JP4934402B2 - Armature manufacturing method and progressive mold apparatus - Google Patents

Armature manufacturing method and progressive mold apparatus Download PDF

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JP4934402B2
JP4934402B2 JP2006290681A JP2006290681A JP4934402B2 JP 4934402 B2 JP4934402 B2 JP 4934402B2 JP 2006290681 A JP2006290681 A JP 2006290681A JP 2006290681 A JP2006290681 A JP 2006290681A JP 4934402 B2 JP4934402 B2 JP 4934402B2
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core
iron core
dividing
forming
connecting portions
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JP2008109785A (en
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俊生 原
芳孝 鹿川
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Kuroda Precision Industries Ltd
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Description

本発明は、回転電機の固定子や回転子として用いられる電機子の製造方法と、この製造方法を実現するための順送り金型装置とに関する。   The present invention relates to a method of manufacturing an armature used as a stator or rotor of a rotating electric machine, and a progressive mold apparatus for realizing the manufacturing method.

回転電機では、主要構成要素である電機子(ロータやステータ)として、巻線を施した磁極を筒状積層鉄心の内周側に形成したものが用いられることが多い。この種の電機子を製造する場合、積層鉄心の内周側に放射状に突設された磁極部に巻線を施すことになるが、巻線治具の挿入代を確保することが難しいこと等から、磁極(コイル)の本数や巻線の巻き量を多くすることができなかった。   In a rotating electric machine, an armature (rotor or stator) that is a main constituent element is often used in which a wound magnetic pole is formed on the inner peripheral side of a cylindrical laminated core. When manufacturing this type of armature, winding will be applied to the magnetic poles projecting radially on the inner circumference side of the laminated core, but it is difficult to secure the insertion allowance of the winding jig, etc. Therefore, the number of magnetic poles (coils) and the amount of windings cannot be increased.

そこで、この問題を解決する電機子の製造方法として、複数の磁極ブロックを薄肉部によって曲折可能に連結してなる帯状の連結ステータコアを採用し、巻線作業の容易化を図ったもの(特許文献1参照)が提案されている。この電機子製造方法では、帯状の連結ステータコアを金型によって打抜き、多数枚の連結ステータコアを積層した後に各磁極ブロックに巻線を施し、薄肉部を曲折させることによって筒状の積層鉄心を得る。また、他の製造方法としては、順送り金型装置によって複数のコア片を帯状に連続した状態で順次打抜き積層し、各コア片に巻線を施した後に環状に形成するもの(特許文献2参照)や、順送り金型装置によって所定の磁極歯部を有する環状の連結磁性部材を順次打抜き積層してコア部材を形成し、各コア部材を磁極歯部が外側となるように逆反り状態に屈曲させた状態で各磁極歯部に巻線を施し、しかる後に各コア部材を再び環状にするもの(特許文献2,3参照)が提案されている。
特開平8−19196号公報 特許3379461号公報 特開2003−18771号公報
Therefore, as a method of manufacturing an armature that solves this problem, a strip-shaped connection stator core formed by connecting a plurality of magnetic pole blocks so as to be bendable by thin portions is employed to facilitate winding work (Patent Literature). 1) has been proposed. In this armature manufacturing method, a strip-shaped connection stator core is punched out by a mold, a plurality of connection stator cores are stacked, a winding is applied to each magnetic pole block, and a thin laminated portion is bent to obtain a cylindrical stacked core. As another manufacturing method, a plurality of core pieces are sequentially punched and laminated in a continuous state by a progressive die apparatus, and each core piece is formed into a ring after being wound (see Patent Document 2). ), Or by forming a core member by sequentially punching and laminating an annular connecting magnetic member having a predetermined magnetic pole tooth portion with a progressive die device, and bending each core member in a reverse warped state so that the magnetic pole tooth portion is on the outside There has been proposed a method in which a winding is applied to each magnetic pole tooth portion in a state in which the core member is made, and then each core member is made annular again (see Patent Documents 2 and 3).
JP-A-8-19196 Japanese Patent No. 3379461 JP 2003-18771 A

特許文献1の方法は、巻線作業の容易化を実現することができるものの、打抜いた連結ステータコアを積層する作業に多くの時間や工数が掛かるという問題を有していた。また、特許文献2のコア片を帯状に連続したコア片を積層する方法は、打抜きの効率を高めることができる反面、帯状に連続したコア片を打抜くために金型の幅が大きくなることから、装置の大型化や製作コストの上昇が避けられないという問題を有していた。一方、特許文献2,3の環状連結磁性部材を順次打抜き積層する方法は、環状の連結磁性部材を順送り金型装置によって打抜くため、装置を大型化することなく打抜きや巻線作業を高速かつ高効率で行える特長を有している。   The method of Patent Document 1 has a problem that it takes a lot of time and man-hours to stack the stamped connecting stator cores, although it can facilitate the winding work. In addition, the method of laminating the core pieces in which the core pieces of the patent document 2 are continuous in a strip shape can improve the punching efficiency, but the die width is increased in order to punch the continuous core pieces in the strip shape. Therefore, there has been a problem that an increase in the size of the apparatus and an increase in production cost are inevitable. On the other hand, in the method of sequentially punching and laminating the annular connecting magnetic members of Patent Documents 2 and 3, since the annular connecting magnetic member is punched by the progressive die device, punching and winding work can be performed at high speed without increasing the size of the device. It has a feature that can be done with high efficiency.

しかしながら、上述した特許文献1〜3の方法には、素材である薄鋼板の板厚偏差により、電機子が組み込まれた回転電機の性能が低下するという大きな問題があった。すなわち、薄鋼板は、圧延加工により製造されるため、圧延ロールの平行度や外径の不均一等に起因して、圧延送り方向と直交する方向(すなわち、幅方向)に微少な板厚偏差が生じる。そのため、打抜き後の連結ステータコアや連結磁性部材をそのまま積層した場合、完成した電機子の両端面が平行にならず、その電機子が組み込まれた回転電機の性能を低下させる虞があった。   However, the methods of Patent Documents 1 to 3 described above have a serious problem that the performance of the rotating electrical machine in which the armature is incorporated is reduced due to the thickness deviation of the thin steel plate as the material. That is, since a thin steel plate is manufactured by rolling, a slight thickness deviation in the direction perpendicular to the rolling feed direction (that is, the width direction) due to the parallelism of the rolling rolls, non-uniformity of the outer diameter, etc. Occurs. Therefore, when the connected stator core and the connected magnetic member after being punched are laminated as they are, both end surfaces of the completed armature are not parallel, and there is a possibility that the performance of the rotating electrical machine in which the armature is incorporated is deteriorated.

