JP6655409B2 - Laminated core and method of manufacturing laminated core - Google Patents

Description

  The embodiments relate to a laminated core and a method of manufacturing the laminated core.

  Some laminated cores have a plurality of block cores. Each of the plurality of block cores is formed by laminating and joining a large number of steel plates, and the laminated core is configured by laminating a plurality of block cores.

JP 2007-159300A JP-A-10-14144

  In the case of the above-described conventional laminated core, since a plurality of block cores are welded on the outer peripheral surface, welding cracks due to residual stress, poor welding due to contained silicon, and iron loss due to melting occurred.

The laminated core of the embodiment includes two or more block cores formed by laminating and joining a plurality of steel plates, and a pin inserted into the two or more block cores, and the pin is inserted between the two or more block cores. The steel plates are joined by crimping heads formed by crushing both ends , and each of the plurality of steel plates has a cantilever-shaped crimping portion formed by cutting and raising a part of the steel plate, and cutting and raising of the crimping portion. An opening which is a trace is provided, and the plurality of steel plates are joined by fitting a caulked portion of the steel plate into an opening of another steel plate different from the steel plate, and the caulked portion is an inclined portion, A flat end portion, a folded portion disposed on a free end side of the caulking portion and inclined upward from the flat portion, wherein the pin is inserted adjacent to the caulking portion on the free end side of the caulking portion. As a result, the free end of the caulking portion is Characterized in place is fitted between the crimping head.

In the method for manufacturing a laminated core according to the embodiment, two or more block cores formed by laminating and joining a plurality of steel plates are laminated, pins are inserted into the two or more block cores, and both ends of the pins are crushed. The two or more block iron cores are joined by a caulking head formed by the above. Each of the plurality of steel plates has a cantilever-shaped caulking portion formed by cutting and raising a part of the steel plate and the caulking An opening that is a cut and raised trace of the portion is provided, and the plurality of steel plates are joined by fitting a caulked portion of the steel plate into an opening of a steel plate different from the steel plate, and the caulked portion is An inclined portion, a flat end portion, and a folded portion disposed on the free end side of the caulking portion and inclined upward from the flat portion, wherein the pin is adjacent to the caulking portion on the free end side of the caulking portion. By being inserted, freedom of the caulking part There has a feature where the is fitted between the crimping head of the pin.

Drawing showing Example 1 (drawing showing appearance of stator core) Diagram showing electrical steel sheet Diagram showing punched plate Sectional view showing the caulked portion in a state before the punching plate is caulked Sectional view showing the swaged part in a state after the punched plate has been swaged The figure which shows the joining state between block iron cores (a is sectional drawing along Xa line, b is Xb view) Diagram for explaining the shape of the caulking pin Diagram for explaining the movement of the radial ash machine Diagram for explaining method of manufacturing stator core FIG. 1 corresponding to FIG. 1 showing a second embodiment. Figure 9 equivalent FIG. 1 equivalent view showing a third embodiment. Figure 9 equivalent

  The stator core 1 shown in FIG. 1 is for an inner rotor type three-phase synchronous motor serving as a drive source of a hybrid vehicle, and has a yoke 2, a plurality of teeth 3, and three mounting pieces 4. The yoke 2 has a cylindrical shape. Each of the teeth 3 protrudes inward from the inner peripheral surface of the yoke 2, and each of the three mounting pieces 4 protrudes outward from the outer peripheral surface of the yoke 2. These three mounting pieces 4 are arranged at a constant pitch of 120 ° in the circumferential direction, and have a circular through hole 5. A bolt is inserted into each of the three through holes 5, and the stator core 1 is fixed by screwing the three bolts to the seat surface. This stator core 1 corresponds to a laminated core.

