JP5291774B2 - Manufacturing method and manufacturing apparatus of laminated iron core - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a lamination core for industrially manufacturing the lamination core where winding to a magnetic pole portion can be performed with high density and manufacturing the lamination core with sufficient productivity from a core piece which is not divided and to provide a manufacturing device of the lamination core. <P>SOLUTION: Processed boards are sequentially made to pass through a press mold line having a plurality of processing stations. A core piece 14 having a plurality of magnetic pole piece portions 16 whose both sides are formed by adjacent slots 20 are blanked. The core piece 14 is caulked/laminated via a caulking portion 17 which is previously formed so as to form the lamination core 10. In the manufacturing method, each slot 20 is divided in a circumferential direction and a half slot 27 on one side is punched and formed by a first punch and a die, and a half slot 28 on the other side, which is partially lapped on the half slot of the one side is punched and formed by a second punch and a die. <P>COPYRIGHT: (C)2012,JPO&amp;INPIT

Description

The present invention relates to a method and a manufacturing apparatus for manufacturing a laminated core (stator or rotor) used for a motor or a generator by effectively using a core material.

As shown in FIG. 4A, the winding of the laminated core to the magnetic pole part 70 is facilitated by making the annular laminated core into a divided laminated core 72 in which the yoke part 71 is divided for each magnetic pole part 70. In addition, it can be wound with high density. However, as shown in FIG. 4B, which is a YY cross section of FIG. 4A, the winding 73 is workable, but when it is wound around the magnetic pole portion 70, the magnetic pole upper end portion 74 and Clearances 76 and 77 are formed in the magnetic pole lower end 75, and the winding density cannot be further increased. In particular, there is a problem that when the thick winding is wound around the magnetic pole portion 70 so as to reduce the copper loss of the motor, the gap is generated wider.

As a technique for coping with this problem, Patent Document 1 discloses a magnetic pole portion 78 of a laminated iron core as shown in FIG. 5B, and an upper end portion 79 and a lower end portion as seen from a cross section as shown in FIG. The width of 80 is gradually reduced. According to this, the winding to the magnetic pole part 78 can be wound without generating a gap in the upper end part 79 and the lower end part 80.

JP 2005-348553 A

However, Patent Document 1 does not clearly disclose the industrial manufacturing method of the laminated core, and there is a problem to develop a method for industrially manufacturing at low cost. In addition, since the laminated core is configured by connecting the divided laminated cores, it is necessary to assemble using a special jig or the like, and punching out the core pieces with a press mold apparatus to directly manufacture the laminated core. There is a problem that cannot be done.

The present invention has been made in view of such circumstances, and industrially manufactures a laminated core capable of high density winding to a magnetic pole part, and manufactures a laminated core with high productivity from undivided core pieces. And an apparatus for manufacturing the laminated core.

According to the first aspect of the invention, there is provided a method for manufacturing a laminated iron core, wherein a workpiece plate is sequentially passed through a press mold line having a plurality of processing stations, and a plurality of magnetic poles having both sides formed by adjacent slots. In the manufacturing method of a laminated core, in which an iron core piece provided with a piece is removed from the outer shape, and the iron core piece is formed by caulking and stacking via a pre-formed caulking part,
The regions forming the slots are each divided in the circumferential direction, the one side region is punched with a first punch and die, and the other side region is secondly wrapped so as to partially wrap around the one side region . wherein in must be unplugged strike by the punch and die to form a respective slot.
The circumferential widths of the first and second punches and dies forming one side of each slot preferably have a circumferential width that is at least half of the slot having the maximum circumferential width.

A method for manufacturing a laminated core according to a second aspect of the invention is the method for manufacturing a laminated core according to the first aspect, wherein the first and second punches and dies are used to punch and form the slots. A connecting slot for connecting the radially outer contour lines of the one side region and the other side region is formed at a position corresponding to the radially outer side at a central position of each slot.
And the manufacturing method of the laminated core which concerns on 3rd invention is a manufacturing method of the laminated core which concerns on 1st, 2nd invention, The said 1st punch and die | dye, The said 2nd punch and die | dye are the said, The distance between the first and second punches and the die is expanded and contracted by rotating about the axis of the iron core piece as the center of rotation.

According to a fourth aspect of the present invention, there is provided a laminated iron core manufacturing apparatus that sequentially passes a work plate through a plurality of processing stations and extrudes an iron core piece including a plurality of magnetic pole piece portions formed on both sides by adjacent slots. In the laminated core manufacturing apparatus for caulking and laminating the iron core pieces via a pre-formed caulking portion,
The split in each circumferential region forming each slot, in the processing station, includes a disconnect Ku first punch and die out each area of the divided one side, about the axis of the core pieces a first slot punching station for punching the areas of rotatable the one side, provided with a disconnect beat each region of the divided other side Ku second punch and die, which can be rotated about the axis of the core pieces A second slot punching station for punching the other side region .

