JP5513757B2 - Rotating electric machine using dust core and method for producing soft magnetic core comprising dust core - Google Patents
Rotating electric machine using dust core and method for producing soft magnetic core comprising dust core Download PDFInfo
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- JP5513757B2 JP5513757B2 JP2009059234A JP2009059234A JP5513757B2 JP 5513757 B2 JP5513757 B2 JP 5513757B2 JP 2009059234 A JP2009059234 A JP 2009059234A JP 2009059234 A JP2009059234 A JP 2009059234A JP 5513757 B2 JP5513757 B2 JP 5513757B2
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- 239000000428 dust Substances 0.000 title claims description 31
- 238000004519 manufacturing process Methods 0.000 title claims description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 35
- 238000012545 processing Methods 0.000 claims description 23
- 239000000843 powder Substances 0.000 claims description 21
- 239000006247 magnetic powder Substances 0.000 claims description 18
- 238000000748 compression moulding Methods 0.000 claims description 16
- 238000000034 method Methods 0.000 claims description 14
- 229910052742 iron Inorganic materials 0.000 claims description 12
- 238000005422 blasting Methods 0.000 claims description 8
- 230000001680 brushing effect Effects 0.000 claims description 6
- 239000011148 porous material Substances 0.000 claims description 5
- 230000002093 peripheral effect Effects 0.000 claims description 4
- 238000005245 sintering Methods 0.000 claims description 3
- 239000011162 core material Substances 0.000 description 57
- 239000002184 metal Substances 0.000 description 8
- 229910052751 metal Inorganic materials 0.000 description 8
- 238000000465 moulding Methods 0.000 description 8
- 239000000314 lubricant Substances 0.000 description 7
- 230000000052 comparative effect Effects 0.000 description 6
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
- 229910019142 PO4 Inorganic materials 0.000 description 4
- 238000005336 cracking Methods 0.000 description 4
- 239000010452 phosphate Substances 0.000 description 4
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 4
- 230000002411 adverse Effects 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 210000000078 claw Anatomy 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 230000006866 deterioration Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 239000011812 mixed powder Substances 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 238000010025 steaming Methods 0.000 description 2
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 2
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 231100000989 no adverse effect Toxicity 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/02—Details of the magnetic circuit characterised by the magnetic material
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
- Manufacture Of Motors, Generators (AREA)
Description
本発明は、絶縁皮膜により被覆された鉄基磁性粉末を圧縮成形して作製した圧粉磁心からなる軟磁性コアを用いる回転電機に関するもので、特に絶縁被膜を有する鉄基磁性粉末を圧縮成形して得られた圧粉体をスチーム処理し、更に得られたスチーム処理体にバリ取り加工を施して作製した圧粉磁心からなる軟磁性コアを用いる回転電機及びこの軟磁性コアの製造方法に関する。 The present invention relates to a rotating electrical machine using a soft magnetic core composed of a dust core produced by compression-molding iron-based magnetic powder coated with an insulating film, and particularly, compression-molding iron-based magnetic powder having an insulating film. The present invention relates to a rotating electrical machine using a soft magnetic core made of a powder magnetic core produced by subjecting the green compact obtained by steam treatment and further deburring the resulting steam treated body, and a method for producing the soft magnetic core.
鉄などの軟磁性金属粉末を圧縮成形して作製した圧粉磁心は、電磁鋼板などによる積層コアと比較して、作製時の材料歩留まりが良く、材料コストが低減できる。
また、形状自由度が高くコア形状の最適設計を行うことにより特性向上を図ることが可能である。さらに、樹脂や無機粉末などの絶縁物と金属粉末を混合したり、金属粉末の表面に絶縁皮膜を被覆して金属粉末間の絶縁性を上昇させることにより、コアの渦電流損を大幅に低減することができる。
これらの理由から、近年、小型化や高効率化が求められている回転電機用の軟磁性コア材料として圧粉磁心が注目されている。
A powder magnetic core produced by compression-molding soft magnetic metal powder such as iron has a better material yield at the time of production and can reduce material costs compared to a laminated core made of electromagnetic steel sheets or the like.