  As shown in FIG. 1, the stator core 1 is formed by stacking three block cores 6 in the axial direction, and each of the three block cores 6 has N pieces (N is an integer of 100 or more. ) Are laminated in the axial direction. As shown in FIG. 2, each of the punched plates 7 is punched from a strip-shaped electromagnetic steel plate 8 having a plate thickness t (t is 0.3 mm or less) by a progressive feeding device, and corresponds to a steel plate. This progressive feeding device has a plurality of processing stages including a punch and a die. The plurality of processing stages are arranged in a line in the direction of the arrow X, and the electromagnetic steel sheet 8 is intermittently conveyed in the direction of the arrow X to be sequentially supplied to the plurality of processing stages. The steel sheet 8 is punched from the electromagnetic steel sheet 8 by being sequentially supplied to a plurality of processing stages.

  As shown in FIG. 2, the punched plate 7 is formed with six swaging portions 9. These six caulking portions 9 are formed by pressing the electromagnetic steel plate 8 at a specific processing stage of the progressive feeding device, and as shown in FIG. It is arranged above and is spaced apart from the center of the through hole 5 by a certain angle in the circumferential direction. As shown in FIG. 4, the caulking portion 9 is obtained by cutting and raising a part of the punching plate 7, and has a cantilever shape in which one end in the circumferential direction is connected to the punching plate 7.

  The punch 10 shown in FIG. 4 is for forming a caulked portion 9 between the electromagnetic steel sheet 8 and a die at a specific working stage of the progressive device, and the caulked portion 9 has an inclined portion 11 and a flat portion 12. ing. The flat portion 12 is a portion parallel to the punching plate 7 and is displaced by the thickness t of the electromagnetic steel plate 8 in the direction in which the pressing force of the punch 10 acts. The inclined portion 11 is a portion connecting the flat portion 12 to the punching plate 7, and the punching plate 7 is formed with an opening 13 which is a trace of the caulking portion 9.

  Each of the three block cores 6 is formed by laminating N punched plates 7 in a state where the punched plates 7 are punched out of the electromagnetic steel plate 8 in the same direction. Reference numeral 14 in FIG. 3 denotes a portion corresponding to the mounting piece 4 of the punching plate 7, and one of the N punching plates 7 has a shaft on one of the three mounting piece corresponding portions 14 on the arrow X direction side. They are stacked so as to overlap in the direction.

  The N punching plates 7 are caulked by a press machine. The punch 15 shown in FIG. 5 is for caulking the N punching plates 7 between the die and the die. The flat portion 12 of the caulking portion 9 is pressed in It is fitted into the opening 13 of the blank 7. The punch 15 is for forming a folded portion 16 on the flat portion 12. The folded portion 16 is located on the free end side of the caulking portion 9 and is inclined upward from the flat portion 12. The folded portion 16 is fitted into the opening 13 of the upper punching plate 7 on which the flat portion 12 is fitted, and the caulking portion 9 is provided between the N punching plates 7. Are fitted into the opening 13 of the lower punching plate 7 and the opening 13 of the upper punching plate 7.

  As shown in FIG. 1, the middle block core 6 of the stator core 1 is disposed by being rotated by 120 ° with respect to the uppermost block core 6, and the lowermost block core 6 is attached to the uppermost block core 6. It is arranged to be turned by 240 °. That is, the middle block core 6 is stacked with the mounting piece equivalent portion 14 shifted from the uppermost block core 6 by 120 °, and the lowermost block core 6 is attached to the uppermost block core 6 with the mounting piece equivalent portion. 14 are shifted by 240 °. These three block cores 6 are pressed in the axial direction in a laminated state, and the axial dimension of the stator core 1 varies due to uneven thickness of the electromagnetic steel sheet 8 (lamination deviation). ) Is suppressed by the rotational arrangement and pressurization of the block core 6.

  As shown in FIG. 3, six punched holes 17 are formed in the punched plate 7. Each of these six caulking holes 17 is circumferentially separated from the center of the through hole 5 by an angle θ (= 22.5 °), and as shown in FIG. Is connected to the opening 13 by being adjacent to the side. Each of these six crimping holes 17 has a circular shape with a diameter of 3 mm, and as shown in FIG. 2, the electromagnetic steel sheet 8 is subjected to shearing processing at a processing stage after forming the crimping portion 9. Is molded. The caulking hole 17 corresponds to a through hole.

