JP5720407B2 - Manufacturing method and manufacturing apparatus for rotor laminated core with permanent magnet - Google Patents

Description

  The present invention relates to a method for manufacturing a rotor laminated iron core with permanent magnets and a manufacturing apparatus therefor.

FIG. 12 is a plan view of a conventional rotor laminated core with permanent magnets, and FIG. 13 is a cross-sectional view. In the figure, 10 is a rotor laminated iron core with permanent magnets, 11 is a rotor core piece, 12 is an upper lid, 13 is a lower lid, and 15 is a permanent magnet.
The rotor core piece 11 is formed with a shaft hole 22 for inserting a rotating shaft (not shown), a permanent magnet insertion hole 23a for inserting the permanent magnet 15, and a first caulking projection 24a used for caulking lamination. Further, the upper lid 12 is formed with a second caulking projection 23b corresponding to the shaft hole 22, the caulking projection 24a, and the permanent magnet insertion hole 23a, and the lower lid 13 is formed with the shaft hole 22 and the first caulking projection 24a. A corresponding through hole 24b is formed.

There exists a thing of patent document 1 as a manufacturing method of the conventional laminated iron core with a permanent magnet. In patent document 1, a rotor lamination | stacking iron core is manufactured from a to-be-processed metal plate with the following procedure with a progressive die apparatus.
(1) At station A, a guide hole is formed.
(2) At station B, the shaft hole is punched and formed.
(3) At station C, the permanent magnet installation opening is punched and formed slightly on the inner diameter side from the portion that becomes the outer shape of the rotor core piece with a gap.
(4) At station D, holes are formed by punching.
(5) At station E, a caulking portion is formed.
(The caulking portion is formed as a through hole in the rotor core piece that is the first laminated layer, and is formed as a caulking projection in the rotor core pieces that are the second and subsequent laminated layers.)
(6) At station F, the outer shape of the rotor core piece is removed and caulked and laminated through the caulking portion.
(7) At the station G, a plurality of slots are punched and formed at locations that become the stator core pieces.
(8) At station H, the caulking portion of the stator core piece is formed.
(9) At station I, the stator core pieces are trimmed and caulked and stacked via caulking portions.

  As described above, the rotor laminated iron core with permanent magnets has a permanent magnet installed in the permanent magnet installation opening of the rotor laminated iron core obtained by caulking and laminating the rotor core pieces punched from the metal plate to be processed and the outer shape removed. Manufactured rotor laminated iron core with magnet.

JP 2004-173375 A (FIGS. 3 to 5)

As described above, in Patent Document 1, a step of punching a rotor core piece from a workpiece metal plate, a step of caulking and stacking the punched and contoured rotor core pieces (hereinafter referred to as a press working step), and permanent The magnet insertion process (hereinafter referred to as the permanent magnet insertion process) is a separate process, and it takes time in each of the press working process and the permanent magnet insertion process, and there is a problem that it takes a lot of time to manufacture the iron core. .
Further, since the cycle time of the permanent magnet insertion process is longer than that in the press working process, there is a problem that the laminated iron core stays as an in-process product in the permanent magnet insertion process. In addition, there is a problem in that a transport from the pressing process to the permanent magnet insertion process and a laminated core storage place in the permanent magnet insertion process are required.

  The present invention has been made to solve such problems, and an object of the present invention is to provide a method of manufacturing a rotor core with a permanent magnet and an apparatus for manufacturing the same, which do not require a stacked core storage place in the permanent magnet insertion step. And

An apparatus for manufacturing a rotor laminated core with a permanent magnet according to the present invention is the first of progressive dies such as production of various holes or caulking projections from a sheet metal material, outer punching of a lower lid, a rotor core piece, and lamination . The first rotor laminated iron core is manufactured by carrying out the press working process and the second press working process of the progressive die such as outer punching and lamination of the upper lid, and the second rotor laminated iron core is manufactured after the first press working process is completed. Production of various holes or caulking projections for manufacturing, and third press working process of progressive mold such as lower cover, outer punching of rotor core pieces, lamination, etc., and outer shape of upper lid after completion of third press working process It has at least a series of progressive die machining steps of carrying out the fourth press working step of the progressive die such as punching and stacking, and in parallel with the execution of the third press working step, the first rotor product It is intended to implement a permanent magnet inserting step for inserting a permanent magnet core.

According to this invention, from a thin metal material, various holes or caulking projections are manufactured, and the outer lid is stamped, outer punching of the rotor core piece, pressing process of the progressive mold such as laminating, and outer punching of the upper lid, lamination by adding in parallel the permanent magnet insertion step in the middle of the progressive die stamping, transfer of the top cover such an intermediate product to be used after the laminated core and the permanent magnet insertion step of using the permanent magnet insertion process, unnecessary storage Therefore, it is possible to manufacture a rotor laminated core with permanent magnets that is space-saving and timely.