The laminated core manufacturing apparatus according to a fifth aspect of the present invention is the laminated core manufacturing apparatus according to the fourth aspect of the present invention, wherein a radius is provided at a central position of the slot in a pre-process of the first and second slot punching stations. A connection slot forming station for forming a connection slot for connecting the regions on the one side and the other side is provided at a position corresponding to the outside in the direction.

4. The method of manufacturing a laminated core according to claim 1, wherein the first and second punches and dies are used to punch and form half slots (regions) on one side and the other side that determine the widths on both sides of the magnetic pole portion of the laminated core. Therefore, it is possible to manufacture core pieces having different widths in the circumferential direction of the slots.

In particular, in the method of manufacturing a laminated core according to claim 2, in the step before punching and forming the half slot with the first and second slots and the punch, the half slot is located at a position corresponding to the radially outer side at the center position of the slot. Therefore, the radially outer positions (that is, contours) of the half slots on one side and the other side are smoothly connected by the connecting slot.

In the method for manufacturing a laminated iron core according to claim 3, the first punch and the die and the second punch and the die rotate around the axis of the iron core piece as a center of rotation. Since the distance between the punch and the die is increased or decreased, the width of the magnetic pole portions on the lower layer side and the upper layer side can be controlled by simultaneously processing a plurality of slots in the circumferential direction.

The laminated core manufacturing apparatus according to claim 4 and 5 includes a first punch and a die that form a half slot on one side of the slot of the core piece from the work plate and are rotatable about the axis of the core piece. A first slot punching station, and a second slot punching station having a second punch and die which are formed by punching the other half slot of each slot and rotatable about the axis of the core piece. Since it is provided separately, the first and second punches and dies that form the half slots on one side and the other side are arranged without interference, and the circumference by these first and second punches and dies. Slots with different direction widths can be formed.
Further, since the first and second punches and die for punching the slot are separated, the press load can be dispersed.

In particular, in the laminated iron core manufacturing apparatus according to claim 5, the half slot is connected to a position corresponding to the outer side in the radial direction at the center position of the slot to the processing station in the previous step of the first and second slot punching stations. Since the connecting slot forming station for forming the connecting slot is provided, even if the radial positions of the first and second punches and the die are slightly different, the contour of the formed slot is smooth and accurate. Well connected.

(A) is a top view of the laminated iron core manufactured by the manufacturing method which concerns on one embodiment of this invention, (B) is arrow XX sectional drawing, (C) is arrow A figure. It is explanatory drawing which shows the process of the manufacturing method of the same laminated iron core. (A), (B) is explanatory drawing of the formation method of the slot of the same laminated iron core, respectively. (A), (B) is explanatory drawing of the laminated iron core which concerns on a prior art example. (A), (B) is explanatory drawing of the laminated iron core which concerns on a prior art example.

Subsequently, a manufacturing method and a manufacturing apparatus for a laminated core according to an embodiment of the present invention will be described with reference to the attached drawings to provide an understanding of the present invention.
First, a stator laminated iron core (an example of a laminated iron core) 10 to which a manufacturing method according to an embodiment of the present invention is applied will be described. As shown in FIG. 1 (A), the stator laminated core 10 has six magnetic pole portions 12 that are equally arranged in the circumferential direction inside an annular yoke portion 11. A rotor hole 13 into which the rotor is fitted is formed inside the magnetic pole portion 12. The laminated core 10 has a yoke piece 15 formed of a core piece 14 formed by stamping a magnetic strip 24 (see FIG. 2), which is an example of a processed plate having a thickness of 0.2 to 0.6 mm, by a press die. And a plurality of caulking portions (in this embodiment, V-shaped caulking is used) 17 formed in the magnetic pole piece portion 16 for caulking and lamination.

The cross section of the magnetic pole portion 12 is shown in FIG. 1B. The upper and lower magnetic pole piece portions 16 are narrowed with the stacking direction on top, and the upper and lower corner portions of the magnetic pole portion 12 are rounded. Yes. Further, as apparent from FIG. 1C, the inner end of the magnetic pole portion 12 has a magnetic pole tooth portion 18 that is widened, but this magnetic pole tooth portion 18 is also adjacent to the upper layer portion and the lower layer portion with a narrow width. The gap 19 of the magnetic pole tooth portion 18 is structured to gradually widen up and down.
In addition, a notch 21 is formed at the center in the circumferential direction outside the slot 20 forming the magnetic pole portion 12 in the radial direction. When the magnetic pole portion 12 is formed in this way, windings (that is, copper wires) can be smoothly applied to the magnetic pole portion 12, and the winding length can be saved with respect to the same number of windings.