  As shown in FIG. 1, six caulking pins 18 are inserted into the stator core 1. Each of these six caulking pins 18 has a columnar shape, and is inserted into the caulking hole 17 after laminating and pressing the three block cores 6. Each of these six caulking pins 18 is made of carbon steel (S45C), and has a diameter dimension substantially equal to that of the caulking hole 17. The caulking pin 18 corresponds to a pin.

  As shown in FIG. 6, a circular plate-shaped crimping head 19 is formed on each of the six crimping pins 18 at both ends in the axial direction. As shown in FIG. 7, the crimping head 19 is formed by crushing an end (see a two-dot chain line) of the crimping pin 18 from the end by 0.5 to 1.5 mm, and has a thickness dimension. T is set to 0.3 to 0.6 mm. The caulking head 19 has a diameter R set to 4 to 6 mm, which is larger than the caulking hole 17. As shown in FIG. 6, each of the six caulking pins 18 is provided between the three block cores 6. It is joined by being fastened between the swaging heads 19. Each of these six caulking pins 18 has the free ends of all the caulking portions 9 adjacent between the caulking heads 19, and all the caulking portions 9 have the free ends between the caulking heads 19. The elastic return due to the residual stress in accordance with the fitting is prevented.

  FIG. 8 shows a radial lashing machine for crushing the end of the caulking pin 18, and the radial lashing machine has a punch 20. The punch 20 presses the end of the caulking pin 18 and operates on a chrysanthemum petal locus (see a two-dot chain line). The punch 20 has a “radial movement from the outer periphery to the center of the caulking pin 18 from the bottom to the upper side”, a “radial movement from the center to the outer periphery of the caulking pin 18 from the top to the bottom”, and a “tangential movement”. The swaging head 19 is formed stepwise from the center of the swaging pin 18 toward the outer periphery in accordance with the repetition of three movements.

The following (1) to (6) are methods for manufacturing the stator core 1.
1) A punched plate 7 having a crimped portion 9, an opening 13, and a crimped hole 17 is punched from an electromagnetic steel plate 8.
2) The block core 6 is manufactured by laminating and joining the punched plates 7.
3) The three block cores 6 are stacked with the mounting piece equivalent portion 14 shifted in the circumferential direction by 120 °.
4) The three block cores 6 are pressed in a laminated state.
5) Insert the swaging pin 18 into the swaging hole 17 (see FIG. 9).
6) Flatten both ends of the caulking pin 18 (see FIG. 9).

The first embodiment has the following advantages.
The crimping pins 18 were inserted into the three block cores 6 in a stacked state, and the three block cores 6 were joined by crushing both ends of the crimping pins 18, so that welding cracks due to residual stress, poor welding due to contained silicon, and iron due to melting. Loss is prevented from occurring.

  The caulking pin 18 was inserted into the free end side of the caulking portion 9 adjacent to the caulking portion 9. For this reason, the free end of the caulking portion 9 is fitted between the caulking heads 19 of the caulking pins 18, so that the caulking portion 9 is prevented from elastically returning due to residual stress. Therefore, a gap is prevented from being formed between the punching plates 7 adjacent in the axial direction, so that the magnetic performance of the three-phase synchronous motor is improved.

  A caulking hole 17 connected to the opening 13 was formed in the punching plate 7, and a caulking pin 18 was inserted into the caulking hole 17. Therefore, the number of scratches on the stator core 1 is reduced, and the magnetic performance of the three-phase synchronous motor is also improved from this point.

Since the three block cores 6 are stacked while being shifted in the circumferential direction, the stacking deviation of the stator core 1 can be suppressed. In addition, since the three block cores 6 were pressed in the axial direction in a stacked state, the stacking deviation of the stator core 1 was also suppressed from this point. Both ends of the caulking pin 18 were crushed by a radial machine. Therefore, a large external force is prevented from acting on the crimping pin 18 at one time when the both ends of the crimping pin 18 are crushed, so that the crimping pin 18 is prevented from being deformed by the external force when the both ends are crushed.