本発明は、このような背景に鑑みなされたものであり、薄鋼板の板厚偏差による性能低下を抑制しつつ、巻線作業の容易化を実現するための電機子製造方法および順送り金型装置を提供することを目的とする。   The present invention has been made in view of such a background, and an armature manufacturing method and a progressive die apparatus for realizing facilitation of winding work while suppressing performance deterioration due to thickness deviation of a thin steel plate The purpose is to provide.

請求項1の発明に係る電機子製造方法は、巻線を施した磁極を筒状積層鉄心の内周側に形成してなる電機子を製造する方法であって、複数のコア片と、当該複数のコア片の外周側を連結する複数の連結部とを有する環状の鉄心薄板を帯状薄鋼板から順次打抜く工程と、重なり合う鉄心薄板のコア片を結合するための加締め結合手段を当該コア片に形成する工程と、上型内に所定の角度間隔で配置されるとともに分断と非分断とを切り換えることができる複数の分断部形成機構を用い、前記鉄心薄板に対し、前記連結部の1つを分断する分断部を、所定枚数ずつ角度位相を変化させながら形成する工程と、前記鉄心薄板を外形打抜きするとともに、当該鉄心薄板を所定枚数ずつ相対回転させながら積層することにより、前記分断部が一線上に位置してなる分断線をコア片間に備えた筒状の積層鉄心を形成する工程と、前記積層鉄心を、前記分断線から開き、前記複数の連結部を塑性変形させることで帯状に展開する工程と、展開した積層鉄心のコア片の内周側にあたる磁極部に巻線を施す工程と、前記磁極が形成された積層鉄心を再び環状にする工程と、環状に戻した積層鉄心での、前記分断線を挟んで対峙する両端面を接合する工程とを含むことを特徴とする。
An armature manufacturing method according to the invention of claim 1 is a method for manufacturing an armature in which a magnetic pole provided with a winding is formed on the inner peripheral side of a cylindrical laminated iron core, and a plurality of core pieces, A step of sequentially punching an annular thin steel sheet having a plurality of connecting portions for connecting outer peripheral sides of a plurality of core pieces from a strip-shaped thin steel sheet, and a caulking coupling means for joining the core pieces of overlapping core thin sheets Using a plurality of divided portion forming mechanisms that are arranged at predetermined angular intervals in the upper mold and can be switched between divided and non-divided , the connecting portion 1 is connected to the iron core thin plate. A step of forming a dividing portion for dividing the steel sheet while changing the angle phase by a predetermined number of times, and punching out the outer shape of the iron core thin plate, and laminating the iron core thin plate by relatively rotating the predetermined number of the core thin plate, thereby Is in line Forming a cylindrical laminated core provided with a dividing line between the core pieces, and opening the laminated iron core from the dividing line and plastically deforming the plurality of connecting portions to develop in a band shape And a step of winding a magnetic pole portion corresponding to the inner peripheral side of the core piece of the developed laminated core, a step of making the laminated iron core on which the magnetic pole is formed again in an annular shape, and the laminated iron core returned to an annular shape, And joining both end faces facing each other across the dividing line.

また、請求項2の発明は、請求項1に記載された電機子製造方法において、前記相対回転は、前記積層鉄心に所定量のスキューを与える角度をもって行われることを特徴とする。   According to a second aspect of the present invention, in the armature manufacturing method according to the first aspect, the relative rotation is performed at an angle that gives a predetermined amount of skew to the laminated core.

また、請求項3の発明に係る電機子製造方法は、巻線を施した磁極を筒状積層鉄心の内周側に形成してなる電機子を製造する方法であって、複数のコア片と、当該複数のコア片の外周側を連結する複数の連結部とを有する環状の鉄心薄板を帯状薄鋼板から順次打抜く工程と、重なり合う鉄心薄板のコア片を結合するための加締め結合手段を当該コア片に形成する工程と、特定の鉄心薄板に対し、前記連結部の1つを分断する分断部を、所定枚数ずつ角度位相を変化させながら形成する工程と、特定のものを除く鉄心薄板に対し、前記連結部の全てに当該連結部を分断する分断部を形成する工程と、前記鉄心薄板を外形打抜きするとともに、当該鉄心薄板を所定枚数ずつ相対回転させながら積層することにより、分断部が一線上に位置してなる分断線をコア片間に備えた筒状の積層鉄心を形成する工程と、前記積層鉄心を、前記分断線から開き、前記複数の連結部を塑性変形させることで帯状に展開する工程と、展開した積層鉄心のコア片の内周側にあたる磁極部に巻線を施す工程と、前記磁極が形成された積層鉄心を再び環状にする工程と、環状に戻した積層鉄心での、前記分断線を挟んで対峙する両端面を接合する工程とを含むことを特徴とする。
An armature manufacturing method according to the invention of claim 3 is a method for manufacturing an armature in which a magnetic pole provided with a winding is formed on the inner peripheral side of a cylindrical laminated iron core, and a plurality of core pieces and , A step of sequentially punching an annular core thin plate having a plurality of connecting portions for connecting the outer peripheral sides of the plurality of core pieces from the strip-shaped thin steel plate, and a caulking coupling means for connecting the core pieces of the overlapping core thin plates A step of forming the core piece, a step of forming a dividing portion for dividing one of the connecting portions with respect to a specific core thin plate while changing the angle phase by a predetermined number of times, and a core thin plate excluding a specific one On the other hand, the step of forming a dividing portion that divides the connecting portion in all of the connecting portions, and punching out the outer shape of the iron core thin plate and laminating the iron core thin plate while relatively rotating a predetermined number of pieces, thereby dividing the divided portion. Is located on a line A step of forming a cylindrical laminated core having a disconnection between core pieces, a step of opening the laminated core from the dividing line, and plastically deforming the plurality of connecting portions, and developing the strip A step of winding a magnetic pole portion corresponding to the inner peripheral side of the core piece of the laminated core, a step of making the laminated core formed with the magnetic pole into an annular shape, and sandwiching the dividing line at the laminated core returned to an annular shape And joining both end faces facing each other.