1 is a configuration diagram of a manufacturing apparatus for a rotor laminated core with permanent magnets according to Embodiment 1. FIG. It is a fragmentary sectional view of the manufacturing apparatus of the rotor laminated iron core with a permanent magnet in the <f-1> process of the 1st cycle which concerns on Embodiment 1. FIG. It is a fragmentary sectional view of the manufacturing apparatus of the rotor laminated iron core with a permanent magnet in the <f-2> process of the 1st cycle concerning Embodiment 1. FIG. It is a fragmentary sectional view of the manufacturing apparatus of the rotor laminated iron core with a permanent magnet in the <f-3> process of the 1st cycle concerning Embodiment 1. FIG. It is a fragmentary sectional view of the manufacturing apparatus of the rotor laminated iron core with a permanent magnet in the <f-4> process of the 1st cycle concerning Embodiment 1. FIG. It is a fragmentary sectional view of a manufacturing device of a rotor lamination iron core with a permanent magnet in the <f-1> process after the 2nd cycle concerning Embodiment 1. It is a fragmentary sectional view of a manufacturing device of a rotor lamination iron core with a permanent magnet in the <f-2> process after the 2nd cycle concerning Embodiment 1. It is a fragmentary sectional view of a manufacturing device of a rotor lamination iron core with a permanent magnet in the <f-3> process after the 2nd cycle concerning Embodiment 1. It is a fragmentary sectional view of a manufacturing device of a rotor lamination iron core with a permanent magnet in the <f-4> process after the 2nd cycle concerning Embodiment 1. FIG. 6 is an operation state diagram of each process with respect to the number of punches in the first cycle according to the first embodiment. It is an operation state diagram of each process with respect to the number of stamping after the 2nd cycle concerning Embodiment 1. It is a top view of the conventional rotor laminated iron core with a permanent magnet. It is sectional drawing of the conventional rotor laminated iron core with a permanent magnet.

  A preferred embodiment of a manufacturing apparatus for a rotor laminated core with a permanent magnet according to the present invention will be described below. Note that the present invention is not limited to these embodiments.

Embodiment 1 FIG.
1 is a configuration diagram of an apparatus for manufacturing a laminated rotor core with permanent magnets according to Embodiment 1. FIG. In the figure, 20 is a thin metal material, 21 is a pilot hole, 22 is a shaft hole for inserting a rotating shaft, 23a is a permanent magnet insertion hole for inserting a permanent magnet, 23b is a caulking protrusion corresponding to the permanent magnet insertion hole 23a, 24a Is a caulking projection used when caulking and laminating the rotor core pieces 11, and 24b is a through hole corresponding to the caulking projection 24a.

FIG. 2 is a partial cross-sectional view of an apparatus for manufacturing a rotor laminated iron core with permanent magnets in the <f-1> step in the first cycle according to the first embodiment.
FIG. 3 is a partial cross-sectional view of the manufacturing apparatus for the rotor laminated iron core with permanent magnets in the <f-2> step in the first cycle according to the first embodiment.
FIG. 4 is a partial cross-sectional view of the manufacturing apparatus of the rotor laminated iron core with permanent magnets in the <f-3> step in the first cycle according to the first embodiment.
FIG. 5 is a partial cross-sectional view of the manufacturing apparatus for the rotor laminated core with permanent magnets in the <f-4> step in the first cycle according to the first embodiment.
FIG. 6 is a partial cross-sectional view of the manufacturing apparatus of the rotor laminated core with permanent magnets in the <f-1> step after the second cycle according to the first embodiment.
FIG. 7 is a partial cross-sectional view of the manufacturing apparatus of the rotor laminated core with permanent magnets in the <f-2> step after the second cycle according to the first embodiment.
FIG. 8 is a partial cross-sectional view of the manufacturing apparatus of the rotor laminated core with permanent magnets in the <f-3> step after the second cycle according to the first embodiment.
FIG. 9 is a partial cross-sectional view of the manufacturing apparatus of the rotor laminated core with permanent magnets in the <f-4> step after the second cycle according to the first embodiment.

  In the figure, 10 is a rotor laminated core, 11 is a rotor core piece, 12 is an upper lid, 13 is a lower lid, and 15 is a permanent magnet. Further, 30 is a rotary table, 31 is a holding part for holding the laminated iron core, and 32 is a cradle for loading the laminated iron core.

