JP4886390B2 - Laminated core manufacturing method and laminated core manufacturing apparatus - Google Patents

Description

The present invention relates to a laminated core manufacturing method and a laminated core manufacturing apparatus, and more particularly to a technique for preventing a winding from being damaged by burrs generated when a core thin plate is punched from a strip-shaped thin steel plate.

  A laminated iron core for a rotating electrical machine is often manufactured by a progressive die using a hoop material (strip-shaped thin steel plate) of an electromagnetic steel sheet as cutting of slots and teeth is complicated and difficult. For example, a laminated core for a stator is usually formed by sequentially punching a pilot hole, a slot, an inner diameter tooth, an outer shape and the like on a hoop material that is intermittently transferred in a progressive die. After obtaining continuously, it manufactures by laminating | stacking / adhering these iron core thin plates for every predetermined number in a die | dye.

  Although the burr caused by the clearance between the punch and the die may occur to some extent in the punching part of the iron core thin plate, the burr on the winding part may damage the coating of the coil winding, etc. It has become a cause of hindering the smoothing of. Burrs can be removed by cutting or shot blasting. However, when such a method is used, the processing man-hours and manufacturing costs increase, and the removed burrs become foreign matter and become a product or metal. There is a risk of sticking to the mold. Therefore, various methods have been proposed for crushing burrs in a progressive die by pressing against a die body or other iron core sheet.

  For example, Patent Literature 1 discloses that “at least one of the punching stations includes a burr removal station provided with a protrusion on the die side or the stripper side corresponding to the processing shape upstream of the station”. The technology is described.

  Patent Document 2 describes a technique of “forming burr crushing protrusions on a cradle provided in a final-stage laminated die for punching an outer shape of an iron core component piece”.

  Patent Document 3 states that “a step of punching a slot of the first core plate from one side, a step of punching a slot of the second core plate from the other side, and punching the outer shapes of both core plates. After sequentially performing the steps, a technique is described in which the core plates are stacked to bring the burrs of the first core plate and the burrs of the second core plate into contact with each other.

  Patent Document 4 states that “the slot of the core component piece located at the lowermost end of the laminated core is punched upward, the slots of the other core component pieces are punched downward, and then the outer shape punching and caulking are performed. Thus, a technique is described in which an upward burr and a downward burr are brought into contact with each other and crushed.

Further, Patent Document 5 states that “when punching a punched steel sheet located at least at the lower end of the laminated core, the inside of the contour is punched, and when punching a steel sheet positioned at least at the upper end of the laminated core, Is a technique in which an upward burr and a downward burr are brought into contact with each other and punched.
Japanese Patent No. 2527498 Japanese Patent No. 2552965 Japanese Patent No. 3373370 Japanese Patent No. 3492008 Japanese Patent No. 2808555

  When the methods of Patent Documents 1 and 2 are adopted, a process dedicated to crushing burrs is provided in the progressive die, so that there is a problem that the physique of the apparatus becomes large and the equipment cost and installation space increase. In addition, when the methods of Patent Documents 3 and 4 are adopted, a step of punching in the opposite direction to the normal is provided, so that the physique of the apparatus is also increased and the equipment cost and installation space are increased. It was also necessary to install a scrap processing mechanism above the mold. On the other hand, although the method of patent document 5 can be implemented without enlarging a metal mold | die, the following problems were included. In other words, the methods of Patent Documents 3 and 4 are the same, but the method of Patent Document 5 makes the upward burrs and the downward burrs contact each other, so that all burrs may be flattened. In other words, it was inevitable that a part of the burr that was bent went to the outside of the laminated core. And since the burr | bend | folded outside the laminated iron core naturally damaged the coil | winding coating | cover etc. and caused a dielectric breakdown, the method of patent document 5 was also admitted to employ | adopt. Furthermore, in the methods of Patent Documents 1 to 5, when a burr is crushed, a minute piece (iron powder) is scattered around and adhered to the surroundings to promote wear of a die (die, squeeze ring, etc.) There was a problem that the adhesion of the iron core thin plate in the iron core was hindered.

  The present invention has been made in view of such a background, and a laminated iron core manufacturing method for producing a laminated iron core having no burr protrusion or the like in a winding portion without causing an increase in the size of a progressive feed and the like. An object of the present invention is to provide a laminated core manufacturing apparatus.