In addition, it is possible to improve the characteristics by optimizing the core shape with a high degree of freedom in shape. Furthermore, by mixing insulating materials such as resin and inorganic powder with metal powder, or by covering the surface of the metal powder with an insulating film to increase the insulation between the metal powder, the core eddy current loss is greatly reduced. can do.
For these reasons, in recent years, dust cores have attracted attention as soft magnetic core materials for rotating electrical machines that are required to be smaller and more efficient.
特許文献１及び２には、圧粉磁心を用いた高効率のクローポール型回転電機が開示されている。 Patent Documents 1 and 2 disclose high-efficiency claw-pole type rotating electrical machines using a dust core.
このような圧粉磁心は、靱性が低く、回転電機の組立工程において欠けやクラックの発生のおそれがあり、クラックが生じている圧粉磁心を回転電機の軟磁性コアとして組み込むと、特性劣化や発熱等の問題の原因となることから、圧粉磁心の慎重な取り扱いが求められる。 Such a dust core has low toughness and may cause chipping or cracks in the assembly process of the rotating electrical machine. If the dust core having a crack is incorporated as a soft magnetic core of the rotating electrical machine, characteristics deterioration and Careful handling of the dust core is required because it may cause problems such as heat generation.
また、圧粉磁心は、通常、型孔を有するダイスと、該型孔と摺動自在に嵌合する上パンチおよび下パンチとを備える成形装置を用いて軟磁性金属粉末を圧縮成形することにより作製されるが、ダイスから圧粉磁心を崩れることなく円滑に抜き出すため、相応の高圧圧縮が必要である。
さらに、近年、磁気特性の向上のため、圧粉磁心を高密度化することが求められており、高圧力での圧縮成形が行われるようになってきている。
そのため、軟磁性金属粉末の圧縮成形時、塑性変形した軟磁性金属粉末がダイスの型孔と上下パンチとの隙間に押し出されて顕著なバリが発生することにつながる。
圧粉磁心を回転電機の軟磁性コアとして用いる場合には、バリにより、コイルの巻線の絶縁被覆が損傷してレアショートが発生したり、断線が発生したりする可能性があるため、圧粉磁心のバリは確実に除去しておく必要がある。
In addition, the dust core is usually obtained by compression-molding soft magnetic metal powder using a molding apparatus including a die having a mold hole and an upper punch and a lower punch that are slidably fitted in the mold hole. Although it is manufactured, in order to smoothly extract the dust core from the die without breaking, a corresponding high pressure compression is required.
Furthermore, in recent years, in order to improve magnetic properties, it has been required to increase the density of the dust core, and compression molding at a high pressure has been performed.
Therefore, at the time of compression molding of the soft magnetic metal powder, the plastically deformed soft magnetic metal powder is pushed out into the gap between the die hole of the die and the upper and lower punches, leading to significant burrs.
When using a dust core as a soft magnetic core for a rotating electrical machine, the burr may damage the insulation coating of the coil winding, causing a short circuit or disconnection. It is necessary to remove burrs from the powder magnetic core.
しかしながら、上述のように未焼結の圧粉磁心は靱性が低いため、バリ取り加工を施す場合にも欠けやクラックが発生しないように細心の注意が必要である。そのため、バリ取り加工において、強い力を加えることができず、純鉄などからなるため延性が高いバリの除去が不充分になってしまっていた。 However, since the unsintered powder magnetic core has low toughness as described above, it is necessary to pay close attention not to cause chipping or cracking even when deburring. Therefore, in the deburring process, a strong force cannot be applied, and since it is made of pure iron or the like, the removal of burrs having high ductility has been insufficient.
また、圧粉成形による歪みを除去してヒステリシス損を低減し、圧粉磁心の磁気特性を高めるため、焼結温度未満の温度で熱処理が施されることが多いが、圧粉磁心のバリ取り加工は、加工歪みによる磁気特性への悪影響が懸念されるため、このような熱処理の前に行うことが好ましいと考えられていた。 In addition, heat treatment is often performed at temperatures below the sintering temperature in order to remove distortion caused by dust molding and reduce hysteresis loss and improve the magnetic properties of the dust core. The processing is considered to be preferably performed before such heat treatment because there is a concern that the processing characteristics may adversely affect the magnetic characteristics.