また、請求項4の発明に係る順送り金型装置は、複数のコア片と、当該複数のコア片の外周側を連結する複数の連結部とを有する環状の鉄心薄板を帯状薄鋼板から順次打抜く順送り金型装置であって、上型内に所定の角度間隔で配置されるとともに分断と非分断とを切り換えることができる複数の分断部形成機構を用い、前記鉄心薄板に対し、前記連結部の1つを分断する分断部を、所定枚数ずつ角度位相を変化させながら形成する分断部形成手段と、重なり合う鉄心薄板のコア片の所定部位に加締め部を形成する加締め部形成手段と、前記鉄心薄板を所定枚数ずつ相対回転させながら積層することにより、前記分断部が一線上に位置した筒状の積層鉄心を形成する回転積層手段とを備えたことを特徴とする。
According to a fourth aspect of the present invention, there is provided a progressive metal mold apparatus in which an annular core thin plate having a plurality of core pieces and a plurality of connecting portions for connecting the outer peripheral sides of the plurality of core pieces is sequentially punched from a strip-shaped thin steel plate. A progressive mold apparatus for pulling out , using a plurality of divided portion forming mechanisms that are arranged in the upper mold at predetermined angular intervals and can be switched between divided and non-divided, and the connecting portion with respect to the iron core thin plate A dividing portion forming means for forming one of the divided portions while changing the angular phase by a predetermined number of sheets, and a crimped portion forming means for forming a crimped portion at a predetermined portion of the core pieces of the overlapping iron thin plates, Rotating and laminating means for forming a cylindrical laminated iron core in which the divided portions are positioned on one line by laminating the iron core thin plates while relatively rotating a predetermined number of sheets.

また、請求項5の発明に係る順送り金型装置は、複数のコア片と、当該複数のコア片の外周側を連結する複数の連結部とを有する環状の鉄心薄板を帯状薄鋼板から順次打抜く順送り金型装置であって、特定の鉄心薄板に対し、前記連結部の1つを分断する分断部を、所定枚数ずつ角度位相を変化させながら形成する第1の分断部形成手段と、特定のものを除く鉄心薄板に対し、前記連結部の全てに当該連結部を分断する分断部を形成する第2の分断部形成手段と、重なり合う鉄心薄板のコア片の所定部位に加締め部を形成する加締め部形成手段と、前記鉄心薄板を所定枚数ずつ相対回転させながら積層することにより、分断部が一線上に位置した筒状の積層鉄心を形成する回転積層手段とを備えたことを特徴とする。
In addition, the progressive mold apparatus according to the invention of claim 5 sequentially punches an annular core thin plate having a plurality of core pieces and a plurality of connecting portions for connecting the outer peripheral sides of the plurality of core pieces from a strip-like thin steel plate. A progressive die device for unloading, a first cut portion forming means for forming a cut portion for cutting one of the connecting portions with respect to a specific iron sheet while changing the angle phase by a predetermined number of times, and specifying 2nd part forming means for forming a split part for splitting the connecting part in all of the connecting parts, and a caulking part is formed at a predetermined part of the core piece of the overlapping iron core thin plate, And a laminating means for forming a cylindrical laminated iron core in which the dividing portions are positioned on a single line by laminating the iron core thin plates while relatively rotating a predetermined number of the core thin plates. And

請求項1の発明に係る電機子製造方法によれば、鉄心薄板を角度位相を変化させながら積層することにより、薄鋼板の板厚偏差によって積層鉄心の端面の平行度が低下することが防止される一方、積層鉄心を帯状に展開した状態でコア片の磁極部に巻線を施す(磁極に巻線を巻き回す、あるいは磁極部に巻線アセンブリを装着する)ことにより、磁極の本数や巻線の巻き量を容易に増大させることができる。また、請求項2の発明に係る電機子製造方法によれば、薄鋼板の板厚偏差による積層鉄心の端面の平行度を低下させず、かつ、磁極の本数や巻線の巻き量が大きい状態でスキューを有する電機子を製造できる。また、請求項3の発明に係る電機子製造方法によれば、積層鉄心を帯状に展開することや、積層鉄心を再び環状にすることが容易となり、製造効率等を向上させることができる。また、請求項4の発明に係る順送り金型装置によれば、板厚偏差の大きい薄鋼板を素材としても、端面の平行度が高く、かつ、連結部をもって帯状に展開可能な積層鉄心を得ることができる。また、請求項5の発明に係る順送り金型装置によれば、製造した積層鉄心を帯状に展開することが容易となり、電機子の製造効率等を向上させることができる。   According to the armature manufacturing method of the first aspect of the present invention, the parallelism of the end faces of the laminated iron core is prevented from being lowered due to the thickness deviation of the thin steel plate by laminating the iron core thin plates while changing the angular phase. On the other hand, by winding the magnetic pole part of the core piece in a state where the laminated iron core is spread in a strip shape (by winding the winding around the magnetic pole or mounting the winding assembly on the magnetic pole part), the number of the magnetic poles and the winding The amount of winding of the wire can be easily increased. According to the armature manufacturing method of the second aspect of the invention, the parallelism of the end face of the laminated iron core due to the thickness deviation of the thin steel plate is not reduced, and the number of magnetic poles and the winding amount of the winding are large. An armature having a skew can be manufactured. Moreover, according to the armature manufacturing method according to the third aspect of the present invention, it becomes easy to expand the laminated iron core in a strip shape, or to make the laminated iron core annular again, thereby improving production efficiency and the like. In addition, according to the progressive die apparatus according to the invention of claim 4, even if a thin steel plate having a large thickness deviation is used as a material, a laminated iron core having a high parallelism of end faces and capable of being developed in a strip shape with a connecting portion is obtained. be able to. Moreover, according to the progressive die apparatus which concerns on invention of Claim 5, it becomes easy to expand | deploy the manufactured laminated iron core in strip | belt shape, and can improve the manufacture efficiency of an armature, etc.

以下、図面を参照して、本発明を適用した回転電機(電動モータ)用のステータの製造方法の実施形態やその一部変形例を詳細に説明する。   Hereinafter, with reference to the drawings, an embodiment of a stator manufacturing method for a rotating electrical machine (electric motor) to which the present invention is applied and a partial modification thereof will be described in detail.

