JP6401605B2 - Laminated body having dummy caulking, method for producing the same, and method for producing laminated iron core - Google Patents

Description

  The present invention relates to a laminated body having dummy caulking, a method for producing the same, and a method for producing a laminated iron core. In the present invention, it is used to temporarily integrate a plurality of workpieces manufactured by punching and is removed from the laminate composed of the plurality of workpieces in the process of manufacturing a product (laminated core). This part is called “dummy caulking”. In the present invention, a processed body that is not formed with caulking (including dummy caulking) and is not connected to an adjacent processed body is referred to as a “bara core”.

  A laminated iron core is a component of a motor, and is formed by stacking a plurality of electromagnetic steel sheets processed into a predetermined shape and fastening them. The motor includes a rotor (rotor) and a stator (stator) made of laminated iron cores, and is completed through a process of winding a coil around the stator, a process of attaching a shaft to the rotor, and the like. A motor employing a laminated core is conventionally used as a drive source for a refrigerator, an air conditioner, a hard disk drive, an electric tool, and the like, and in recent years is also used as a drive source for a hybrid car.

  Caulking and welding are known as means for fastening electromagnetic steel sheets adjacent in the vertical direction in the process of manufacturing a laminated core. These fastening means are excellent in terms of cost and work efficiency, and have been widely adopted conventionally. On the other hand, when priority is given to high torque, low iron loss, and high dimensional accuracy of a motor, electromagnetic steel sheets may be fastened together using a resin material or an adhesive instead of caulking or welding.

  Patent Document 1 is a method of manufacturing a laminated iron core, wherein an unnecessary removed thin plate portion to be punched and removed after lamination is once punched in a half-punched state or a completely punched state, and then pushed back into a punched hole and fitted in a press-fit state. And a method of using the removed thin plate portion for caulking and bonding.

Japanese Patent No. 3294348

  In the method described in Patent Document 1, a caulking joint portion 17 is formed in the entire stacking direction of the laminated cores 14 (see FIGS. 3 and 4 of Patent Document 1). There is room for improvement in that the caulking joint portion 17 formed in this way is difficult to remove.

  By the way, in order to manufacture a laminating core without caulking (caulking-less), a laminating body may be manufactured by laminating processed bodies (baracore) without caulking, and these may be integrated. However, a laminate made of a rose core has a difficulty in handling. For example, when an impact is applied to the laminate in the process of transporting the laminate, the laminate may be broken. Moreover, the laminated body which consists of a process body (bara core) which does not have crimping also had room for improvement also at the point that it was difficult to grasp | ascertain which transposition was performed between which process body and which process body. Rolling means that, when a processed body is laminated to obtain a stacked body, the angle between the stacked body of the processed bodies already stacked and the stacked body newly stacked on the stacked body is relatively shifted. Rolling is carried out mainly for the purpose of offsetting the thickness deviation of the work plate.

This invention is made | formed in view of the said subject, It is a laminated body containing the laminated block formed by laminating | stacking the several processed body which has a dummy caulking, Comprising: It has the following advantages (1)-(3) It aims at providing a laminated body. Moreover, an object of this invention is to provide the manufacturing method of the said laminated body, and the manufacturing method of a laminated iron core.
(1) The dummy caulking can be removed sufficiently easily, and thereby a caulking-free (caulking-less) laminated iron core can be efficiently manufactured.
(2) The laminated rose cores are not easily broken, that is, they are excellent in handleability.
(3) It is easy to grasp the boundary between the processed body constituting the laminated block and another processed body.

  The laminated body according to the present invention includes a first laminated block including a plurality of processed bodies each having a dummy caulking and connected to the plurality of processed bodies by the dummy caulking, and at least one laminated on the first laminated block. With a single rose core.

  According to the above laminated body, a block in which a plurality of dummy caulkings are laminated by using a processed body having a dummy caulking and a rose core in comparison with a case where the entire laminated body is configured by a processed body having a dummy caulking ( Hereinafter, the thickness of the dummy caulking block) can be reduced, and the dummy caulking block can be easily removed from the laminated body. As a result, a caulking-free (caulking-less) laminated iron core can be efficiently produced.

  According to the said laminated body, the 1st laminated block can play the role of the stand of the rose core by which it is laminated | stacked on it. Thereby, the effect that the rose core is not easily broken, in other words, the handleability of the laminate is excellent.

  According to the laminated body, an effect is obtained that it is easy to grasp the boundary between the first laminated block and the bulk core laminated thereon. This boundary may be visually confirmed. Even if visual confirmation is difficult, since the first laminated block and the bulk core can be separated, the boundary can be grasped by confirming this separation location. For example, it is possible to grasp at which timing the transposition is performed by performing the transposition in the segment unit composed of the first laminated block and the bulk core laminated thereon.