特許文献３には、絶縁皮膜を有する磁性粉末を圧縮成形して得られた圧粉体をスチーム処理することで、強度を向上した圧粉磁心が開示されている。 Patent Document 3 discloses a dust core whose strength is improved by subjecting a green compact obtained by compression-molding a magnetic powder having an insulating film to a steam treatment.
しかしながら、特許文献３には、圧縮成形に伴うバリの発生についての課題認識が何ら開示されておらず、上述したような圧粉磁心の課題を解決するため、バリ取り加工を、スチーム処理に対しどのようなタイミングで行うかについて何ら開示がなされていない。 However, Patent Document 3 does not disclose any problem recognition regarding the generation of burrs associated with compression molding, and in order to solve the above-described problem of the dust core, deburring is performed on the steam process. There is no disclosure about what timing.
また、被処理物の表面全体にスチームを接触させるために、スチーム処理は、通常、金網上に被処理物を載置して処理を行うのが一般的である。そのため、変形が起こりやすく、スチーム処理体は平面度等の寸法精度に劣り、特に多相モータ等のようにコアを重ね合わせて用いる場合には、組み付け精度に悪影響を及ぼすが、特許文献３には、スチーム処理するに際し、圧粉体をどのように支持するかについて何ら示されていない。 In order to bring steam into contact with the entire surface of the object to be processed, the steam process is generally performed by placing the object to be processed on a wire mesh. For this reason, deformation is likely to occur, and the steam processing body is inferior in dimensional accuracy such as flatness. Particularly when the cores are overlapped and used like a multiphase motor, the assembly accuracy is adversely affected. Does not show how to support the green compact during steaming.
圧粉磁心の圧縮成形時に発生したバリを確実に除去してバリに起因する巻線のレアショートや断線の発生を防止し、圧粉磁心を用いた回転電機の性能を安定化することを目的とする。 The purpose is to stabilize the performance of rotating electrical machines using dust cores by reliably removing burrs generated during compression molding of dust cores and preventing the occurrence of rare shorts and wire breakage due to burrs. And
また、圧粉磁心の平面度等の寸法精度を向上することで、回転電機の組み付け精度を向上し、回転電機の運転時における精度ばらつきに起因する振動等の発生の低減を図ることを目的とする。 Also, the purpose is to improve the assembly accuracy of the rotating electrical machine by improving the dimensional accuracy such as the flatness of the dust core, and to reduce the occurrence of vibration and the like due to the accuracy variation during the operation of the rotating electrical machine. To do.
本発明者らは、種々の検討の結果、絶縁皮膜により被覆された磁性粉末を高圧力で圧縮成形し、得られた圧粉体を４００〜７００℃の温度でスチーム処理することによって、圧縮成形によるひずみ除去のための熱処理としての効果も同時に付与し、かつその後スチーム処理体にバリ取り加工を施しても、加工歪みによる磁気特性への悪影響が小さく、各種モータコアとして使用に耐える特性を維持できることを見い出し、本発明を完成した。 As a result of various studies, the inventors of the present invention compression-molded the magnetic powder coated with the insulating film at a high pressure, and subject the resulting green compact to steam treatment at a temperature of 400 to 700 ° C. At the same time, the effect of heat treatment for removing strain due to rusting is also given, and even if deburring is performed on the steam treated body, the adverse effect on the magnetic properties due to processing strain is small and the characteristics that can be used as various motor cores can be maintained. The present invention has been completed.
本発明の回転電機は、絶縁皮膜により被覆された鉄基磁性粉末を圧縮成形し、得られた圧粉体に焼結工程を施すことなく４００〜７００℃の温度でスチーム処理し、該圧粉体中の気孔内周面及び該圧粉体の表面にＦｅ ３ Ｏ ４ 皮膜を形成し、これにより得られたスチーム処理体に、ブラッシング、バレル加工、ショットブラスト、リューター加工のいずれかによりバリ取り加工を施して作製した圧粉磁心からなる軟磁性コアを用いることを特徴とする。 Rotating electrical machine of the present invention, the iron-based magnetic powder coated with an insulating film by compression molding, and steam at a temperature of 400 to 700 ° C. without applying sintering process the obtained green compact, piezoelectric powder A Fe 3 O 4 film is formed on the inner surface of the pores in the body and the surface of the green compact, and the resulting steam-treated body is deburred by any of brushing, barrel processing, shot blasting, and luter processing. It is characterized by using a soft magnetic core made of a dust core produced by processing.