[第1実施形態]
図1は実施形態に係るステータの斜視図であり、図2は実施形態に係るストリップレイアウト図であり、図3は実施形態に係る鉄心薄板の平面図であり、図4は実施形態に係る分断部形成機構の概略構造図であり、図5は実施形態に係る外形打抜き/回転積層機構の概略構造図であり、図6は実施形態に係るステータの製造工程を示す説明図である。
[First Embodiment]
1 is a perspective view of a stator according to the embodiment, FIG. 2 is a strip layout diagram according to the embodiment, FIG. 3 is a plan view of an iron core thin plate according to the embodiment, and FIG. 4 is a division according to the embodiment. FIG. 5 is a schematic structural diagram of a part forming mechanism, FIG. 5 is a schematic structural diagram of an outer punching / rotating lamination mechanism according to the embodiment, and FIG. 6 is an explanatory view showing a manufacturing process of the stator according to the embodiment.

≪ステータ≫
図1に示すように、ステータ(電機子)1は、複数(本実施形態では、8つ)のコア片2を連結部3によって連結してなる円筒状のステータコア(筒状積層鉄心)4と、各コア片2の内周側に突設された磁極5に施された巻線6とから構成されている。連結部3の1つには分断線7が設けられているが、この分断線7に臨むステータコア4の両端面4a,4bは、レーザ溶接等によって接合されている。なお、図1中の符号8は、各コア片2に形成された半円形状の切込みを示す。
≪Stator≫
As shown in FIG. 1, a stator (armature) 1 includes a cylindrical stator core (cylindrical laminated iron core) 4 formed by connecting a plurality of (in this embodiment, eight) core pieces 2 by a connecting portion 3. , And a winding 6 applied to the magnetic pole 5 projecting from the inner peripheral side of each core piece 2. One of the connecting portions 3 is provided with a dividing line 7, and both end faces 4 a and 4 b of the stator core 4 facing the dividing line 7 are joined by laser welding or the like. In addition, the code | symbol 8 in FIG. 1 shows the semicircle-shaped cut formed in each core piece 2. In FIG.

≪ステータコアの製造工程≫
本実施形態では、図2に示すように、順送り金型装置内で帯状の薄鋼板Wに対して各種のプレス加工を施し、図3に示す鉄心薄板10をかたちづくった後、所定枚数の鉄心薄板10を積層固着することによってステータコア4を製造する。
≪Stator core manufacturing process≫
In this embodiment, as shown in FIG. 2, various pressing processes are performed on the strip-shaped thin steel sheet W in the progressive die apparatus to form the core thin sheet 10 illustrated in FIG. 3, and then a predetermined number of sheets are formed. The stator core 4 is manufactured by laminating and fixing the iron core thin plates 10.

薄鋼板Wには、順送り金型装置内で間欠送りされながら、以下に記す第1工程〜第9工程の加工が順次施され、第9工程に設けられた下型34(後述)からステータコア4が排出される。なお、図2中の符号60は、薄鋼板Wに上下に穿設された送り用のパイロット孔を示す。
(1)第1工程・・・連結部53の内周縁を形成する内側逃げ孔61の打抜き
(2)第2工程・・・連結部53の外周縁を形成する外側逃げ孔62の打抜き
(3)第3工程・・・磁極部55を形成するスロット63の打抜き
(4)第4工程・・・連結部53の1つを分断する分断部57の形成
(5)第5工程・・・内側逃げ孔61の内周部分を切断する半円形状の切込部58の形成
(6)第6工程・・・積層される1枚目の鉄心薄板10に対し、加締め用の計量孔66の打抜き
(7)第7工程・・・磁極部55の内周縁を形成する内径67の打抜き
(8)第8工程・・・積層される2枚目以降の鉄心薄板10に対し、加締め用の突起68の形成
(9)第9工程・・・鉄心薄板10の外縁を形成する外形打抜き、下型34内での回転積層および加締め
なお、第4工程を除くプレス加工は順送り金型内のパンチ/ダイにより行われるが、その構成が公知のものであるため、本実施形態ではそれらの図示は行わない。
The thin steel plate W is subjected to processing in the following first to ninth steps sequentially while being intermittently fed in a progressive die apparatus, and the stator core 4 from a lower die 34 (described later) provided in the ninth step. Is discharged. Note that reference numeral 60 in FIG. 2 indicates a pilot hole for feeding formed in the thin steel plate W vertically.
(1) First step: punching of the inner escape hole 61 forming the inner peripheral edge of the connecting portion 53 (2) Second step: punching of the outer escape hole 62 forming the outer peripheral edge of the connecting portion 53 (3 ) Third step: punching of the slot 63 for forming the magnetic pole portion 55 (4) Fourth step: formation of the dividing portion 57 for dividing one of the connecting portions 53 (5) Fifth step: inside Formation of a semicircular cut portion 58 for cutting the inner peripheral portion of the escape hole 61 (6) Sixth step: A measuring hole 66 for caulking is formed on the first core thin plate 10 to be laminated. Punching (7) Seventh step: punching inner diameter 67 that forms the inner periphery of magnetic pole part 55 (8) Eighth step: For caulking the second and subsequent core thin plates 10 to be laminated Formation of protrusions (9) Ninth step: external punching that forms the outer edge of the iron core thin plate 10, rotational lamination in the lower die 34, and Tighten Although pressing except fourth step is performed by a punch / die in progressive die, since its configuration is of known, in the present embodiment does not perform those illustrated.

<分断部形成機構>
工程の上型32内には、図4にその概略構造を示す分断部形成機構22が、180°の角度間隔で一対設けられている。両分断部形成機構22は、分断パンチ23や、カム24、流体シリンダ25等からそれぞれ構成されており、分断パンチ23を交互に進入させることにより、1枚ごとに角度が180°ずつずれた位置で鉄心薄板10に分断部57を形成する。
<Partition formation mechanism>
In the upper mold 32 of the fourth step, a pair of split part forming mechanisms 22 whose schematic structure is shown in FIG. 4 are provided at an angular interval of 180 °. The both split part forming mechanisms 22 are each composed of a split punch 23, a cam 24, a fluid cylinder 25, and the like. By alternately entering the split punches 23, the positions are shifted from each other by 180 °. Then, the dividing portion 57 is formed in the iron core thin plate 10.