  As shown in FIG. 10, the stator core 1 is provided with holding plates 21 located at both end faces. Each of these holding plates 21 is made of an electromagnetic steel plate, and has a larger thickness dimension than the punched plate 7. Each of these holding plates 21 has an annular shape, and covers the yoke 2 of the stator core 1 from the axial direction.

As shown in FIG. 10, six through holes 22 are formed in each of the holding plates 21. Each of the through holes 22 overlaps the swaging hole 17 in the axial direction, and the swaging pin 18 passes through the swaging hole 17 of the stator core 1 from each of the six through holes 22 of one of the holding plates 21 and the other holding hole. It is inserted into the through hole 22 of the plate 21. Both ends of each of the six caulking pins 18 are crushed by a radial caulking machine, and both holding plates 21 are caulked together with the three block cores 6 by the six caulking pins 18. The following [11] to [13] are crimping procedures of both holding plates 21.
[11] After pressing the three block cores 6 in a laminated state, the holding plates 21 are overlapped on both end faces of the three block cores 6 (see FIG. 11A).
[12] The caulking pin 18 is inserted into the through hole 22 of the other holding plate 21 from each of the six through holes 22 of the one holding plate 21 through the swaging hole 17 (see FIG. 11B).
[13] Both ends of each of the six caulking pins 18 are crushed at portions protruding in the axial direction as compared with the holding plate 21 (see FIG. 11C).

According to the second embodiment, the following effects can be obtained.
A pressing plate 21 having a larger thickness than the punching plate 7 is attached to each of both end surfaces of the three block cores 6, and both ends of the caulking pin 18 project in the axial direction as compared with the pressing plate 21. Since it is crushed, it is possible to prevent the punching plate 7 from being deformed by an external force from the radial caulking machine when the caulking pin 18 is crushed. In addition, since a magnetic plate is used as the holding plate 21, it is possible to prevent the holding plate 21 from interfering with the magnetic path.

  As shown in FIG. 12, the stator core 1 is provided with a holding plate 31 located at each of both end faces. Each of these holding plates 31 is made of an electromagnetic steel plate, and has a larger thickness dimension than the punching plate 7. Each of these presser plates 31 has an annular yoke plate portion 32, and each of the yoke plate portions 32 of both presser plates 31 covers the yoke 2 of the stator core 1 in the axial direction.

  As shown in FIG. 12, each of the two holding plates 31 has a plurality of teeth plate portions 33 protruding from the inner peripheral surface of the yoke plate portion 32. Reference numeral 33 covers the teeth 3 of the stator core 1 from the axial direction. Each of these holding plates 31 has a plurality of mounting plate portions 34 projecting from the outer peripheral surface of the yoke plate portion 32, and each of the plurality of mounting plate portions 34 of the both holding plates 31 mounts the stator core 1. The piece 4 is covered from the axial direction. Each of the plurality of mounting plate portions 34 of these two holding plates 31 has a through hole 35, and bolts pass through the inside of the plurality of through holes 35 of one holding plate 31 and through the through hole 5 of the mounting piece 4. It is inserted into the through hole 35 of the other holding plate 31.

As shown in FIG. 12, six through holes 36 are formed in each of the holding plates 31. Each of these through holes 36 overlaps the caulking hole 17 in the axial direction, and the caulking pin 18 passes through the caulking hole 17 of the stator core 1 from each of the six through holes 36 of the one holding plate 31 to the other holding hole. It is inserted into the through hole 36 of the plate 31. Both ends of each of these six caulking pins 18 are crushed by a radial caulking machine, and both holding plates 31 are caulked together with the three block cores 6 by the six caulking pins 18. The following [21] to [23] are crimping procedures for both holding plates 31.
[21] After pressing the three block cores 6 in a laminated state, the holding plates 31 are overlapped on both end surfaces of the three block cores 6 (see FIG. 13A).
[22] The caulking pin 18 is inserted into the through-hole 36 of the other holding plate 31 from each of the six through-holes 36 of the holding plate 31 through the inside of the swaging hole 17 (see FIG. 13B).
[23] Each of both ends of the six caulking pins 18 is crushed at a portion protruding in the axial direction as compared with the holding plate 31 (see FIG. 13C).