The manufacturing method of the rotor laminated iron core with a permanent magnet which concerns on Embodiment 1 is demonstrated using FIGS. In FIG. 1 to FIG. 9, for example, the process of manufacturing the first rotor laminated core corresponds to the first cycle, and the process of manufacturing the second rotor laminated core corresponds to the second cycle.

<a> Process: The pilot hole 21 and the shaft hole 22 are punched out from the thin metal material 20.
<B> Step: Only when the rotor core piece 11 is manufactured, the permanent magnet insertion hole 23a is punched out. In the case of the upper lid 12 and the lower lid 13, it is an intermittent process in which punching is not performed.
<C> Step: In the case of the upper lid 12, a caulking projection 23 b corresponding to the permanent magnet insertion hole 23 a is formed. In the case of the rotor core piece 11 and the lower lid 13, the intermittent process is performed without punching.
<D> Step: Only when the lower lid 13 is manufactured, the through hole 24b corresponding to the caulking protrusion 24a is punched out. In the case of the rotor core piece 11 and the upper lid 12, it is an intermittent process which is not punched.
<E> Process: In the case of the rotor core piece 11 and the upper lid 12, the caulking protrusion 24a is formed. In the case of the lower lid 13, it is an intermittent process that does not punch.

<F> step: <f-1> step of punching and laminating lower lid 13 and rotor core piece 11, <f-2> step of inserting a magnet, and punching and laminating upper lid 12 <f-3> > And a rotor laminated iron core with a permanent magnet, and the <f-4> step for discharging the rotor core. The rotary table 30 is rotated about the O axis.

<F-1> Step: Corresponds to, for example, the first press working step and the third press working step, see FIG. 2 for the state of the first cycle, and FIG. 6 for the state after the second cycle.
Only when the rotor core piece 11 and the lower lid 13 are manufactured, the outer diameter is punched, and the lower lid 13 and the rotor core piece 11 are received by the holding part 31 that holds the rotary table 30 and the laminated core depending on the thickness of the laminated core. It is stacked on the table 32. In the case of the upper lid 12, an intermittent process is performed without punching.
When the outer diameter 14 of the lower lid 13 and the rotor core piece 11 is punched out, the laminated core is pushed down in the punching direction by the thickness of the punched metal sheet and lowered. The lower lid 13 and the rotor core piece 11 are stacked on the cradle 32 on the rotary table 30 and the holding component 31 that holds the stacked core, depending on the thickness of the stacked core.
When the predetermined number of rotor core pieces 11 are stacked, the rotary table 30 rotates clockwise and moves from the <f-1> step to the <f-2> step. At this time, the cradle 32 also rotates in synchronization with the rotary table 30. However, when the time required for the work process for inserting the magnet in the next process is long, after the work process for inserting the magnet is completed, the turntable 30 rotates clockwise, from the <f-1> process to the <f- 2> Move to the process.

<F-2> Step: Corresponds to the permanent magnet insertion step, see FIG. 3 for the state of the first cycle, and FIG. 7 for the state after the second cycle.
In this step, a magnet insertion device (not shown) is provided, and the permanent magnet 15 is inserted into the permanent magnet insertion hole 23a. At this time, a plurality of permanent magnets 15 may be inserted depending on the thickness of the laminated iron core. (The figure shows an example in which two upper and lower parts are inserted.)
After confirming the end of both the work process of inserting the magnet and the work process of laminating the predetermined number of rotor core pieces 11, the turntable 30 rotates clockwise, and <f-2> process To <f-3> step. At this time, the cradle 32 also rotates in synchronization with the rotary table 30.
At this time, the next laminated iron core moves from the <f-1> step to the <f-2> step.

<F-3> Step: For example, it corresponds to the second press working step and the fourth press working step, and FIG. 4 shows the state of the first cycle, and FIG. 8 shows the state after the second cycle.
The upper lid 12 is punched out, and the laminated iron core into which the magnet is inserted is covered, and the rotor laminated iron core 10 with permanent magnets is completed.

<F-4> Step: See FIG. 5 for the state of the first cycle, and FIG. 9 for the state after the second cycle.
In this process, a discharge device (not shown) is provided, and the cradle 32 is once lowered to discharge the rotor laminated core 10 with permanent magnets.
However, in the state of the 1st cycle shown in FIG. 5, since the rotor laminated iron core 10 with a permanent magnet is supported by the rotary table 30 and the holding component 31, the rotor laminated iron core 10 with a permanent magnet is discharged. The cradle 32 rises again and moves to the <f-1> step.
Further, in the state after the second cycle shown in FIG. 9, when the cradle 32 is lowered, the lower laminated rotor core 10 with the permanent magnet is not supported by the rotary table 30 and the holding component 31 and can be taken out. Therefore, after discharging by the discharging device, the cradle 32 rises again and moves to the <f-1> step.