本発明の回転電機では、圧粉体を敷き板状の治具上に載置して前記のスチーム処理を施した圧粉磁心からなる軟磁性コアを用いることが好ましい。
さらに、本発明は、絶縁皮膜により被覆された鉄基磁性粉末を、高圧縮成形する第一の工程、前記第一の行程で得られた圧粉体を４００〜７００℃の温度でスチーム処理し、該圧粉体中の気孔内周面及び該圧粉体の表面にＦｅ ３ Ｏ ４ 皮膜を形成する第二の工程、及び前記第二の工程で得られたスチーム処理体に、ブラッシング、バレル加工、ショットブラスト、リューター加工のいずれかによりバリ取り加工を施して圧粉磁心からなる軟磁性コアを作製する第三の工程からなる方法により、回転電機の軟磁性コアを製造した。
上記方法を実施する際、前記第一工程終了後、治具に載置する工程を備え、治具に載置したスチーム処理体に前記第二の工程を実施することが好ましい。
In the rotating electrical machine of the present invention, it is preferable to use a soft magnetic core made of a powder magnetic core in which a green compact is placed on a sheet-like jig and subjected to the steam treatment.
Furthermore, the present invention provides a first step of high compression molding an iron-based magnetic powder coated with an insulating film, and the green compact obtained in the first step is steam-treated at a temperature of 400 to 700 ° C. , piezoelectric second step of forming a Fe 3 O 4 film on the surface of the pores in the peripheral surface and the piezoelectric powder in the powder, and the steaming body obtained in the second step, brushing, barrel A soft magnetic core of a rotating electrical machine was manufactured by a method consisting of a third step of producing a soft magnetic core made of a dust core by performing deburring by any one of machining, shot blasting, and leutering .
When carrying out the above method, it is preferable that after the first step is completed, a step of placing on a jig is provided, and the second step is carried out on the steam processing body placed on the jig.
本発明の回転電機は、軟磁性コアとして、絶縁皮膜により被覆された磁性粉末を圧縮成形し、得られた圧粉体をスチーム処理し、更に得られたスチーム処理体に、ブラッシング、バレル加工、ショットブラスト、リューター加工のいずれかによりバリ取り加工を施した圧粉磁心を用いる。 The rotating electrical machine of the present invention is a soft magnetic core, compression-molding a magnetic powder coated with an insulating film, steam processing the obtained green compact, further brushing, barrel processing, Uses a dust core that has been deburred by either shot blasting or leutering .
スチーム処理体は強度が高いため、バリ取り加工工程や組立工程において圧粉磁心の欠けやクラックが発生しにくく、回転電機の特性低下等の問題を減らすことができる。 Since the steam processing body has high strength, chipping and cracking of the powder magnetic core are less likely to occur in the deburring process and assembly process, and problems such as deterioration of the characteristics of the rotating electrical machine can be reduced.
また、スチーム処理体は欠けやクラックが発生しにくく、充分強い力でのバリ取り加工を施すことができるとともに、バリをスチーム処理により酸化させてバリの延性を低下させることができるため、バリを確実に除去することが可能である。そのため、圧粉磁心のバリに起因するレアショートや断線の発生をより確実に防止することができる。 In addition, the steam-treated body is less prone to chipping and cracking, and can be deburred with a sufficiently strong force, and the burr can be oxidized by steam treatment to reduce the ductility of the burr. It can be reliably removed. Therefore, it is possible to more reliably prevent the occurrence of rare shorts and disconnections due to dust core burrs.