In the laminated core manufacturing method according to the invention of claim 1, an iron core thin plate having a winding portion is extracted from a strip-shaped thin steel plate downward by an outer punching punch using a progressive die, and the outer core punched sheet is formed into a die and a die. A method of manufacturing a laminated iron core by sequentially laminating / integrating in a squeeze ring, wherein an outer side of an outline of the winding portion is formed before the outer shape of the upper iron core thin plate including the iron core thin plate located at the upper end of the laminated iron core is removed. Is formed by punching downward by a winding contour punch, and the contour of the winding portion in the upper iron core thin plate is located inside with a predetermined width with respect to the contour of the winding portion in the other iron core thin plate. It is characterized by doing.

  According to a second aspect of the present invention, in the method of manufacturing a laminated core according to the first aspect, the contour of the winding portion in the upper core thin plate is substantially 0 with respect to the contour of the winding portion in another core thin plate. It is located inside with a width of .05 mm.

According to a third aspect of the present invention, there is provided a laminated iron core manufacturing apparatus that uses a progressive die to punch an iron core thin plate having a winding portion from a strip-shaped thin steel plate, and sequentially stacks the punched iron core thin plate in a die and a squeeze ring. An apparatus for producing a laminated iron core by integrating the outer shape punching means for punching the outer shape of the iron core thin plate downward, and an outer punching means installed in a process preceding the outer shape punching means, and the iron core thin plate Winding portion contour punching means having a winding portion contour punching punch for punching the outside of the winding portion contour in the lower direction, and switching means for switching the winding portion contour punching punch between a punching position and a non-punching position; And the winding in the thin iron plate punched out by the outer shape punching means is the outline of the winding portion in the thin iron core sheet punched out by the winding portion contour punching means. To contour, characterized in that located inside with a predetermined width.

  According to a fourth aspect of the present invention, in the laminated core manufacturing apparatus according to the third aspect, the outline of the winding portion in the core thin plate punched by the winding portion contour punching means is punched by the outer shape punching means. It is characterized in that it is located on the inner side with a width of about 0.05 mm with respect to the outline of the winding portion in the iron core thin plate.

  According to the present invention, for example, by placing the contour of the winding portion of the uppermost core thin plate on the inner side with respect to the contour of the winding portion of the second core thin plate, the burr of the uppermost core thin plate can be reduced. The second core thin plate is crushed in the state of being fitted inside the burrs, and the burrs are prevented from protruding to the outside of the laminated core due to the burrs contacting each other. Further, the burr of the second iron core thin plate is fastened within the squeeze ring so as to surround the uppermost iron core thin plate, and therefore does not protrude outside the laminated iron core. Further, in the case where the outline of the winding part in the inner punching process is positioned on the inner side with a width of about 0.05 mm with respect to the outline of the winding part in the outer punching process, the burr of the uppermost iron core thin plate is Even if minute iron powder or the like is generated when being crushed, the iron powder is enclosed between the uppermost core thin plate and the second core thin plate and is not scattered outside.

  Hereinafter, an embodiment of a laminated core manufacturing apparatus to which the present invention is applied will be described in detail with reference to the drawings. In addition, the laminated core manufacturing apparatus of this embodiment manufactures the divided | stacked laminated iron core used for the stator (stator) of an electric motor one by one.

  FIG. 1 is a diagram showing a strip layout according to the embodiment, FIG. 2 is a conceptual diagram showing a cam mechanism for driving a measuring hole punch according to the embodiment, and FIG. 3 is a winding contour punching according to the embodiment. FIG. 4 is a conceptual diagram showing a cam mechanism for driving a punch, FIG. 4 is a plan view showing a split-type laminated core according to the embodiment, and FIG. 5 is a perspective view showing the split-type laminated core according to the embodiment. It is. FIG. 6 is a plan view showing the outline of the inner punch and the outline of the outer punch according to the embodiment.

The hoop material W is processed in the first to sixth steps while being intermittently fed in a progressive die.
(1) First step: punching of a pair of pilot holes P by a pilot hole punch PP.
(2) Second step: For each iron core sheet A (described later), punching of three first small holes H1 and one second small hole H2 by a small hole punch PH.

(3) Third step: Punching of three measurement holes (through holes) Kl by the measurement hole punch PK1 with respect to the core sheet A laminated at the lowermost end. In the third step, as shown in FIGS. 2A and 2B, the cam mechanism CM1 including the cam CK1 and the fluid cylinder HC1 is used to advance and retract the measuring hole punch PK1 with respect to the hoop material W. The iron core thin plate A is provided with a measuring hole Kl by a measuring hole punch PK1 every predetermined number (for example, every 50 sheets).