  The laminate may further include a second laminate block laminated on at least one or more of the rose cores. The second stacked block is composed of a plurality of processed bodies each having a dummy caulking, and the plurality of processed bodies are connected by the dummy caulking. As described above, the first laminated block serves as a stand, and in addition to this, the second laminated block serves as a weight, so that the rose core is more difficult to collapse (the handling property of the laminated body is improved). An effect is produced.

  The first laminated block is preferably thicker than the second laminated block. By adopting such a configuration, when performing punching and stacking of workpieces with a mold, it is sufficient that the laminate is discharged from the mold before preparation for discharging the stack from the mold is complete. It can be suppressed (see FIG. 6).

  When the first laminated block, the group of bulk cores, and the second laminated block are transposed, it is preferable that these have the following configuration. That is, the first laminated block and the second laminated block each have a plurality of dummy caulking and a plurality of through-holes arranged along the circumferential direction of the circle having the center of the laminated body in plan view, It is preferable to have a plurality of through holes arranged in the circumferential direction of the circle in plan view. In plan view, the position of the dummy caulking of the first laminated block, the position of the through hole of the second laminated block, and the position of the through hole of the bulk core coincide with each other, It is preferable that the position of the dummy caulking of the two laminated blocks coincides with the position of the through hole of the rose core.

  The dummy caulking may be formed by half-cutting the processed plate or by push-back after punching in the process of manufacturing the processed body by punching the processed plate. That is, a portion (hereinafter referred to as “scrap”) that does not become a product (laminated core) itself may be used as a dummy caulking. By adopting such a configuration, it is possible to use a small mold as compared with a case where dummy caulking is separately formed in a portion other than scrap, and cost can be reduced.

The manufacturing method of the said laminated body is equipped with the following processes.
(A) The process of obtaining the processed body which has a dummy crimp by performing the punching process of a to-be-processed board.
(B) A step of obtaining a first laminated block by stacking a plurality of processed bodies and integrating them by dummy caulking.
(C) The process of obtaining a rose core by performing the punching process of the processed plate.
(D) A step of laminating at least one rose core on the first laminated block.

  In the manufacturing method, after the step (c) and before the step (d), the first stacking block and a process that is newly stacked on the first stacking block are relatively shifted (shifted). A stacking step).

  The method for producing a laminated core according to the present invention includes a step of fastening the laminate produced by the production method using a resin material, welding, adhesion, or a combination thereof, and a step of removing dummy caulking from the laminate.

  According to the method for manufacturing a laminated core, the laminated core without caulking can be finally obtained by removing the dummy caulking from the laminated body.

  According to the present invention, there is provided a laminated body including a laminated block in which a plurality of processed bodies having dummy caulking are laminated, and having the advantages (1) to (3) above.

It is a perspective view which shows an example of a rotor (rotor). It is a schematic cross section in the II-II line | wire shown in FIG. It is a perspective view which shows an example (1st embodiment) of the laminated body with the dummy crimping for rotors shown in FIG. (A) is a schematic cross section in the IV-IV line | wire shown in FIG. 3, (b) is a schematic cross section which expands and shows a dummy caulking. It is the schematic which shows an example of the apparatus for manufacturing the laminated body which concerns on this invention. It is sectional drawing which shows typically the mechanism in which a process body is laminated | stacked, and the mechanism in which a laminated body is discharged | emitted from a metal mold | die. (A) is a side view which shows more typically the laminated body shown to Fig.4 (a), (b) And (c) is a side view which each shows typically the modification of the laminated body shown to (a). It is. (A) It is a side view which shows typically 2nd embodiment of the laminated body which concerns on this invention, (b) is a side view which shows typically the modification of the laminated body shown to (a). (A) And (b) is a side view which shows typically the laminated body arrange | positioned by inverting the upper and lower sides of some segments of a some segment, respectively. It is a top view which shows typically the processed body used for manufacture of the laminated body which concerns on 3rd embodiment of this invention. It is a schematic cross section of the laminated body which concerns on 3rd embodiment of this invention. (A) is a top view which shows the other example of the processed body which has a dummy caulking, (b) is a schematic cross section in the bb line | wire shown to (a). (A) is a top view which shows the further another example of the processed body which has a dummy caulking, (b) is a schematic cross section in the bb line | wire shown to (a). (A) is a top view which shows the further another example of the processed body which has a dummy caulking, (b) is a schematic cross section in the bb line | wire shown to (a). It is a perspective view which shows an example of a stator (stator). FIG. 16 is a plan view schematically showing a processed body for the stator shown in FIG. 15 that has dummy caulking in some slots. It is a top view which shows the example of the through-hole formed in the laminated iron core for stators. It is a top view which shows the other example of the through-hole formed in the laminated iron core for stators. (A) is a schematic cross section which shows the process of forming dummy caulking by half punching, (b) And (c) is a schematic cross section which shows the process of forming dummy caulking by punching and subsequent pushback, respectively. (A) is a sectional view schematically showing a dummy caulking (scrap) having caulking, and (b) schematically shows a dummy caulking further having an opening (tension adjusting portion) in the central portion of the caulking shown in (a). It is sectional drawing.