さらに本発明の回転電機は、軟磁性コアとして、圧粉体を敷き板状の治具上に載置して前記のスチーム処理を施した寸法精度の高い圧粉磁心を用いることで、組み付け精度を向上できるため、運転時において寸法精度ばらつきに起因する振動等の発生を少なくすることができる。 Furthermore, the rotating electrical machine of the present invention uses a powder magnetic core with high dimensional accuracy, which has been subjected to the above-mentioned steam treatment by placing a green compact on a plate-like jig as a soft magnetic core, so that the assembly accuracy can be improved. Therefore, it is possible to reduce the occurrence of vibration and the like due to dimensional accuracy variations during operation.
本発明の回転電機は上述したように、その構成部品の軟磁性コアが、絶縁皮膜により被覆された磁性粉末を圧縮成形し、得られた圧粉体をスチーム処理し、更に得られたスチーム処理体にバリ取り加工を施した圧粉磁心からなるものである。以下、軟磁性コアの実施形態につき、さらに詳しく説明する。 As described above, in the rotating electrical machine of the present invention, the soft magnetic core of the component parts is compression-molded with the magnetic powder coated with the insulating film, the obtained green compact is subjected to the steam treatment, and the obtained steam treatment. It consists of a dust core with a deburred body. Hereinafter, embodiments of the soft magnetic core will be described in more detail.
１．磁性粉末
磁性粉末としては、純鉄粉末または鉄合金粉末を用いることができる。この磁性粉末は、渦電流損を低減するために燐酸塩、金属酸化物や樹脂等の絶縁皮膜で覆われている必要がある。
1. Magnetic powder As the magnetic powder, pure iron powder or iron alloy powder can be used. This magnetic powder needs to be covered with an insulating film such as phosphate, metal oxide or resin in order to reduce eddy current loss.
２．圧縮成形
磁性粉末を金型に充填し、圧縮成形して圧粉体を作製する。磁性粉末には、通常は金属石けんやワックス系等の成形用潤滑剤を添加するが、成形潤滑剤を添加せずに金型に潤滑剤を塗布して圧縮成形を行っても良い。
2. Compression molding Magnetic powder is filled into a mold and compression molded to produce a green compact. Usually, metal soap or wax-based molding lubricant is added to the magnetic powder, but compression molding may be performed by applying the lubricant to the mold without adding the molding lubricant.
３．スチーム処理
前記の圧粉体にスチーム処理を施し、圧粉体中の気孔内周面および圧粉体の表面にＦｅ３Ｏ４皮膜を形成してスチーム処理体とする。この処理により圧粉磁心の強度を向上することができるとともに、バリを除去しやすくすることができる。処理温度は４００〜７００℃が好ましく、５００〜６００℃であることがより好ましい。処理温度が低すぎるとＦｅ３Ｏ４皮膜が充分生成せず、高すぎると磁気特性や耐食性に劣るＦｅ２Ｏ３が生成してしまうため好ましくない。なお、磁性粉末に成形用潤滑剤を添加している場合には、スチーム処理に先立ち脱ろう処理を施して成形用潤滑剤を除去しておくことが好ましい。
3. Steam treatment The above green compact is subjected to a steam treatment, and an Fe 3 O 4 film is formed on the pore inner peripheral surface and the green compact surface in the green compact to obtain a steam treatment body. By this treatment, the strength of the dust core can be improved and burrs can be easily removed. The processing temperature is preferably 400 to 700 ° C, more preferably 500 to 600 ° C. If the treatment temperature is too low, a Fe 3 O 4 film is not sufficiently formed, and if it is too high, Fe 2 O 3 inferior in magnetic properties and corrosion resistance is generated. When a molding lubricant is added to the magnetic powder, it is preferable to remove the molding lubricant by performing a dewaxing process prior to the steam process.
４．バリ取り加工
前記のスチーム処理体にバリ取り加工を施すことにより、磁性粉末の圧縮成形の際に生じたバリを除去する。バリ取り加工は、ブラッシング、バレル加工、ショットブラスト、リューター加工のいずれかにより行うことができる。
特に、上記３のスチーム処理を行うと、圧粉磁心の強度をバレル加工に耐え得る程度にまで高めることができ、効率的なバリ取り加工を行うことができる。
4). Deburring By removing deburring from the steam-treated body, burrs generated during compression molding of the magnetic powder are removed. The deburring process can be performed by any of brushing, barreling, shot blasting, and leutering.