(4) Fourth step: Half-cutting of the caulking protrusions K2 at three locations by the caulking protrusion punch PK2 for the iron core sheet A laminated after the second sheet. The caulking protrusion K2 is for fixing and integrating the respective iron core thin plates A at the time of lamination, and is formed at the same position and the same shape (same contour) with respect to the measuring hole Kl.

(5) Fifth step: punching of the outer peripheral portion E of the magnetic pole part (winding part) J by the winding part outline punching punch PO with respect to the iron core sheet A1 laminated at the uppermost end (coiling part punching punch) External cutting with PO). In the fifth step, as shown in FIGS. 3A and 3B, a cam mechanism CM2 (including a cam CK2 and a fluid cylinder HC2) is used to advance and retract the winding portion contour punching punch PO with respect to the hoop material W. Switching means) is installed, and after the outer peripheral portion E of the magnetic pole portion J of the iron core sheet A1 laminated at the uppermost end is punched, the winding portion contour punching punch PO is retracted by the cam mechanism CM2, and the other The iron core sheet A2 proceeds to the sixth step described later without being subjected to the punching process in the fifth step.

(6) Sixth step: For each core sheet A, punching of the outer shape F of the core sheets A1, A2 by the outer punching punch PI (inner punching process by the outer shape punching punch PI), and of the core sheets A1, A2 Stacking and caulking in the die D and squeeze ring SQ. Thereby, the iron core thin plates A1 and A2 are fixed and integrated by the measuring hole Kl and the caulking protrusion K2 while being laminated and tightened in the die D and the squeeze ring SQ, so that a laminated iron core C shown in FIGS. 4 and 5 is obtained. . At this time, the entire outer shape is punched by the outer shape punching punch PI in this step from the core sheet A having the measurement hole K1 stacked in the lowermost layer to the previous number of stacked sheets, but the core stacked in the uppermost end. In the thin plate A1, the outline of the magnetic pole portion J is punched in the fifth step, and the portion other than the magnetic pole portion J is punched in the sixth step. In the case of the present embodiment, as shown in FIG. 6, the contour JI of the portion corresponding to the magnetic pole portion J in the outer punching punch PI is the portion corresponding to the magnetic pole portion J in the winding portion contour punching punch PO in the fifth step. Is located on the inside with a slight width (0.05 mm in this embodiment) with respect to the contour JO.

  After the laminated iron core C discharged from the die D is subjected to the coil winding SC on the magnetic pole part J (or after the coil assembly is attached), as shown by a two-dot chain line in FIG. It becomes stator ST by connecting to.

  As shown in FIG. 7, the second and subsequent iron core thin plates A2 drawn into the die D have the outer shape F punched downward by the outer punching punch PI, so that an upward burr B2 is formed on the outer periphery of the magnetic pole portion J. It is formed. And between the laminated core thin plates A2, the burrs B2 of the lower core thin plate A2 are externally fitted to the outer periphery of the upper core thin plate A2, so that, together with being tightened by the squeeze ring SQ, The burr B2 does not protrude from the outer peripheral surface of the laminated iron core C. Since the burr B2 is formed upward, there is almost no risk of damaging the inner peripheral surface of the die D or squeeze ring SQ.

  On the other hand, as shown in FIG. 8, the outermost portion E (that is, the outside of the magnetic pole part J) of the uppermost iron core sheet A1 drawn into the die D is punched downward by the winding part outline punching punch PO. Therefore, a downward burr B1 is formed on the outer periphery of the magnetic pole part J. Since the contour JI of the magnetic pole portion J on the iron core thin plate A1 side is located inside the contour JO of the magnetic pole portion J on the iron core thin plate A2 side, the burr B1 on the iron core thin plate A1 side is the burr on the iron core thin plate A2 side. It will be fitted inside B2.

  When the iron core thin plate A1 is pressed against the iron core thin plate A2 in the die D or squeeze ring SQ, the burr B1 is first bent inward along the upper surface of the iron core thin plate A2, as shown in FIG. When the iron core thin plate A1 and the iron core thin plate A2 are in close contact with each other, as shown in FIG. 9B, the burr B1 is completely crushed and enclosed between the iron core thin plate A1 and the iron core thin plate A2. In addition, since the difference between the outline JI of the magnetic pole part J on the iron core sheet A1 side and the outline JO of the magnetic pole part J on the iron sheet sheet A1 side is very small, even if a small amount of iron powder is generated when the burr B1 is crushed, The iron powder hardly scatters outside the laminated core C. As a result, in the completed laminated core C, as shown in FIG. 10, no burr protrudes from the outer surface of the magnetic pole portion J, and the coating of the wound coil winding SC is not damaged. The inventors changed the difference between the contour JI of the portion corresponding to the magnetic pole portion J in the outer punching punch PI and the contour JO of the portion corresponding to the magnetic pole portion J in the winding portion contour punching punch PO. When the test was conducted, it was confirmed that the outer surface of the laminated iron core C was smoothest when the contour JI was positioned on the inner side with a width of 0.05 mm with respect to the contour JO.

