holes 90g to 90l in this manner, the laminated steel plates and the punched holes punched by the punched holes 90g and 90l in the same manner as the laminated steel plates 101 to 106 and 201 to 206. A plurality of laminates can be obtained by laminating the laminate steel plates punched at 90i and 90j as boundaries. Then, the magnetic core 1 can be formed by adjoining these laminated bodies with the positions punched by the movable punches opposite to each other. Here, since the punching of holes 90g~90l shape width except for a position corresponding to the first rib component 14a and the second flange portion component 14b is constant, to form a magnetic core shown in FIG. 17 be able to.

  Moreover, the punching holes 90g-90l shown in FIG. 18 are employable about the magnetic core 1 which provides a pair of collar parts 14 without providing the embedded part 13 like FIG. These holes are also obtained only by a movable punch. The punching holes 90g to 90l are all the same shape, differ only in the position in the width direction in the rectangular region Q, and the width dimension is constant except for the positions corresponding to the pair of flange portions 14. Therefore, it can laminate | stack like the steel plates 101-106,201-206 for lamination | stacking, a laminated body is obtained, and the magnetic core shown by FIG. 19 can be formed by making these adjoin. In addition, since the shape of the steel plates 101 to 106 and 201 to 206 for lamination is a shape that is plane-symmetric with respect to a plane orthogonal to the axial direction Z, all the laminates have the same shape, and any two laminates are formed. The magnetic core 1 can be configured by using it.

  In the case of obtaining the magnetic core 1 not provided with the flange portion 14, a rectangular shape can be adopted as the shape of the punched holes 90g to 90l.

Third embodiment.
The magnetic core 1 obtained by implementing only the second embodiment has a trapezoidal shape in the plan view in the opposite direction. However, it is preferable that the corners of the trapezoid be chamfered or rounded so that the armature winding 15 can be in close contact with the winding part 11. Therefore, the difference in the width dimension in the circumferential direction θ between the electromagnetic steel sheet disposed at the outer end in the radial direction R or the inner end and the electromagnetic steel sheet adjacent thereto is adjacent to the central portion in the radial direction R. It is desirable that it is larger than the difference in the width dimension between the pair of electrical steel sheets.

  Therefore, once the laminated bodies 10a and 10b or the laminated bodies 20a and 20b obtained by the second embodiment are additionally laminated with electromagnetic steel plates from the inside and outside in the radial direction R, respectively, You may obtain 1 part 1a and 2nd part 1b. Alternatively, it is possible to prepare another punching die (punch) in the same progressive die and further punch out the chamfered or rounded portion.

Variation of shape.
The angle formed by the two hypotenuses of the trapezoid can be set to a value obtained by dividing the peripheral angle (360 degrees) by the number of magnetic cores arranged in an annular shape in the armature.

Further, as shown in the above embodiment, magnetic cores divided in the circumferential direction θ may be mixed with magnetic cores that are not divided as in the prior art. For example, the magnetic cores that are not divided have a rectangular shape in a plan view in the opposite direction, and are alternately arranged in the annular direction with the magnetic core into which the magnetic cores are divided. In this case, two oblique side formed to the angle of the trapezoid in the opposing direction in plan view of the divided magnetic core, the circumferential angle (360 degrees), divided by the number of the divided magnetic core is arranged in the armature Can be set to a value. Note that the angle between the two hypotenuses of the trapezoid and the base must be the same isosceles trapezoid.

  It is desirable that the area of the magnetic core in the opposing direction plan view is the same for all the magnetic cores. This is because the number of turns of the armature winding is usually selected equally for all the magnetic cores, so that the symmetry of the magnetic field generated by the armature is improved.

Of course, varying the number of turns of the armature winding for each magnetic core does not impair the success of the above-described embodiment, and is an item that can be appropriately designed and selected according to other requirements. Regarding the punching pattern, the two portions are a pair of electrical steel sheets, but a plurality of units may be simultaneously punched in the width direction of the electrical steel sheet with this as one unit.

1 core 1a first portion 1b second portion 100 electromagnetic steel 101～106,201～206 laminated steel plate 11 winding portion 11a first winding unit component 11b second winding portion component 110a first boundary surface 110b second Boundary surface 15 Armature winding 4 Field element 8 Raw material 90a to 90l Punching hole 91, 91a to 91f Position of fixed punch 92, 92a to 92f Position of movable punch K Conveying direction P Predetermined length R Radial direction Z Axial direction θ Circumferential direction

Claims (3)

  The raw material (8), which is an electromagnetic steel plate, is conveyed every predetermined length (P) in the conveying direction (K),
  (A) when the conveyance of the raw material is stopped, the step of punching the raw material using the first punch (92);
  (B) The magnetic steel sheet left in the raw material in the step (a) is punched into a rectangle (Q) whose dimension in the transport direction is equal to or less than the predetermined length, and the steel sheets for lamination (101 to 106, 201 To 206),
  (C) Among the steel sheets for lamination obtained in the step (b), those obtained on one side with respect to the first punch in the width direction perpendicular to the transport direction (101 to 106), Laminating in the punched order and
With
  The step (a) reciprocates the first punch between the first position (92a, 92f; 90g, 90l) and the second position (92c, 92d; 90i, 90j) in the width direction. By repeatedly updating the position of the first punch,
  In the step (c), the laminate steel plates (101, 106) punched at the first position and the laminate steel plates (103, 104) punched at the second position are used as boundaries. A plurality of laminated bodies (10a, 10b) are obtained by laminating laminated steel sheets,
  (D) forming the magnetic core (1) by adjoining the stacked bodies in the step (c) with the positions punched by the first punches opposite to each other;
A method for manufacturing a magnetic core, further comprising:   (E) Of the steel sheets for lamination obtained in the step (b), those obtained on the other side with respect to the first punch in the width direction perpendicular to the transport direction (201 to 206), In the punched order, the laminated steel plates (201, 206) punched at the first position and the laminated steel plates (203, 204) punched at the second position as a boundary. A steel plate is laminated to obtain a plurality of laminates (20a, 20b);
  (F) forming the magnetic core (1) by adjoining the stacked bodies in the step (e) with the positions punched by the first punches opposite to each other;
The method of manufacturing a magnetic core according to claim 1, further comprising:   (G) Prior to the execution of the step (c), when the conveyance of the raw material (8) is stopped in a pair with the step (a), the position in the width direction (91a ~ 91f) The step of punching out the raw material using the second punch (91) maintained
The method of manufacturing a magnetic core according to claim 1, further comprising:

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