<外形打抜き/回転積層機構>
工程には、図5にその概略構造を示す外形打抜き/回転積層機構31が設けられている。外形打抜き/回転積層機構31は、上型32に設置された外形打抜きパンチ33と、下型34に回転自在に支持されたスクイズリング35と、スクイズリング35の上部に内嵌したダイ36と、図示しないウォーム減速機構(あるいは、プーリとタイミングベルトによる回転駆動機構等)を介してスクイズリング35を回転駆動するモータ37等から構成されている。外形打抜き/回転積層機構31では、薄鋼板Wから鉄心薄板10が一枚ずつダイ36内に打抜かれると同時に、スクイズリング35が分断部形成機構22と連動して180°ずつ間欠回転する。これにより、各鉄心薄板10は、スクイズリング35内で加締め用の計量孔66および突起68によって加締められ、所定枚数積層されてステータコア4となる。下型34(スクイズリング35)から排出されたステータコア4では、素材である薄鋼板Wに板厚偏差があっても両端面の平行度が確保されるとともに、分断部57が一線上(垂直線上)に位置して分断線7が形成される。
<Outline punching / Rotating lamination mechanism>
In the ninth step, an outer punching / rotating lamination mechanism 31 whose schematic structure is shown in FIG. 5 is provided. The outer punching / rotating lamination mechanism 31 includes an outer punching punch 33 installed on the upper die 32, a squeeze ring 35 rotatably supported by the lower die 34, a die 36 fitted inside the squeeze ring 35, The motor 37 etc. which rotationally drive the squeeze ring 35 via the worm deceleration mechanism (or the rotational drive mechanism by a pulley and a timing belt) etc. which are not shown in figure are comprised. In the outer punching / rotation laminating mechanism 31, the core thin plates 10 are punched one by one from the thin steel plate W into the die 36, and at the same time, the squeeze ring 35 is intermittently rotated by 180 ° in conjunction with the dividing portion forming mechanism 22. Accordingly, each iron core thin plate 10 is crimped by the measuring hole 66 and the protrusion 68 for crimping in the squeeze ring 35, and a predetermined number of layers are laminated to form the stator core 4. In the stator core 4 discharged from the lower die 34 (squeeze ring 35), the parallelism of both end faces is ensured even if there is a thickness deviation in the thin steel plate W as the material, and the dividing portion 57 is on one line (on the vertical line) ), The dividing line 7 is formed.

≪ステータの製造工程≫
順送り金型装置によって製造されたステータコア4は、図6(a)に示すように分断線7から開かれ、各連結部3を塑性変形させることで帯状に展開される。展開されたステータコア4は、図6(b)に示すように巻線治具(図示せず)によって各磁極5に巻線が施された後、図6(c)に示すように再び環状に戻されて分断線7を挟んで対峙する両端面4a,4bがレーザ溶接によって接合される。なお、本実施形態では、連結部3の内周側に半円形状の切込み8を設けたため、展開したステータコア4を環状に戻した際のずれが生じ難くなった。
≪Stator manufacturing process≫
The stator core 4 manufactured by the progressive die apparatus is opened from the dividing line 7 as shown in FIG. 6A, and is developed into a belt shape by plastically deforming each connecting portion 3. The developed stator core 4 is wound around each magnetic pole 5 by a winding jig (not shown) as shown in FIG. 6 (b), and then again in an annular shape as shown in FIG. 6 (c). Both end faces 4a and 4b that are returned and face each other across the dividing line 7 are joined by laser welding. In the present embodiment, since the semicircular cut 8 is provided on the inner peripheral side of the connecting portion 3, it is difficult to cause a shift when the developed stator core 4 is returned to an annular shape.

本実施形態では、このような構成を採ったことにより、順送り金型装置を徒に大型化せずに、両端面の平行度が高く、かつ、磁極5の本数や巻線6の巻き量が多いステータ1を効率的に製造することができるようになった。   In this embodiment, by adopting such a configuration, without increasing the size of the progressive die device, the parallelism of both end faces is high, the number of magnetic poles 5 and the winding amount of the winding 6 are increased. A large number of stators 1 can be efficiently manufactured.

[一部変形例]
図7は第1変形例に係るストリップレイアウト図であり、図8は第2変形例に係るストリップレイアウト図である。
[Partial modification]
FIG. 7 is a strip layout diagram according to the first modification, and FIG. 8 is a strip layout diagram according to the second modification.

第1変形例は、上述した実施形態と略同様の構成を採っているが、分断部形成機構22が、90°の角度間隔で4つ設けられており、分断パンチ23が順番に進入することにより、鉄心薄板10には1枚ごとに角度が90°ずつずれた位置で分断部57が形成される。そして、外形打抜き/回転積層機構31では、薄鋼板Wから鉄心薄板10が一枚ずつダイ36内に打抜かれると同時に、スクイズリング35が分断部形成機構22と連動して90°ずつ間欠回転する。これにより、各鉄心薄板10の分断部57が一線上(この場合は、垂直線上)に位置し、加締め用の計量孔66および突起68によって各鉄心薄板10が結合/一体化される。そして、下型34(スクイズリング35)から排出されたステータコア4では、素材である薄鋼板Wに板厚偏差があっても、両端面の平行度がより一層向上する。   The first modified example adopts substantially the same configuration as that of the above-described embodiment, but four divided portion forming mechanisms 22 are provided at an angular interval of 90 °, and the divided punches 23 enter in order. Thereby, the dividing part 57 is formed in the iron core thin plate 10 in the position where the angle shifted | deviated 90 degree | times for every sheet. In the outer punching / rotation laminating mechanism 31, the iron core thin plate 10 is punched one by one from the thin steel plate W into the die 36, and at the same time, the squeeze ring 35 is intermittently rotated by 90 ° in conjunction with the dividing portion forming mechanism 22. To do. Thereby, the division part 57 of each iron core thin plate 10 is located on one line (in this case, on a vertical line), and each iron core thin plate 10 is couple | bonded / integrated by the measuring hole 66 and protrusion 68 for caulking. And in the stator core 4 discharged | emitted from the lower mold | type 34 (squeeze ring 35), even if there is a plate | board thickness deviation in the thin steel plate W which is a raw material, the parallelism of both end surfaces improves further.