  Although description of specific embodiment is finished above, the aspect of the present invention is not limited to this embodiment. For example, in the above embodiment, the present invention is applied to a split laminated core for a stator of an electric motor. However, the present invention may be applied to a split stacked core for a rotor of an electric motor or a generator. The present invention may be applied to a split laminated core for a stator or a rotor. Further, in the above embodiment, the present invention is applied to a split-type laminated core having a single magnetic pole part. However, the present invention is applied to a split-type laminated core having a plurality of (for example, 2 to 4) magnetic pole parts. Alternatively, it may be applied to a non-divided (annular) laminated core. Further, in the above embodiment, only the magnetic pole part of the iron core thin plate laminated on the uppermost end is punched by the winding part contour punching punch, but the magnetic pole part of a plurality of iron core thin plates is punched from the uppermost end by the winding part contour punching. You may make it punch with a punch. In addition, the specific layout or the like of the progressive die is not limited to the example in the above embodiment, and can be changed as appropriate without departing from the gist of the present invention.

It is a figure which shows the strip layout which concerns on embodiment. It is a conceptual diagram which shows the cam mechanism which drives the punch for measurement holes which concerns on embodiment. It is a conceptual diagram which shows the cam mechanism which drives the winding part outline punching punch which concerns on embodiment. It is a top view which shows the division | segmentation type | mold laminated iron core which concerns on embodiment. It is a perspective view which shows the split-type laminated iron core which concerns on embodiment. It is a top view which shows the outline of the inside punch which concerns on embodiment, and the outline of an outside punch. It is explanatory drawing which shows the effect | action of embodiment. It is explanatory drawing which shows the effect | action of embodiment. It is explanatory drawing which shows the effect | action of embodiment. It is explanatory drawing which shows the effect | action of embodiment.

Explanation of symbols

A1 Iron core thin plate A2 Iron core thin plate B1 Burr B2 Burr C Laminated core CM2 Cam mechanism (switching means)
D Die J Magnetic pole part (winding part)
JI Contour JO Contour PI Contour punch punch PO Coil contour punch punch SC Coil winding SQ Squeeze ring ST Stator W Hoop material (banded steel sheet)

Claims (4)

Using a progressive die, the iron core thin plate having the winding portion is extracted from the strip-shaped thin steel plate to the lower side by an outer punching punch, and the outer core thin plate is sequentially laminated / integrated in a die and a squeeze ring to form a laminated iron core A method of manufacturing
Prior to the outer shape of the upper core thin plate including the iron core thin plate positioned at the upper end of the laminated core, the outside of the contour of the winding portion is configured to be punched downward by a winding portion contour punching punch ,
The laminated core manufacturing method, wherein a contour of the winding portion in the upper iron core thin plate is located inside with a predetermined width with respect to a contour of the winding portion in another iron core thin plate.   The outline of the winding part in the upper iron core thin plate is located on the inner side with a width of about 0.05 mm with respect to the outline of the winding part in another iron core thin plate. Laminated core manufacturing method. An apparatus for manufacturing a laminated iron core by punching out an iron core thin plate having a winding portion from a strip-shaped thin steel plate using a progressive die, and sequentially laminating / integrating the punched iron core thin plate in a die and a squeeze ring,
An outer shape punching means having an outer shape punch for punching the outer shape of the iron core thin plate downward ;
Winding part contour punching means, which is installed in a step prior to the outer shape punching means, and has a winding part contour punching punch for punching downward outside the contour of the winding part in the iron core thin plate;
Switching means for switching the winding part contour punching punch between a punching position and a non-punching position,
The outline of the winding part in the iron core thin plate punched by the winding part outline punching means is located on the inner side with a predetermined width with respect to the outline of the winding part in the iron core thin plate punched by the outer shape punching means. A laminated iron core manufacturing apparatus characterized by that.   The outline of the winding part in the iron core thin plate punched by the winding part outline punching means is approximately 0.05 mm wide with respect to the outline of the winding part in the iron core thin plate punched by the outer shape punching means. The laminated core manufacturing apparatus according to claim 3, which is located in

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