Then, the manufacturing method and manufacturing apparatus of the laminated core which concern on one embodiment of this invention are demonstrated, referring FIG. 2, FIG.
This laminated core manufacturing apparatus 23 has a plurality of processing stations (A) to (J) that constitute a press mold line, and each processing station excluding an idle station includes a punch and a die paired with the punch. A die means comprising the combination of the above is provided, and a predetermined pressing process is performed on the magnetic sheet material 24 that is intermittently conveyed.

Pilot holes 25 are formed at predetermined intervals on both sides. Although this processing station is not shown in this embodiment, it is preferable to provide a station for punching and forming pilot holes 25 in a process preceding the processing station (A) of the manufacturing apparatus 23.
The processing station (A) is a connection slot forming station, and forms a connection slot 26 remaining as a notch 21 formed in the center in the circumferential direction on the radially outer side of the slot 20 of each core piece 14. It is sufficient that the width of the connecting slot 26 is 1 to 2 times the circumferential direction (maximum width−minimum width) of the magnetic pole portion 12 of the stator laminated core 10. The width in the radial direction is, for example, 0.05 to 0.5 mm with respect to the radially outer contour line 29 (see FIG. 1) of the finally formed slot 20. The processing station (B) is an idle station.

In the processing station (C) serving as the first slot punching station, punching of the half slot 27 on one side that has about half the area of each slot 20 and forms one side (clockwise direction) of the magnetic pole piece 16 is performed. Processing is performed using a first punch and die (not shown). When punching out the core piece 14 on the lower layer side in the initial stage of lamination of the stator laminated core 10 and the upper layer side in the final stage of lamination, it is necessary to narrow the width of the magnetic pole piece 16 toward the lower end side and the upper end side, respectively. Since the iron core pieces 14 are stacked from the bottom to the top, the punching of the iron core piece 14 at the lowermost end on the lower layer side is performed by placing the first punch and die on the magnetic pole piece portion 16 around the axis of the iron core piece 14. The rotation is performed counterclockwise by an angle θ degrees from the normal position. Here, as shown in FIG. 1 (A), when the arc angle at the position of the average radius r1 of the portion excluding the magnetic pole teeth 18 of one magnetic pole portion 12 is α degrees, θ degrees is, for example, 1/20 to 1/6 times is preferable. The regular position refers to the position where the half slot 27 on one side of the magnetic pole piece 16 having the normal width is formed.

In this processing station (C), the half slot 27 of the next core piece 14 is also punched. If n is the number of the lower-layer core pieces 14 that reduce the width of the magnetic pole piece 16, the number of θ / n degrees is 1 punch and die are returned (that is, rotated clockwise) to perform press working. The punching operation is performed on the iron core pieces 14 from the bottom to the nth while returning the first punch and die by θ / n degrees. In the n + 1-th iron core piece 14 from the bottom, the positions of the first punch and the die are the normal positions. Here, n is usually about 3 to 10 sheets, and the core piece 14 of the intermediate layer (that is, the core piece 14 excluding the upper layer portion and the lower layer portion) is half-slot 27 at the normal position (ie, θ = 0). Punching is performed.

For the upper-layer core piece 14, at this processing station (C), gradually move the first punch and die from the normal position to θ / m degrees (m is the number of the upper-layer core pieces 14, and normally m is n. Rotate in the counterclockwise direction (that is, the direction in which the width of the magnetic pole piece portion 16 is narrowed) by the same amount, but may be different, and finally punch the half slot 27 of the uppermost iron core piece 14 at a position of θ degrees. Finish processing.
Even if the half slot 27 punched and formed by the first punch and die is moved from the normal angular position to the maximum offset position (that is, θ-degree rotation), the outer edge in the radial direction becomes the connection slot 26. The size is determined so as to overlap. The details of the processing station (C) are shown in FIG.

The next station (D) is an idle station. In the processing station (E) serving as the second slot punching station, as shown in FIG. 3B, a half punch in the circumferential direction of the slot 20 of the core piece 14 is used by using a second punch and die (not shown). Punching of the other half slot 28 having the area is performed. In this case, the n-th lower-layer core pieces 14 from the lowermost part are biased by θ degrees in the clockwise direction from the normal position around the axis of the core piece 14 in the first core piece 14. The half-slot 28 is punched by moving the second punch and the die to a position where the magnetic pole piece 16 is finally narrowed to the smallest width. Then, in the second core piece 14 from the bottom, the second punch and die are moved in the normal position direction (that is, counterclockwise direction) by θ / n degrees, and punching of the half slot 28 is performed. When the above process is applied to the nth core piece 14 from the bottom, the half slot 28 of the (n + 1) th core piece is in the normal position. Here, the positions of the second punch and the die are fixed, and the half slot 28 of the iron core piece 14 of the required number of intermediate layers is punched as it is.