  Embodiments of the present invention will be described in detail with reference to the drawings. In the following description, the same reference numerals are used for the same elements or elements having the same functions, and redundant description is omitted.

<First embodiment>
(Laminated core for rotor)
1 and 2 are a perspective view and a sectional view of a laminated core R for a rotor according to this embodiment. The shape of the laminated iron core R is a substantially cylindrical shape. The laminated core R is a laminated body 10 composed of a plurality of electromagnetic steel plates MR, a shaft hole 12 for inserting a shaft (not shown) located at the center of the laminated body 10, and a magnet for inserting a magnet. An insertion hole 15 and a lightweight hole 18 formed between the shaft hole 12 and the magnet insertion hole 15 are provided. In FIG. 2, for convenience, the laminated body 10 including a total of 27 electromagnetic steel plates MR is illustrated, but the number of electromagnetic steel plates MR is not limited to this.

  The laminated iron core R has a total of 16 magnet insertion holes 15. Two adjacent magnet insertion holes 15 form a pair, and eight pairs of magnet insertion holes 15 are arranged at equal intervals along the outer periphery of the laminated core R. Each magnet insertion hole 15 extends from the upper surface to the lower surface of the laminated iron core R. The total number of the magnet insertion holes 15 is not limited to 16, but may be determined according to the use of the motor, the required performance, and the like. Further, the shape and position of the magnet insertion hole 15 may be determined according to the use of the motor, the required performance, and the like.

  A magnet (not shown) is accommodated in the magnet insertion hole 15. The magnet is a permanent magnet, and for example, a sintered magnet such as a neodymium magnet can be used. The number of magnets inserted into each magnet insertion hole 15 may be one or two or more. The type of magnet may be determined according to the application of the motor, the required performance, and the like, and for example, a bonded magnet may be used instead of the sintered magnet. Moreover, you may use the magnet divided | segmented into multiple in the thickness direction or the width direction, or both. After inserting the magnet of the magnet insertion hole 15, the magnet can be fixed in the magnet insertion hole 15 by filling the magnet insertion hole 15 with the resin material 16.

  As the resin material 16, for example, a thermosetting resin can be used. Specific examples of the thermosetting resin include a resin composition containing an epoxy resin, a curing initiator, and an additive. Examples of the additive include a filler, a flame retardant, and a stress reducing agent. The resin material 16 joins the electromagnetic steel plates MR adjacent in the vertical direction. Note that a thermoplastic resin may be used as the resin material 16. The resin material 16 (excluding the resin material used for the flux barrier portion) may include a magnetic material. When the resin material 16 contains a magnetic body, the content can be made into the range of 5-90 volume%. If the content of the magnetic substance in the resin material 16 is less than 5% by volume, the motor torque tends to decrease or cracks due to the difference in thermal expansion coefficient tend to occur. The workpieces are more electrically connected to each other, and the magnetic properties of the laminated iron core R tend to deteriorate due to this.

  The laminated iron core R has a total of eight lightweight holes 18 between the shaft hole 12 and the magnet insertion hole 15. The lightweight hole 18 has a substantially triangular shape. The eight lightweight holes 18 are arranged along the circumferential direction of the shaft hole 12. More specifically, the eight lightweight holes 18 are arranged so as to have point symmetry with the central axis of the laminated iron core R as a symmetric point, and each lightweight hole 18 is rotated by 45 ° around the symmetric point. Are formed so as to coincide with each other. As shown in FIG. 2, each lightweight hole 18 is formed so as to penetrate from the upper surface to the lower surface of the laminated iron core R. In addition, the lightweight hole 18 may bring about the effect of cooling the laminated iron core R.

(Laminated body for rotor with dummy caulking)
3 and 4 are a perspective view and a cross-sectional view of the laminated body 20 used for manufacturing the laminated iron core R. FIG. The laminated body 20 has a dummy caulking 8 at a position corresponding to the lightweight hole 18 in the laminated iron core R. The laminated iron core R described above is manufactured through a step of filling the resin insertion material 16 into the magnet insertion hole 15 of the laminated body 20 and a step of removing the dummy caulking 8 from the laminated body 20.

  The configuration of the stacked body 20 will be described with reference to FIG. As shown to (a) of FIG. 4, the laminated body 20 is comprised by three segment 20A, 20B, 20C. The segment 20 </ b> A includes a plurality of processed bodies WR each having a dummy caulking 8, and a plurality of processed bodies WR connected by the dummy caulking 8, and at least one layer stacked on the first stacked block 21. A group 22 composed of a single core, and a second laminated block 23 which is stacked on the group 22 and includes a plurality of processed bodies WR each having a dummy caulking 8 and the plurality of processed bodies WR are connected by the dummy caulking 8. And is composed of. The segments 20B and 20C have the same configuration as the segment 20A.