In the first to third embodiments, a metal pin such as stainless steel or a resin pin may be used as the caulking pin 18.
In the first to third embodiments, the present invention may be applied to a rotor core.

In the first to third embodiments, the stator core 1 may be configured by stacking two or four or more block cores 6.
In the first to third embodiments, the swaging hole 17 may be formed at the processing stage before the swaging portion 9 is formed in the electromagnetic steel sheet 8.

In the above-described first to third embodiments, the swaging portion 9 of the punching plate 7 may be fitted into two or more lower openings 13, that is, a punching plate 7 different from the punching plate 7. May be fitted into the opening portion 13 of the main body.
Although the embodiment of the present invention has been described above, this embodiment is presented by way of example and is not intended to limit the scope of the invention. This new embodiment can be implemented in other various forms, and various omissions, replacements, and changes can be made without departing from the spirit of the invention. This embodiment and its modifications are included in the scope and spirit of the invention, and are also included in the invention described in the claims and the equivalents thereof.

  1 is a stator core (laminated core), 6 is a block core, 7 is a punched plate (steel plate), 9 is a caulking portion, 13 is an opening, 17 is a caulking hole (through hole), 18 is a caulking pin (pin), 21 is a holding plate and 31 is a holding plate.

Claims (4)

Two or more block cores formed by laminating and joining a plurality of steel plates;
A pin inserted into the two or more block cores,
The two or more block cores are joined by a caulking head formed by crushing both ends of the pin ,
Each of the plurality of steel plates is provided with a cantilevered caulked portion formed by cutting and raising a part of the steel plate, and an opening which is a trace of the caulked portion.
The plurality of steel plates are joined by fitting a caulked portion of the steel plate into an opening of another steel plate,
The caulking portion includes an inclined portion, a flat end portion, and a folded portion that is disposed on a free end side of the caulking portion and that is inclined upward from the flat portion,
The pin is inserted into the free end side of the caulking portion adjacent to the caulking portion, so that the free end of the caulking portion is fitted between the caulking heads of the pin. And laminated iron core. Each of the plurality of steel plates is provided with a cantilevered caulked portion formed by cutting and raising a part of the steel plate and an opening that is a trace of cutting and raising the caulked portion,
The plurality of steel plates are joined by fitting a caulked portion of the steel plate into an opening of another steel plate,
Wherein the each of the plurality of steel plates, laminated core according to claim 1, wherein the pin be those leading to the opening, characterized in that the through hole is inserted is formed. A press plate provided on each of both axial end surfaces of the two or more block cores, and made of a magnetic plate having a thickness dimension larger than that of the steel plate,
The pin is inserted into one of the holding plates, the two or more block cores, and the other of the holding plates,
3. The laminated core according to claim 1, wherein the pin is crushed at a portion protruding in the axial direction as compared with each of the pressing plates. 4. Laminate two or more block cores made by laminating and joining multiple steel sheets,
Insert a pin into the two or more block cores,
A method for manufacturing a laminated core, comprising joining the two or more block cores with a caulking head formed by crushing both ends of the pin ,
Each of the plurality of steel plates is provided with a cantilevered caulked portion formed by cutting and raising a part of the steel plate and an opening that is a trace of cutting and raising the caulked portion,
The plurality of steel plates are joined by fitting a caulked portion of the steel plate into an opening of another steel plate,
The caulking portion includes an inclined portion, a flat end portion, and a folded portion that is disposed on a free end side of the caulking portion and that is inclined upward from the flat portion,
The pin is inserted into the free end side of the caulking portion adjacent to the caulking portion, so that the free end of the caulking portion is fitted between the caulking heads of the pin. Manufacturing method of a laminated iron core.

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