また、第2変形例も、上述した実施形態と略同様の構成を採っているが、9つの磁極部55(すなわち、ステータコア4の磁極5)を有するとともに、分断部形成機構22が、120°の角度間隔で3つ設けられている。第2変形例では、分断部形成機構22の分断パンチ23が順番に進入することにより、鉄心薄板10には1枚ごとに角度が120°ずつずれた位置で分断部57が形成される。そして、外形打抜き/回転積層機構31では、薄鋼板Wから鉄心薄板10が一枚ずつダイ36内に打抜かれると同時に、スクイズリング35が分断部形成機構22と連動して120°ずつ間欠回転する。これにより、各鉄心薄板10の分断部57が一線上(この場合は、垂直線上)に位置し、加締め用の計量孔66および突起68によって各鉄心薄板10が結合/一体化される。そして、下型34(スクイズリング35)から排出されたステータコア4では、素材である薄鋼板Wに板厚偏差があっても、やはり両端面の平行度がより一層向上する。   The second modified example also has a configuration substantially similar to that of the above-described embodiment, but has nine magnetic pole portions 55 (that is, the magnetic pole 5 of the stator core 4), and the dividing portion forming mechanism 22 is 120 °. Three are provided at an angular interval of. In the second modified example, when the dividing punch 23 of the dividing part forming mechanism 22 enters in order, the dividing part 57 is formed in the iron sheet 10 at a position where the angle is shifted by 120 ° for each sheet. In the outer punching / rotation laminating mechanism 31, the iron core thin plate 10 is punched one by one from the thin steel plate W into the die 36, and at the same time, the squeeze ring 35 is intermittently rotated by 120 ° in conjunction with the dividing portion forming mechanism 22. To do. Thereby, the division part 57 of each iron core thin plate 10 is located on one line (in this case, on a vertical line), and each iron core thin plate 10 is couple | bonded / integrated by the measuring hole 66 and protrusion 68 for caulking. And in the stator core 4 discharged | emitted from the lower mold | type 34 (squeeze ring 35), even if there is a plate | board thickness deviation in the thin steel plate W which is a raw material, the parallelism of both end surfaces will improve further.

[第2実施形態]
次に、先に説明した図2,図7,図8の各レイアウト図に基づき、本発明の第2実施形態を説明する。
上述した実施例や一部変形例は、各コア片2が連結部3で一体に連結された環状の鉄心薄板10を所定枚数回転積層し、1箇所の分断線形成位置で展開するものであったが、第2実施形態では、例えば両端側の1枚あるいは2〜3枚の鉄心薄板10(特定の鉄心薄板)のみが1箇所の分断部57で分断されており、他の鉄心薄板10については各コア片2ごとに分断された状態で積層される。これによって、環状のステータコア4を帯状に展開したり、また逆に帯状から環状へ戻す際に容易に変形させることができる。このようなステータコア4を製造する場合には、実施例としての図面は改めて提示しないが、前記各レイアウト図において、分断線形成工程を変更するだけで可能である。すなわち、例えば図2では、分断線形成工程(4)における分断線形成機構22を全ての連結部3を分断するように設けることにより可能になる。これらの分断線形成機構22は、いずれも図4に示すような分断パンチ23の出入り制御機構と同じ機構を有しており、個別に打抜き制御される。
[Second Embodiment]
Next, a second embodiment of the present invention will be described based on the layout diagrams of FIGS. 2, 7, and 8 described above.
In the above-described embodiments and some modified examples, a predetermined number of annular core thin plates 10 in which the core pieces 2 are integrally connected by the connecting portion 3 are rotated and stacked, and deployed at one parting line forming position. However, in the second embodiment, for example, only one or two or three iron core thin plates 10 (specific iron core thin plates) at both ends are divided by one dividing portion 57. Are laminated in a state of being divided for each core piece 2. Thereby, the annular stator core 4 can be easily deformed when it is developed into a band shape or when it is returned from the belt shape to the ring shape. When such a stator core 4 is manufactured, drawings as examples are not presented again, but it is possible only by changing the dividing line forming process in each of the layout diagrams. That is, for example, in FIG. 2, it becomes possible by providing the dividing line forming mechanism 22 in the dividing line forming step (4) so as to divide all the connecting portions 3. Each of these dividing line forming mechanisms 22 has the same mechanism as the entering / exiting control mechanism of the dividing punch 23 as shown in FIG. 4, and is individually punched and controlled.

実際の製造においては、鉄心薄板10の最初の1枚あるいは複数枚は、連結部3の1つのみを分断する形で形成し、その後の所定枚数分については前述した全ての分断線形成機構22をONさせ、分断パンチ23を打抜き位置に前進させて、全ての連結部3に分断部57を形成する。所定枚数の鉄心薄板10に対して全ての連結部3における分断部57の形成が終了すると、鉄心薄板10の最後の1枚あるいは複数枚に対して、所定の連結部3に対する以外の分断線形成機構22をOFFさせて分断パンチ23を後退させる。このような順序で加工が行われていき、外形打抜き積層工程において、前述の実施例と同様に回転積層されていく。この時本実施例においては、外形打抜きにより全ての連結部3に分断部57が形成された鉄心薄板10はコア片2が分断されることになるが、実際には前述したかしめ結合手段により重なり合うコア片2が結合/一体化されているので、一体化された状態で積層されていく。このように、積層方向の中間部分について完全分離したコア片2が積層された形態のステータコア4が製造される。説明の中では両端側のみ連結したステータコア4としたが、それに限定されず、所定枚数毎に完全分離されたコア片2が位置するような形態も可能である。金型装置としては、前述した構造に対して、全ての連結部3を分断するように分断線形成機構22を設ければよい。なお、製品外形が小さいような場合には工程を分けて設けてもよい。 In actual manufacturing, the first sheet or a plurality of the iron core thin plates 10 are formed in such a manner that only one of the connecting portions 3 is divided, and all of the above-described dividing line forming mechanisms 22 for a predetermined number of sheets thereafter. Is turned ON, and the dividing punch 23 is advanced to the punching position to form the dividing portions 57 in all the connecting portions 3. When the formation of the dividing portions 57 in all the connecting portions 3 with respect to the predetermined number of the iron core thin plates 10 is completed, the dividing line other than the predetermined connecting portion 3 is formed on the last sheet or a plurality of the iron core thin plates 10. The mechanism 22 is turned off and the dividing punch 23 is moved backward. Processing is performed in such an order, and in the outer punching and stacking step, rotation stacking is performed in the same manner as in the above-described embodiment. At this time, in the present embodiment, the core thin plate 10 in which the dividing portions 57 are formed in all the connecting portions 3 by the outer shape punching, the core piece 2 is divided. Since the core pieces 2 are joined / integrated, they are laminated in an integrated state. Thus, the stator core 4 in the form in which the core pieces 2 completely separated at the intermediate portion in the stacking direction are stacked is manufactured. In the description, the stator core 4 is connected only at both ends. However, the present invention is not limited to this, and a configuration in which the core pieces 2 that are completely separated for each predetermined number of sheets is also possible. As a mold apparatus, a dividing line forming mechanism 22 may be provided so as to divide all the connecting portions 3 with respect to the structure described above. If the product outer shape is small, the steps may be provided separately.