  When the laminated body 20 is continuously manufactured, the lowermost layer of the first laminated block 21 is formed so that the first laminated block 21 is not fastened by the dummy caulking 8 with respect to the already produced second laminated block (not shown). A through hole 9 is formed in the formed workpiece WR instead of the dummy caulking 8 (see FIG. 4B). A through hole 9 is formed instead of the dummy caulking 8 in the processed body WR forming the lowermost layer of the second laminated block 23 so that the second laminated block 23 is not fastened by the dummy caulking 8 to the group 22 composed of the rose cores. . In FIG. 4, for convenience, the laminated body 20 in which the first laminated block 21, the group 22, and the second laminated block 23 are each composed of three processed bodies WR is illustrated, but the number of electromagnetic steel plates MR is limited to this. It is not something.

(Punching device)
FIG. 5 is a schematic diagram showing an example of a punching device that manufactures a workpiece WR constituting the laminate 20 by punching. The punching device 100 shown in the figure includes an uncoiler 110 to which the winding body C is mounted, a feeding device 130 for an electromagnetic steel sheet (hereinafter referred to as “working plate W”) drawn from the winding body C, and the processing plate W. Are provided with a progressive die 140 for punching and a press machine 120 for operating the progressive die 140.

  The uncoiler 110 holds the winding body C in a rotatable manner. The length of the electrical steel sheet constituting the wound body C is, for example, 500 to 10,000 m. The thickness of the electrical steel sheet constituting the wound body C may be about 0.1 to 0.5 mm. From the viewpoint of achieving more excellent magnetic properties of the laminated core R, the thickness is about 0.1 to 0.3 mm. There may be. The width | variety of an electromagnetic steel plate (workpiece board W) should just be about 50-500 mm.

  The feeding device 130 includes a pair of rollers 130a and 130b that sandwich the work plate W from above and below. The workpiece plate W is introduced into the progressive die 140 via the feeder 130. The progressive die 140 is for continuously performing punching, pushback, and the like on the work plate W. The progressive die 140 has a function of sequentially stacking the processed bodies WR obtained by punching and manufacturing a stacked block, and a function of discharging the manufactured stacked block. As shown in FIG. 6, a die 141 is disposed below the punch P for removing the outer periphery of the workpiece WR, and a squeeze ring 141 a is disposed below the die 141. The squeeze ring 141a has an inner diameter that is slightly smaller than the outer diameter of the workpiece WR. The workpiece WR punched out by the punch P is press-fitted into the upper opening of the squeeze ring 141a of the die 141. The workpieces WR to be fastened by the dummy caulking 8 are fastened by a pressing force of the punch P, a reaction force of a cylinder 142 described later, and a frictional force between the inner surface of the squeeze ring 141a. On the other hand, the workpiece WR is gradually pushed out from the lower opening of the squeeze ring 141a.

  As shown in FIG. 4A, the first laminated block 21 is integrated by the dummy caulking 8, whereas the first laminated block 21 and the group 22 made of rose cores are not integrated. For this reason, if the boundary between the first laminated block 21 and the group 22 is pushed out to the position of the lower opening of the squeeze ring 141a, the first laminated block 21 may fall downward. In order to prevent this, a cylinder 142 is provided below the squeeze ring 141a, which can move in the vertical direction and holds the first laminated block 21 coming out from the lower opening of the squeeze ring 141a. When the stacked body 20 including the predetermined number of processed bodies WR is formed on the cylinder 142, the cylinder 142 moves downward and becomes flush with the stage 143. In this state, the pusher 145 located on the side is actuated to transport the laminate 20 to the next step. When pushing out the laminated body 20 by the pusher 145, a mechanism for supporting the laminated body 20 is provided so that the laminated body 20 does not fall down or collapse, or by using a servo motor as a drive motor for the pusher 145, You may control so that the speed of the end of pushing becomes slow.

  FIG. 7A is a side view schematically showing the configuration of the laminate 20. In this figure, the first laminated block 21 and the second laminated block 23 are represented by white squares, and the group 22 composed of rose cores is represented by a plurality of horizontal lines. The laminated body 20 shown in FIG. 7B is different from the laminated body 20 shown in FIG. 7A in that the first laminated block 21 of the segment 20A is configured to be thicker than the second laminated block 23. To do. By increasing the thickness of the first laminated block 21 located on the lowermost side of the laminated body 20, it is possible to prevent the first laminated block 21 from falling from the squeeze ring 141a without rising of the cylinder 142 in time. In order to prevent the first laminated block 21 from falling more reliably, the entire segment 20A may be constituted by the laminated block 21 as shown in FIG.