In particular, when the above steam treatment 3 is performed, the strength of the powder magnetic core can be increased to a level that can withstand barrel processing, and efficient deburring processing can be performed.
燐酸塩皮膜処理を施したアトマイズ鉄粉に成形潤滑剤としてステアリン酸亜鉛を０．５ｍａｓｓ％添加した混合粉末を金型により密度７．５Ｍｇ／ｍ３に圧縮成形し、内径２０ｍｍ、外径３０ｍｍ、高さ５ｍｍの圧粉体とした。
燐酸塩被覆処理を施したアトマイズ鉄粉の場合、密度７．５Ｍｇ／ｍ３程度の高密度であれば、磁気特性の観点からみて十分に高密度といえる。
このように形成した圧粉体に５５０℃でのスチーム処理を行い、スチーム処理体の鉄損を測定した。更にスチーム処理体にバレル加工によるバリ取り加工を施して作製した圧粉磁心の鉄損を測定した。
A mixed powder obtained by adding 0.5 mass% of zinc stearate as a molding lubricant to atomized iron powder subjected to phosphate coating treatment is compression-molded to a density of 7.5 Mg / m 3 using a mold, and has an inner diameter of 20 mm, an outer diameter of 30 mm, The green compact was 5 mm high.
In the case of the atomized iron powder subjected to the phosphate coating treatment, a high density of about 7.5 Mg / m 3 can be said to be sufficiently high in terms of magnetic properties.
The green compact thus formed was subjected to steam treatment at 550 ° C., and the iron loss of the steam-treated body was measured. Furthermore, the iron loss of the dust core produced by deburring the barrel with barrel treatment was measured.
表１にバリ取り加工前後の鉄損の測定結果を示す。バリ取り加工の前後で鉄損はほぼ同等の値を示しており、加工歪みによる悪影響は無いことが判った。 Table 1 shows the measurement results of iron loss before and after deburring. The iron loss was almost the same before and after deburring, and it was found that there was no adverse effect due to processing distortion.
燐酸塩皮膜処理を施したアトマイズ鉄粉に成形潤滑剤としてステアリン酸亜鉛を０．５ｍａｓｓ％添加した混合粉末を金型により密度７．５Ｍｇ／ｍ３に圧縮成形し、図１に示すようなクローポールコア形状の圧粉体とした。圧粉体に５５０℃でのスチーム処理を行い、更にスチーム処理体にバレル加工によるバリ取り加工を施した。作製した圧粉磁心につき、バリの除去状態を観察するとともに、巻線をしてレアショート試験を実施した。 A mixed powder obtained by adding 0.5 mass% of zinc stearate as a molding lubricant to atomized iron powder that has been subjected to a phosphate film treatment is compression-molded to a density of 7.5 Mg / m 3 using a mold, and a claw as shown in FIG. It was a green compact with a pole core shape. The green compact was steam-treated at 550 ° C., and the steam-treated body was deburred by barrel processing. The produced dust core was observed for the removal state of burrs and wound to conduct a rare short test.
[比較例１]
実施例２の圧粉体にバレル加工を施した。
スチーム処理していない圧粉体にバレル加工を施すと、欠けや割れの発生が顕著になったため、磁気特性を評価に供するコアを作製することができなかった。
[Comparative Example 1]
The green compact of Example 2 was barrel processed.
When barrel processing was performed on a green compact that had not been steamed, chipping and cracking became prominent, making it impossible to produce a core for evaluation of magnetic properties.
[比較例２]
実施例２の圧粉体にショットブラストによるバリ取り加工を施した後、スチーム処理を施した。作製した圧粉磁心につき、バリの除去状態を観察するとともに、巻線をしてレアショート試験を実施した。なお、本比較例においては、バリ取り加工によって、圧粉体に欠けが生じないように、ショットブラストのメディアの噴射圧力を低くした。
[Comparative Example 2]
The green compact of Example 2 was deburred by shot blasting and then steamed. The produced dust core was observed for the removal state of burrs and wound to conduct a rare short test. In this comparative example, the shot blasting media injection pressure was lowered by deburring so as not to cause chipping in the green compact.