  Although the example which discharged | emitted the rotor laminated iron core 10 with a permanent magnet by the <f-4> process after the 2nd cycle was demonstrated above, it is made to discharge | emit from the 1st cycle as a structure which can open and close the holding component 31. Also good.

FIG. 10 is an operation state diagram of each process with respect to the number of punches in the first cycle according to the first embodiment, and FIG. 11 is an operation state diagram of each process with respect to the number of punches after the second cycle according to the first embodiment. In the figure, ◯: punching or forming, ×: punching or forming not performed, −: a sheet metal material or laminated iron core to be processed does not exist.

  10 and 11, the punching number t represents the total quantity of the rotor core piece 11, the upper lid 12 and the lower lid 13 in the rotor laminated core 10 with permanent magnets. In the first embodiment, the upper lid 12 An example in which one piece, one lower lid 13 and t-2 pieces of rotor core pieces 11 are shown.

As described above, in the present invention, pilot holes, shaft holes, permanent magnet insertion holes, caulking protrusions, caulking protrusions, and the like are manufactured, and outer die punching of the lower lid and rotor core pieces, and presses for progressive molds such as lamination By adding a permanent magnet insertion process in parallel between the machining process and the press die stamping process of the top cover, such as punching the outer shape of the upper lid, the transfer work to the rotor laminated core and the permanent magnet insertion process of the upper lid can be performed. A manufacturing apparatus capable of manufacturing a rotor laminated iron core with permanent magnets that is space-saving and timely can be obtained because the laminated iron core place and the upper lid place in the permanent magnet insertion step can be made unnecessary.

10 Rotor laminated iron core with permanent magnet 11 Rotor core piece 12 Upper lid 13 Lower lid 14 Lower lid 13, rotor core piece 11, outer diameter 15 of upper lid 12 Permanent magnet 20 Sheet metal material 21 Pilot hole 22 Insert rotation shaft Shaft hole 23a Permanent magnet insertion hole 23b Second caulking projection 24a corresponding to permanent magnet insertion hole 23a First caulking projection 24b Through hole 30 corresponding to first caulking projection 24a Rotary table 31 Holding component for holding laminated iron core 32 A cradle for loading laminated iron cores

Claims (4)

Production of various holes or caulking projections from sheet metal materials, and the first press working process of progressive molds such as lower lid, outer shape of rotor core pieces, lamination, etc. The second press working step is performed to manufacture the first rotor laminated core, and after the completion of the first press working step, various holes or caulking projections for producing the second rotor laminated core, and the lower lid The third press working step of the progressive die such as the outer punching and lamination of the rotor core piece is performed, and the fourth press working step of the progressive die of the outer die punching and lamination of the upper lid after the third press working step is completed. In a manufacturing apparatus for a rotor laminated core with a permanent magnet having at least a series of progressive die machining steps to be performed,
In parallel with the execution of the third press working step, a permanent magnet inserting step for inserting a permanent magnet into the first rotor laminated core is performed. . Rotating the first and third press working steps, the permanent magnet inserting step, the second and fourth press working steps, and the step of discharging the first and second rotor laminated cores; The apparatus for producing a rotor laminated core with a permanent magnet according to claim 1, wherein the apparatus is arranged on a table. 3. The manufacturing apparatus for a rotor laminated core with a permanent magnet according to claim 2, wherein the rotary table is rotated after confirming the end of both the permanent magnet insertion step and the third press working step. . Stages of production of various holes or caulking projections, and the first press working process of progressive molds such as lower lid, outer punching of rotor core pieces, and lamination, and
The stage of carrying out the second press working process of the progressive die of punching the outer shape of the upper lid and laminating,
The second press working step is performed to manufacture the first rotor laminated core, and after the completion of the first press working step, various holes or caulking protrusions for producing the second rotor laminated core are manufactured, and Performing the third press working process of the progressive die such as lid, outer punching of the rotor core piece, lamination, etc .;
A step of performing a fourth press working process of a progressive metal mold of outer punching and stacking of the upper lid after completion of the third press working process;
In parallel with the implementation of the third press working step, performing a permanent magnet insertion step for inserting a permanent magnet into the first rotor laminated core;
Performing the step of discharging the first and second rotor laminated cores;
Having at least
After confirming the completion of both the permanent magnet insertion step and the third press working step , the method moves to the next stage, and a method for manufacturing a rotor laminated core with a permanent magnet.

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