(Manufacturing method of laminated iron core for rotor)
Next, a method for manufacturing the laminated iron core R will be described. The manufacturing method of the laminated iron core R includes a process for producing the laminated body 20 integrated by the dummy caulking 8 (steps (A) to (F) below) and a process for producing the laminated iron core R from the laminated body 20 (following (D ) Step and (E) step). More specifically, the method for manufacturing the laminated iron core R includes the following steps.
(A) A step of obtaining a workpiece WR having the dummy caulking 8 by punching the workpiece W in the progressive die 140.
(B) A step of obtaining the first laminated block 21 by stacking a plurality of workpieces WR and integrating them with the dummy caulking 8.
(C) A step of obtaining a loose core by punching the workpiece W in the progressive die 140.
(D) A step of laminating at least one rose core on the first laminated block 21.
(E) A step of obtaining a second laminated block 23 by stacking a plurality of workpieces WR and integrating them by dummy caulking 8.
(F) The process of obtaining the laminated body 20 by laminating | stacking the 2nd lamination | stacking block 23 on the group 22 which consists of at least 1 piece of rose core.
(G) The process of fastening the laminated body 20 by filling the magnet insertion hole 15 with the resin material 16.
(H) A step of removing the dummy caulking 8 from the laminate 20.

  As long as the dummy caulking 8 is removed, the dummy caulking 8 may be removed before fastening with the resin material 16 as long as the laminated body 20 does not fall apart. For example, if the laminated body 20 is fixed to a resin filling device, the dummy caulking 8 may be removed before the resin material 16 is filled, and then the resin material 16 may be filled into the magnet insertion hole 15. Further, the dummy caulking 8 may be removed simultaneously with the filling of the resin material 16.

  In the present embodiment, the case where the magnet insertion hole 15 of the laminate 20 is finally fastened by being filled with the resin material 16 has been illustrated, but the hole for filling the resin in addition to the magnet insertion hole 15. (Not shown) may be separately provided, and the resin material 16 may be filled therein to reinforce the fastening of the stacked body 20. Moreover, you may use together the resin material 16 and other fastening means (welding, adhesion | attachment, etc.). When annealing is performed to eliminate the distortion of the workpiece WR, the annealing may be performed at an appropriate timing. For example, when the laminate 20 is integrated with the resin material 16, annealing may be performed prior to filling the resin material 16, and when welding is used in combination, annealing may be performed after welding.

According to the laminate 20, the following effects (1) to (3) are exhibited.
(1) Compared with the dummy caulking formed in the entire stacking direction of the stacked body, the dummy caulking 8 is partially formed in the stacking direction of the stacked body 20 (see FIG. 4A). For this reason, the frictional force (resistance) generated when the dummy caulking 8 is removed can be made sufficiently small, whereby the dummy caulking 8 can be removed sufficiently easily. Therefore, the laminated iron core R without caulking (caulking-less) can be efficiently manufactured.

(2) The group 22 composed of the rose cores is laminated on the first laminated block 21, and the second laminated block 23 is arranged on the group 22. That is, the first laminated block 21 serves as a stand and the second laminated block 23 serves as a weight. Thereby, even if it pushes out the laminated body 20 with the pusher 145, the group 22 which consists of rose cores is hard to collapse (it is excellent in a handleability). For example, the first laminated block 21 serving as a table can be held to perform a transshipment operation or a lamination operation.

(3) It is easy to grasp the boundary between the processed body WR constituting the first laminated block and the processed body WR constituting the second laminated block. For example, it is possible to grasp at which timing the transposition has been performed by performing transposition between the second laminated block 23 and the first laminated block 21 laminated thereon. The rollover may be performed manually by the operator on the laminate 20 discharged from the progressive die 140, may be performed using an automatic machine, or may be performed in combination. May be. Further, the rollover may be performed in the progressive die 140. When rolling in the progressive die 140, the squeeze ring 141a shown in FIG. 6 may be rotated at a predetermined timing. In order to clarify the presence or absence of rolling, an identification shape, for example, a notch or the like may be provided on the outer periphery of the processed body WR.

<Second embodiment>
As shown to (a) of FIG. 8, the laminated body 25 which concerns on 2nd embodiment comprises segment 25A, 25B, 25C by the 1st laminated block 21, and the group 22 which consists of the rose core laminated | stacked on it, respectively. The second stacked block 23 is different from the stacked body 20 according to the first embodiment in that the second stacked block 23 is not provided.

  According to the laminated body 25, the effect of said (1) is show | played similarly to the laminated body 20. FIG. Regarding the effect (2), according to the laminated body 25, the group 22 composed of the rose cores is laminated on the first laminated block 21, that is, the first laminated block 21 serves as a base. Further, even if the laminated body 25 is pushed out by the pusher 145, the group 22 composed of the rose cores is not easily broken (excellent handling property). For example, the first laminated block 21 serving as a table can be held to perform a transshipment operation or a lamination operation. Regarding the effect (3), according to the laminated body 25, it is easy to grasp the boundary between the processed body WR constituting the first laminated block and the rose core (group 22). For example, it is possible to grasp at which timing the transposition is performed by performing the transposition in the segment unit composed of the first laminated block 21 and the bulk cores laminated thereon.