以上で具体的実施形態の説明を終えるが、本発明の態様はこの実施形態に限られるものではない。例えば、上記実施形態は、本発明を電動モータのステータに適用したものであるが、電動モータのロータ等に適用してもよいし、発電機のステータやロータに適用してもよい。また、上記実施形態ではコア片に形成された磁極に巻線を施すようにしたが、各コア片の内周に形成された磁極部に巻線アセンブリを取り付ける構成としてもよい。また、上記実施形態や一部変形例では、それぞれ180°,90°,120°ずつ角度をずらしながら分断部を形成するものとしたが、360°を整数で除した角度ずつずらしながら分断部を形成するようにしてもよい。また、第9工程で回転角度は板厚偏差を解消するためのものを説明したが、それに限定されず、さらに鉄心薄板を1枚(所定枚数)打抜く毎に微小角度ずつ回転を付加して鉄心の特性を向上させるためのスキューを付与することが可能である。その他、鉄心薄板の具体的形状や加締めの方法等についても、上記実施形態での例示に限られるものではなく、本発明の主旨を逸脱しない範囲であれば適宜変更可能である。   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 stator of an electric motor, but may be applied to a rotor or the like of an electric motor, or may be applied to a stator or rotor of a generator. In the above embodiment, the winding is applied to the magnetic pole formed on the core piece. However, the winding assembly may be attached to the magnetic pole portion formed on the inner periphery of each core piece. Further, in the above embodiment and some modified examples, the dividing portion is formed while shifting the angle by 180 °, 90 °, and 120 °, respectively. However, the dividing portion is shifted while shifting the angle by 360 ° divided by an integer. You may make it form. In the ninth step, the rotation angle has been described for eliminating the thickness deviation, but the present invention is not limited to this. Further, every time a single core sheet (predetermined number) is punched, a rotation is added by a minute angle. It is possible to impart a skew for improving the characteristics of the iron core. In addition, the specific shape of the iron core thin plate, the caulking method, and the like are not limited to the examples in the above embodiment, and can be changed as appropriate without departing from the gist of the present invention.

実施形態に係るステータの斜視図である。It is a perspective view of the stator which concerns on embodiment. 実施形態に係るストリップレイアウト図である。It is a strip layout figure concerning an embodiment. 実施形態に係る鉄心薄板の平面図である。It is a top view of the iron core thin plate concerning an embodiment. 実施形態に係る分断部形成機構の概略構造図である。It is a schematic structure figure of the parting part formation mechanism concerning an embodiment. 実施形態に係る外形打抜き/回転積層機構の概略構造図である。It is a schematic structure figure of the external punching / rotation lamination mechanism concerning an embodiment. 実施形態に係るステータの製造工程を示す説明図である。It is explanatory drawing which shows the manufacturing process of the stator which concerns on embodiment. 第1変形例に係るストリップレイアウト図である。It is a strip layout figure concerning the 1st modification. 第2変形例に係るストリップレイアウト図である。It is a strip layout figure concerning the 2nd modification.

符号の説明Explanation of symbols

1 ステータ
2 コア片
3 連結部
4 ステータコア
5 磁極
6 巻線
7 分断線
10 鉄心薄板
57 分断部
21 上型
22 分断部形成機構
31 回転積層機構
W 薄鋼板
DESCRIPTION OF SYMBOLS 1 Stator 2 Core piece 3 Connection part 4 Stator core 5 Magnetic pole 6 Winding 7 Dividing line 10 Iron core thin plate 57 Dividing part 21 Upper mold | type 22 Dividing part formation mechanism 31 Rotation lamination mechanism W Thin steel plate

Claims (5)