（バリの除去状態）
図２はバリ取り加工の前後の状態を示す写真である。比較例ではバリの除去が不充分であるのに対し、実施例ではバリの除去状態が良好であった。
(Burr removal state)
FIG. 2 is a photograph showing the state before and after deburring. In the comparative example, the removal of burrs was insufficient, whereas in the examples, the burrs were removed well.
（レアショートの発生率）
表２にレアショートの発生率を示す。なお、実施例、比較例ともに試験サンプル数は１００個とした。比較例では１６％のレアショートが発生したのに対し、実施例ではレアショートが発生しなかった。以上から、軟磁性コアとして絶縁皮膜により被覆された磁性粉末を圧縮成形し、得られた圧粉体をスチーム処理し、更に得られたスチーム処理体にバリ取り加工を施した圧粉磁心を用いることが、圧粉磁心を用いた回転電機の性能の安定化に有効であることが確認された。
(Rare short rate)
Table 2 shows the incidence of rare shorts. Note that the number of test samples was 100 in both the examples and comparative examples. In the comparative example, 16% rare short occurred, whereas in the example, no rare short occurred. From the above, a magnetic powder coated with an insulating film as a soft magnetic core is compression-molded, the obtained green compact is steam-treated, and a dust core obtained by deburring the obtained steam-treated body is used. This was confirmed to be effective in stabilizing the performance of a rotating electrical machine using a dust core.
実施例２の圧粉体をアルミナ製の敷き板状の治具に載置してスチーム処理を施し、スチーム処理体の底面の平面度を測定した。比較として、圧粉体を金網上に載置してスチーム処理を施し、スチーム処理体の底面の平面度を測定した。測定結果を表３に示す。 The green compact of Example 2 was placed on an alumina laying plate jig and subjected to steam treatment, and the flatness of the bottom surface of the steam treated body was measured. As a comparison, the green compact was placed on a wire net and subjected to a steam treatment, and the flatness of the bottom surface of the steam treatment body was measured. Table 3 shows the measurement results.
スチーム処理の際に、圧粉体を敷き板状の治具に載置して処理することにより、スチーム処理体の平面度が改善されることが確認された。
なお、この実施例では、敷き板状の治具に、蒸気を流通させるための孔等は設けなかったが、治具と接触していた圧粉体表面にも十分な酸化鉄層の形成が確認された。十分な酸化鉄層が形成されないような場合は、小径の蒸気流通孔を適当な箇所に設ければよい。
It was confirmed that the flatness of the steam-treated body was improved by placing the green compact on a laying plate-shaped jig during the steam treatment.
In this example, no hole or the like for circulating steam was provided in the laying plate-shaped jig, but a sufficient iron oxide layer was also formed on the surface of the green compact that was in contact with the jig. confirmed. When a sufficient iron oxide layer is not formed, a small-diameter steam flow hole may be provided at an appropriate location.
Claims (4)
絶縁皮膜により被覆された鉄基磁性粉末を、高圧縮成形する第一の工程、
前記第一の行程で得られた圧粉体を４００〜７００℃の温度でスチーム処理し、該圧粉体中の気孔内周面及び該圧粉体の表面にＦｅ ３ Ｏ ４ 皮膜を形成する第二の工程、
前記第二の工程で得られたスチーム処理体に、ブラッシング、バレル加工、ショットブラスト、リューター加工のいずれかによりバリ取り加工を施して圧粉磁心からなる軟磁性コアを作製する第三の工程。 A method for producing a soft magnetic core of a rotating electrical machine comprising the following first to third steps.
A first step of high-compression molding iron-based magnetic powder coated with an insulating film,
The green compact obtained in the first step is steam-treated at a temperature of 400 to 700 ° C. to form a Fe 3 O 4 film on the inner peripheral surface of the pores in the green compact and the surface of the green compact. The second step,
A third step of producing a soft magnetic core made of a dust core by performing deburring processing on the steam-treated body obtained in the second step by any of brushing, barrel processing, shot blasting, and leuter processing .
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