  8 (b) is similar to FIG. 8 (a) in that the first laminated block 21 of the segment 25A is thicker than the first laminated blocks 21 and 21 of the segments 25B and 25C. It is different from the laminated body 25 shown. By thickening the first laminated block 21 positioned on the lowermost side of the laminated body 25, it is possible to prevent the first laminated block 21 from falling from the squeeze ring 141a without the cylinder 142 rising in time. In order to prevent the first laminated block 21 from falling more reliably, the entire segment 20 </ b> A may be constituted by the laminated block 21 although not shown. According to the second embodiment described above, since the second laminated block 23 is not provided, when the laminated iron core R is manufactured from the laminated body 25, the dummy caulking 8 included in the first laminated block 21 may be removed. Can be manufactured more efficiently.

  In the first embodiment and the second embodiment, it is assumed that the laminated segments are overlapped in the direction of being discharged from the progressive die 140, as shown in FIGS. 9A and 9B. Of the plurality of segments constituting the stacked bodies 20 and 25, some segments may be arranged upside down. By disposing the first laminated block 21 integrated by the dummy caulking 8 on the upper surface and the lower surface of the laminated body 25, it is possible to more reliably prevent the loose core from collapsing. For the purpose of preventing the workpiece WR (electromagnetic steel sheet) located on the end surface in the stacking direction from jumping up, the plurality of workpieces WR constituting the first laminated block are caulked, welded, bonded, resin molded, or these You may integrate by a combination.

<Third embodiment>
FIG. 10 is a plan view schematically showing a processed body WR (with dummy caulking) used for manufacturing the laminated body 30 according to the third embodiment. The processed body WR shown in FIG. 10 is different from the stacked body 20 according to the first embodiment in that a total of four dummy caulkings 8 are provided every other out of the eight lightweight holes 18.

  By reducing the number of dummy caulking 8, the dummy caulking 8 can be removed more easily, and the caulking-free (caulking-less) laminated iron core R can be more efficiently manufactured. Further, according to the processed body WR shown in FIG. 10, the number of blocks of the dummy caulking 8 is reduced in the lightweight hole 18 extending from the upper surface to the lower surface of the laminated body 30 by performing the rollover at the boundary between the segments. Accordingly, the dummy caulking 8 can be removed more easily (see FIG. 11).

  The first laminated block 21 and the second laminated block 23 include a plurality of dummy caulking 8 and a plurality of lightweight holes (through holes) 18 arranged along the circumferential direction of a circle having the center of the laminated body 20 in plan view. Have each. The rose core has a plurality of light-weight holes 18 arranged along the circumferential direction of the circle in plan view. In plan view, the position of the dummy caulking 8 of the first laminated block 21, the position of the lightweight hole 18 of the second laminated block 23, and the position of the lightweight hole 18 of the rose core coincide with each other, and the lightweight of the first laminated block 21 is obtained. The position of the hole 18, the position of the dummy caulking 8 of the second laminated block 23, and the position of the lightweight hole 18 of the rose core coincide with each other (see FIGS. 10 and 11).

  As mentioned above, although embodiment of this invention was described in detail, this invention is not limited to the said embodiment. For example, in the above embodiment, the case where the scrap that becomes the lightweight hole 18 of the workpiece WR is used as the dummy caulking 8 is illustrated, but the scrap that can be used as the dummy caulking 8 is not limited to the lightweight hole 18. FIG. 12 is a view showing a processed body WR that uses the scrap that becomes the shaft hole 12 as the dummy caulking 8. In addition, as shown in FIG. 12, you may form the opening 8a as needed in the center part of the dummy caulking 8 (scrap used as the axial hole 12). By forming the opening 8a in the dummy caulking 8, the tension of the dummy caulking 8 can be relaxed and the dummy caulking 8 can be easily removed. In addition to this, by providing the opening 8a, when the dummy caulking 8 is actually removed, the dummy caulking 8 can be efficiently removed by inserting and pushing the rod-like member into the opening 8a.

  FIG. 13 is a view showing a processed body WR that uses the scrap that becomes the magnet insertion hole 15 as the dummy caulking 8. This processed body WR has a total of four dummy caulks 8. Also in this case, as shown in FIG. 13, an opening 8a may be formed in the central portion of the dummy caulking 8 (scrap that becomes the magnet insertion hole 15) as necessary.

  In the above embodiment, the case where the scrap is used as the dummy caulking 8 is illustrated, but a part of the scrap may be left and the dummy caulking 8 may be formed there. In the processed body WR shown in FIG. 14, a part of the scrap remains so as to bridge two opposing sides of the magnet insertion hole 15, thereby forming a dummy caulking portion 8 </ b> A having a caulking (dummy caulking) 8. . A cut 8b is formed at the boundary between the dummy caulking portion 8A and the inner surface of the magnet insertion hole 15. The present invention is not limited to the case where the dummy caulking 8 is provided by leaving a part of the scrap. For example, a recess is provided on the outer periphery or inner periphery of the processed body WR, and a dummy caulking portion 8A that fits into the recess is provided. (Dummy caulking) 8 may be formed.