With respect to the m core pieces 14 in the upper layer portion, the second punch and die in the normal position are moved eccentrically by θ / m degrees (that is, rotated in the clockwise direction), and the half-slot 28 is gradually moved. Move the cut position clockwise. The second punch and die are symmetrical with the first punch and die. One slot 20 is formed by the two half slots 27 and 28. Then, both sides of the magnetic pole piece 16 are formed by the adjacent slots 20. The lower layer part and the upper layer part core piece 14 constituting the stator laminated core 10 have a slot 20 that becomes wider toward the lower end side and the upper end side, respectively, thereby reducing the width of the magnetic pole piece part 16.

The station (F) is an idle station, and the next processing station (G) is a station for forming a caulking hole 17a in the lowermost iron core piece 14. The processing station (G) is an idle station for the second and subsequent iron core pieces 14.
The next processing station (H) is a station for forming the caulking portion 17 (V-shaped caulking) on the second and subsequent iron core pieces 14 from the bottom. The first iron core piece 14 is an idle station.
The processing station (I) is a processing station for punching out the rotor hole 13, and this punch and die are formed between adjacent magnetic pole tooth pieces 30 formed at the tip of the magnetic pole piece 16 of each iron core piece 14. A blade for punching the gap 19 is also provided.
The processing station (J) is an outer shape removal station, in which the iron core pieces 14 are punched from the magnetic sheet material 24 and are caulked and laminated in a lower mold. The stator laminated core 10 is formed through the above processing stations (A) to (J).

In the above embodiment, the upper and lower iron core pieces 14 of the magnetic pole part 12 are formed at the same angle (that is, θ / n or θ / m) by the first and second punches. Since the die is moved, the four corners of the cross section of the magnetic pole portion 12 are chamfered in a straight line. However, when the arc portion is formed, the first and second punches with respect to the thickness of the iron core piece and Arbitrary cross-sectional shapes can be obtained by placing the movement amount of the die on a circle function or an ellipse function.
Moreover, in the said embodiment, although the number of magnetic poles was 6, it is applicable also to the laminated iron core which has the magnetic pole of the number of other than that.

10: Stator laminated iron core, 11: Yoke part, 12: Magnetic pole part, 13: Rotor hole, 14: Iron core piece, 15: Yoke piece part, 16: Magnetic pole piece part, 17: Caulking part, 17a: Caulking hole, 18 : Magnetic pole tooth part, 19: gap, 20: slot, 21: notch, 23: laminated core manufacturing device, 24: magnetic strip material, 25: pilot hole, 26: connecting slot, 27, 28: half slot, 29: Outline, 30: Magnetic pole piece

Claims (5)

The plate to be processed is sequentially passed through a press mold line having a plurality of processing stations, an iron core piece having a plurality of magnetic pole pieces formed on both sides by adjacent slots is extracted, and the iron core piece is formed in advance. In the manufacturing method of the laminated iron core formed by caulking and laminating through the caulking portion,
The regions forming the slots are each divided in the circumferential direction, the one side region is punched with a first punch and die, and the other side region is secondly wrapped so as to partially wrap around the one side region . method for manufacturing a laminated core, and forming the respective slot must be unplugged strike by the punch and die. 2. The method of manufacturing a laminated core according to claim 1, wherein the first and second punches and dies are punched to form each slot at a position corresponding to the radially outer side at a central position of each slot. A method of manufacturing a laminated iron core, comprising forming a connecting slot for connecting the radially outer contour lines of the one side region and the other side region . 3. The method of manufacturing a laminated core according to claim 1, wherein the first punch and the die and the second punch and the die rotate around the axis of the core piece as the rotation center, A method of manufacturing a laminated iron core, wherein the interval between the second punch and the die is enlarged or reduced. A plate to be processed is sequentially passed through a plurality of processing stations, an iron core piece having a plurality of magnetic pole pieces formed on both sides by adjacent slots is extracted, and the iron core piece is inserted through a pre-formed caulking portion. In the manufacturing equipment for laminated iron cores that are caulked and laminated,
The split in each circumferential region forming each slot, in the processing station, includes a disconnect Ku first punch and die out each area of the divided one side, about the axis of the core pieces a first slot punching station for punching the areas of rotatable the one side, provided with a disconnect beat each region of the divided other side Ku second punch and die, which can be rotated about the axis of the core pieces An apparatus for manufacturing a laminated core, comprising: a second slot punching station for punching out the region on the other side. 5. The laminated core manufacturing apparatus according to claim 4, wherein the region on the one side and the other side is positioned at a position corresponding to a radially outer side at a central position of the slot in a pre-process of the first and second slot punching stations. An apparatus for manufacturing a laminated iron core, comprising a connection slot forming station for forming a connection slot for connecting the two.

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