巻線を施した磁極を筒状積層鉄心の内周側に形成してなる電機子を製造する方法であって、
複数のコア片と、当該複数のコア片の外周側を連結する複数の連結部とを有する環状の鉄心薄板を帯状薄鋼板から順次打抜く工程と、
重なり合う鉄心薄板のコア片を結合するための加締め結合手段を当該コア片に形成する工程と、
上型内に所定の角度間隔で配置されるとともに分断と非分断とを切り換えることができる複数の分断部形成機構を用い、前記鉄心薄板に対し、前記連結部の1つを分断する分断部を、所定枚数ずつ角度位相を変化させながら形成する工程と、
前記鉄心薄板を外形打抜きするとともに、当該鉄心薄板を所定枚数ずつ相対回転させながら積層することにより、前記分断部が一線上に位置してなる分断線をコア片間に備えた筒状の積層鉄心を形成する工程と、
前記積層鉄心を、前記分断線から開き、前記複数の連結部を塑性変形させることで帯状に展開する工程と、
展開した積層鉄心のコア片の内周側にあたる磁極部に巻線を施す工程と、
前記磁極が形成された積層鉄心を再び環状にする工程と、
環状に戻した積層鉄心での、前記分断線を挟んで対峙する両端面を接合する工程と
を含むことを特徴とする電機子製造方法。
A method of manufacturing an armature in which a magnetic pole subjected to winding is formed on the inner peripheral side of a cylindrical laminated iron core,
A step of sequentially punching an annular core thin plate having a plurality of core pieces and a plurality of connecting portions that connect outer peripheral sides of the plurality of core pieces from the strip-shaped thin steel plate,
Forming a caulking coupling means on the core piece for coupling the core pieces of overlapping iron core thin plates;
Using a plurality of divided portion forming mechanisms that are arranged in the upper mold at predetermined angular intervals and can be switched between divided and non-divided, a divided portion that divides one of the connecting portions with respect to the iron core thin plate A step of changing the angle phase by a predetermined number of times, and
A cylindrical laminated iron core having a dividing line between the core pieces, in which the dividing part is positioned on one line by punching the outer shape of the iron core sheet and laminating the core sheet while rotating relative to each other by a predetermined number of sheets. Forming a step;
Opening the laminated iron core from the dividing line, and plastically deforming the plurality of connecting portions to develop a belt shape; and
Winding the magnetic pole part corresponding to the inner peripheral side of the core piece of the developed laminated core;
Re-annularizing the laminated iron core on which the magnetic pole is formed;
And a step of joining both end faces facing each other across the dividing line in the laminated core returned to an annular shape.
前記相対回転は、前記積層鉄心に所定量のスキューを与える角度をもって行われることを特徴とする、請求項1に記載された電機子製造方法。   The armature manufacturing method according to claim 1, wherein the relative rotation is performed at an angle that gives a predetermined amount of skew to the laminated core. 巻線を施した磁極を筒状積層鉄心の内周側に形成してなる電機子を製造する方法であって、
複数のコア片と、当該複数のコア片の外周側を連結する複数の連結部とを有する環状の鉄心薄板を帯状薄鋼板から順次打抜く工程と、
重なり合う鉄心薄板のコア片を結合するための加締め結合手段を当該コア片に形成する工程と、
特定の鉄心薄板に対し、前記連結部の1つを分断する分断部を、所定枚数ずつ角度位相を変化させながら形成する工程と、
特定のものを除く鉄心薄板に対し、前記連結部の全てに当該連結部を分断する分断部を形成する工程と、
前記鉄心薄板を外形打抜きするとともに、当該鉄心薄板を所定枚数ずつ相対回転させながら積層することにより、分断部が一線上に位置してなる分断線をコア片間に備えた筒状の積層鉄心を形成する工程と、
前記積層鉄心を、前記分断線から開き、前記複数の連結部を塑性変形させることで帯状に展開する工程と、
展開した積層鉄心のコア片の内周側にあたる磁極部に巻線を施す工程と、
前記磁極が形成された積層鉄心を再び環状にする工程と、
環状に戻した積層鉄心での、前記分断線を挟んで対峙する両端面を接合する工程と
を含むことを特徴とする電機子製造方法。
A method of manufacturing an armature in which a magnetic pole subjected to winding is formed on the inner peripheral side of a cylindrical laminated iron core,
A step of sequentially punching an annular core thin plate having a plurality of core pieces and a plurality of connecting portions that connect outer peripheral sides of the plurality of core pieces from the strip-shaped thin steel plate,
Forming a caulking coupling means on the core piece for coupling the core pieces of overlapping iron core thin plates;
Forming a dividing portion for dividing one of the connecting portions with respect to a specific iron core thin plate while changing the angle phase by a predetermined number of times;
For the iron core thin plate excluding a specific one, a step of forming a dividing portion for dividing the connecting portion in all of the connecting portions ;
A cylindrical laminated iron core having a dividing line in which a dividing part is located on one line is provided between core pieces by punching the outer shape of the iron core sheet and laminating the iron sheet sheet while relatively rotating a predetermined number of sheets. Forming, and
Opening the laminated iron core from the dividing line, and plastically deforming the plurality of connecting portions to develop a belt shape; and
Winding the magnetic pole part corresponding to the inner peripheral side of the core piece of the developed laminated core;
Re-annularizing the laminated iron core on which the magnetic pole is formed;
And a step of joining both end faces facing each other across the dividing line in the laminated core returned to an annular shape.
複数のコア片と、当該複数のコア片の外周側を連結する複数の連結部とを有する環状の鉄心薄板を帯状薄鋼板から順次打抜く順送り金型装置であって、
上型内に所定の角度間隔で配置されるとともに分断と非分断とを切り換えることができる複数の分断部形成機構を用い、前記鉄心薄板に対し、前記連結部の1つを分断する分断部を、所定枚数ずつ角度位相を変化させながら形成する分断部形成手段と、
重なり合う鉄心薄板のコア片の所定部位に加締め部を形成する加締め部形成手段と、
前記鉄心薄板を所定枚数ずつ相対回転させながら積層することにより、前記分断部が一線上に位置した筒状の積層鉄心を形成する回転積層手段と
を備えたことを特徴とする順送り金型装置。
A progressive mold apparatus for sequentially punching an annular core thin plate having a plurality of core pieces and a plurality of connecting portions connecting the outer peripheral sides of the plurality of core pieces from a strip-shaped thin steel plate,
Using a plurality of divided portion forming mechanisms that are arranged in the upper mold at predetermined angular intervals and can be switched between divided and non-divided, a divided portion that divides one of the connecting portions with respect to the iron core thin plate , A dividing portion forming means for forming while changing the angle phase by a predetermined number of sheets,
A caulking portion forming means for forming a caulking portion at a predetermined portion of the core pieces of the overlapping iron core thin plates;
A progressive mold apparatus, comprising: a rotating lamination means for forming a cylindrical laminated iron core in which the divided portions are positioned on a single line by laminating the iron core thin plates while rotating by a predetermined number of sheets.
複数のコア片と、当該複数のコア片の外周側を連結する複数の連結部とを有する環状の鉄心薄板を帯状薄鋼板から順次打抜く順送り金型装置であって、
特定の鉄心薄板に対し、前記連結部の1つを分断する分断部を、所定枚数ずつ角度位相を変化させながら形成する第1の分断部形成手段と、
特定のものを除く鉄心薄板に対し、前記連結部の全てに当該連結部を分断する分断部を形成する第2の分断部形成手段と、
重なり合う鉄心薄板のコア片の所定部位に加締め部を形成する加締め部形成手段と、
前記鉄心薄板を所定枚数ずつ相対回転させながら積層することにより、分断部が一線上に位置した筒状の積層鉄心を形成する回転積層手段と
を備えたことを特徴とする順送り金型装置。
A progressive mold apparatus for sequentially punching an annular core thin plate having a plurality of core pieces and a plurality of connecting portions connecting the outer peripheral sides of the plurality of core pieces from a strip-shaped thin steel plate,
A first divided portion forming means for forming a divided portion for dividing one of the connecting portions with respect to a specific iron core thin plate while changing the angle phase by a predetermined number of times;
For the iron core thin plate excluding a specific one, a second divided portion forming means for forming a divided portion for dividing the connecting portion in all of the connecting portions ;
A caulking portion forming means for forming a caulking portion at a predetermined portion of the core pieces of the overlapping iron core thin plates;
A progressive metal mold apparatus comprising: a rotating and laminating unit that forms a cylindrical laminated iron core in which a dividing portion is positioned on one line by laminating the iron core thin plates while relatively rotating a predetermined number of sheets.
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