(Laminated core for stator)
In the above embodiment, the case where the laminated core R for the rotor is produced from the laminated body having the dummy caulking 8 is illustrated, but the present invention may be applied to the production of the laminated core S for the stator. FIG. 15 is a perspective view of the laminated iron core S constituting the stator. The shape of the laminated iron core S is substantially cylindrical, and the opening Sa located in the center is for arranging the laminated iron core R (rotor). The laminated iron core S has a substantially annular yoke portion Sy and a teeth portion St extending in the center direction from the inner peripheral side of the yoke portion Sy.

  The laminated iron core S has a total of 12 tooth portions St. The number of teeth portions St is not limited to twelve. The laminated iron core S has a resin filling hole 41 formed in the yoke portion Sy and a resin filling hole 42 formed in the tooth portion St. By filling the resin material 16 into the resin filling holes 41 and 42, a plurality of electromagnetic steel plates MS constituting the laminated body 40 are integrated.

  FIG. 16 is a view showing a processed body WS that uses a scrap that becomes an area (hereinafter referred to as “slot SL”) between adjacent tooth portions St as a dummy caulking 8. This processed body WS has a total of four dummy caulks 8. Also in this case, as shown in FIG. 16, an opening 8a may be formed in the central portion of the dummy caulking 8 (scrap serving as the slot SL) as necessary.

  When the side surface of the slot SL is formed in parallel, or when the side surface of the slot SL is formed so as to expand from the yoke portion Sy toward the center direction, the dummy caulking 8 that becomes the slot SL is formed at the center of the opening Sa. There is an advantage that it can be removed in the direction (radial direction). Here, the case where the dummy caulking 8 is formed in the slot SL is illustrated, but when an ear portion (not shown) having an opening for fixing a bolt is provided on the outer periphery of the laminated core S, for example, this ear portion opening is formed. The scrap may be used as the dummy caulking 8.

  FIG. 17 is a plan view showing an example of a resin filling hole (through hole) formed in the laminated core S for the stator. As shown in FIG. 17, the resin filling hole 41 is formed in the yoke part Sy, and the resin filling hole 42 is formed in the teeth part St. The position and shape of the resin filling hole 41 are assumed to be concentrated winding as a winding method of the coil. The resin filling holes 41 and 42 are provided in regions where magnetic flux is sparse. Moreover, the shape of the resin filling holes 41 and 42 is devised so as not to obstruct the flow of magnetic flux as much as possible.

  The resin filling hole 41 is provided on the extension line of the center line C1 extending in the radial direction of each tooth portion St in plan view and along the outer periphery of the yoke portion Sy. The resin filling hole 41 has a substantially triangular cross-sectional shape. One vertex 41a of the substantially triangular shape faces the teeth portion St side, and the side that is the opposite side of the vertex 41a extends along the outer periphery of the yoke portion Sy. Two sides constituting the apex 41a extend in a direction away from each other from the inner peripheral side to the outer peripheral side of the yoke portion Sy. The three sides constituting the resin filling hole 41 each have a convex portion 42b at the center. The convex portion 42b is for suppressing the occurrence of residue rise when the resin filling hole 41 is punched.

  The resin filling hole 42 is provided on the center line C1 extending in the radial direction of each tooth portion St and on the tip side of the tooth portion St. By providing the resin filling hole 42 on the center line C1 extending in the radial direction of the tooth portion St, the flow of magnetic flux can be inhibited by the resin filling hole 42 and the magnetic imbalance can be minimized. As shown in FIG. 17, the resin filling hole 42 has an elongated shape and is arranged so that the major axis coincides with the center line C <b> 1. The ratio (A / B) between the length A of the major axis and the length B of the minor axis shown in FIG. 17 is preferably 2 to 5, and more preferably 3 to 4. Similarly to the resin filling hole 41 described above, the resin filling hole 42 also has a convex portion 42a from the viewpoint of suppressing the occurrence of residue rise.

  FIG. 18 is a plan view showing another example of the through hole formed in the laminated core S for the stator. As shown in FIG. 18, a resin filling hole 43 is formed in the yoke portion Sy, and a resin filling hole 42 is formed in the tooth portion St. The position and shape of the resin filling hole 43 are assumed to be distributed winding as a coil winding method. The resin filling hole 43 is provided in a region where the magnetic flux is relatively sparse. The shape of the resin filling holes 42 and 43 is devised so as not to obstruct the flow of magnetic flux as much as possible.

  The position and shape of the resin filling hole 42 are the same as those of the resin filling hole 42 shown in FIG. 17, whereas the position and shape of the resin filling hole 43 are different from the resin filling hole 41 shown in FIG. The resin filling hole 43 has the same shape as the resin filling hole 42. The resin filling hole 43 is provided on the center line C1 extending in the radial direction of each tooth portion St, at the central portion in the width direction of the yoke portion Sy, and arranged so that the long diameter coincides with the circumferential direction of the yoke portion Sy. ing. The position of the resin filling hole 43 is not limited to the center line C1 and may be another position in the circumferential direction of the yoke portion Sy.

  FIG. 19 is a diagram showing a variation of the method of forming the dummy caulking 8 on the work plate W. FIG. FIG. 19A shows a process of forming the dummy caulking 8 by half blanking. The processed plate W is not completely cut by the half punching process, whereas the processed plate W is cut by the punching process shown in FIGS. 19 (b) and 19 (c). In FIG. 19B, the cut scrap (dummy caulking 8) is pushed back to the opening by pushback, but the dummy caulking 8 protrudes to the lower surface side of the work plate W. In FIG. 19C, the scrap (dummy caulking 8) protrudes to the upper surface side of the work plate W by increasing the pushback amount (push back amount) of the cut scrap (dummy caulking 8). By causing the dummy caulking 8 to protrude from the upper surface side, there may be a case where the work in the subsequent process can be performed efficiently. For example, the dummy caulking 8 is removed upward. In addition, according to the aspect shown to FIG.19 (b) and (c), the position of the dummy caulking 8 can be freely set to some extent by adjusting the pushback amount (pushback amount).

  FIG. 20A is a cross-sectional view schematically showing a dummy caulking 8 (scrap) having caulking 8c. By integrating the dummy caulking 8 with the caulking 8c, there is an advantage that the dummy caulking 8 can be easily detached from the laminated body. If the caulking 8c is formed on the dummy caulking 8 and the dummy caulking 8 is too tight, the opening 8a is provided at the center of the caulking 8c as shown in FIG. What is necessary is just to ease the tension of the dummy caulking 8. The dummy caulking 8 in the lowermost layer shown in FIG. 20 may be provided with a hole 8d instead of the caulking 8c, and may be formed with caulking 8c like other processed bodies WR.

  Although the said embodiment assumes the case where the processed body WR and the processed body WS are each punched out from the one processed board W, the processed body WR and processed body overlap | superposed several processed board W. You may make it punch each WS. In this case, when using the some to-be-processed board W together, you may use combining a thing from which a kind, thickness, and / or width differ. Further, both the processed body WR and the stator processed body may be punched from one processed plate W. Moreover, in the said embodiment, although the case which manufactures a non-caulking (caulking-less) laminated iron core using the processed object which has the dummy caulking 8 (processed object which does not have caulking in the part used as a product) was illustrated, 1st In addition to the dummy caulking 8, the laminated block 21 and / or the second laminated block 23 may have caulking in a portion that becomes a product (laminated core) as necessary.

8 ... dummy caulking, 15 ... magnet insertion hole (through hole), 18 ... lightweight hole (through hole), 21 ... first laminated block, 22 ... group (at least one rose core), 23 ... second laminated block, WR, WS ... Processed body.

Claims (8)

A first laminated block including a plurality of processed bodies each having a dummy caulking, and the plurality of processed bodies connected by the dummy caulking;
At least one rose core laminated on the first laminated block;
A laminate comprising: A second laminated block laminated on the at least one rose core;
The laminated body according to claim 1, wherein the second laminated block includes a plurality of processed bodies each having a dummy caulking, and the plurality of processed bodies are connected by the dummy caulking.   The laminate according to claim 2, wherein the first laminated block is thicker than the second laminated block. The first laminated block and the second laminated block each have a plurality of dummy caulkings arranged in a circumferential direction of a circle having the center of the laminated body in a plan view, and a plurality of through holes.
The rose core has a plurality of through holes arranged along the circumferential direction of the circle in plan view,
In plan view, the position of the dummy caulking of the first laminated block, the position of the through hole of the second laminated block, and the position of the through hole of the bulk core coincide with each other. The laminated body according to claim 2 or 3, wherein a position of the through hole, a position of the dummy caulking of the second laminated block, and a position of the through hole of the rose core coincide.   The dummy caulking is formed by half-punching the processed plate or by push-back after punching in the process of manufacturing the processed body by punching the processed plate. The laminate according to any one of the above. A method for producing a laminate having dummy caulking,
(A) A step of obtaining a processed body having a dummy crimp by performing a punching process on a workpiece plate;
(B) stacking a plurality of the processed bodies and integrating them by the dummy caulking to obtain a first laminated block;
(C) A step of obtaining a rose core by punching a work plate;
(D) laminating at least one piece of the rose core on the first laminated block;
The manufacturing method of a laminated body provided with.   The method further includes a step of relatively shifting an angle between the first laminated block and the processed body newly stacked on the first laminated block after the step (c) and before the step (d). Item 7. A method for producing a laminate according to Item 6. A step of fastening the laminate produced by the production method according to claim 6 or 7 using a resin material, welding, adhesion or a combination thereof;
Removing the dummy caulking from the laminate;
A method for manufacturing a laminated iron core.

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