JPH09215279A - Manufacture for laminated iron core with amorphous alloy foil sheet line - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a laminated iron core of high quality with high production efficiency by restraining internal residual stress accumulated in the laminated iron core in addition to smooth intermittent conveyance of the foil sheet, even in the case of manufacturing the laminated iron core by press-processing utilizing a amorphous alloy foil sheet line. SOLUTION: By jointing amorphous alloy foil sheet line 100 (thickness: 0.02-0.025mm) of prescribed quantity to each other through heat resistant adhesives, a laminated foil sheet line 10 is formed. By press-processing with a plurality of shaping stations 14a, 14b, 14f, main components of the first laminated foil iron core plate pieces and the second laminated foil iron core pieces where caulking protrusions and through-holes of prescribed quantity are arranged alternately are formed alternately.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a laminated core of a stator and a rotor of an electric motor, a laminated core of a transformer, etc. using a strip-shaped amorphous alloy foil plate, and more particularly,
The present invention relates to a method for manufacturing a laminated core using an amorphous alloy foil strip material, which is formed by laminating a plurality of amorphous alloy foil strip materials and press-working to laminate laminated foil sheet core pieces.

[0002]

2. Description of the Related Art Amorphous alloys have attracted industrial attention as metal materials having high hardness, tensile strength, corrosion resistance and magnetic properties. Focusing on this excellent magnetic property, when using an amorphous alloy foil sheet material as a core material of a stator of an electric motor, which is an example of an electric component, conventionally, a progressive die in which a plurality of shape processing stations are appropriately arranged is used. Using the equipment, the amorphous alloy foil plate (plate thickness: 0.02-0.0
25 mm) The strip material is supplied to this mold device, and by press working, it is intermittently transported between the respective shape processing stations, and the required electric motor is formed by sequentially punching and removing the unnecessary parts of the foil plate strip material. The required shape of the foil plate core piece of the stator is formed. Then, an outer shell of the foil plate core piece is formed, and the core pieces are sequentially laminated in the mold device to form a laminated core of the stator of the electric motor. As is well known, the progressive die apparatus used for this punches out the first shape processing station that forms the positioning hole of each station and the inner diameter of the stator, and the slot of the stator of the foil plate piece of the laminated iron core. A second shape processing station for forming the shape of the magnetic pole teeth, a third shape processing station for intermittently forming through holes for separation of the laminated iron core, and a caulking protrusion for fixing the foil plate pieces of the laminated iron core in a laminated manner. The fourth shape processing station for forming and the fifth shape processing station for forming a laminated core by punching to form the outer shape of the foil plate piece of the laminated core are provided.

However, in the conventional method for manufacturing a laminated iron core using a foil strip material of an amorphous alloy, when the foil strip material is intermittently conveyed to the progressive die apparatus,
Since this plate thickness is as thin as 0.02-0.025 mm, even if a lifter for foil strip material is equipped, the foil strip material is attached to the die device surface by punching oil etc. during transportation. Wear
There has been a problem that jamming of the foil strip material occurs in the die device, and feeding failure occurs, smooth and intermittent transportation cannot be performed, and productivity is reduced.

Further, since the punching foil plate piece is fitted and fixed by the combination of the convex and concave portions of the caulking projections, the internal residual stress due to pressure bonding around the fitting portion and the concave and convex portions are fitted together. There is a problem that a gap is generated between the iron pieces of the foil plate and the magnetic characteristics are deteriorated.

Further, since a plate pressing plate (stripper plate) having a structure in which the plate pressings of the respective shape processing stations of the progressive die apparatus are integrated is used, each of them can be used for the shape processing of the punched foil plate piece. There is a problem that the necessary plate pressing pressure is not applied for each shape of the shape processing station and the drawing phenomenon of the foil strip material occurs, the punching clearance changes due to the inclination of the plate pressing, and residual distortion occurs around the punched part. there were.

[0006]

DISCLOSURE OF THE INVENTION The present invention solves the above problems of the prior art by press working using a foil strip material of an amorphous alloy having high hardness, tensile strength, corrosion resistance and magnetic properties. Even when manufacturing laminated cores, the foil sheet material can be smoothly transported intermittently, and internal residual stress that remains in the laminated cores can be suppressed, producing high-quality laminated cores with high long-term reliability. It is an object of the present invention to provide a method for efficiently manufacturing.

[0007]

[Means for Solving the Problems] In order to solve the above problems, a foil plate of an amorphous alloy having a required number of strips (plate thickness: 0.02
-0.025mm) It is supposed that there will be a process for forming a laminated foil plate strip by joining the strips together with a heat resistant adhesive.
By forming such a laminated foil plate strip, it is possible to secure the conveyance strength of the strip, and the amorphous alloy foil strip (plate thickness: 0.02-0.025 mm) is used. Even in this case, the intermittent transfer can be smoothly performed in the press working process of the next process. Further, since they are joined via the heat-resistant adhesive material layer, they can function as a cushioning material when forming the caulking projections.

Further, a progressive die having a shape processing station for alternately forming the first laminated foil core piece and the second laminated foil core piece in which the crimping projections and the through holes are alternately arranged. A pressing process with the device installed will be provided. Then, by configuring in this way, it is possible to carry out polymerization in a combination of the through-holes and the caulking projections of the above-mentioned component parts, and compared with the conventional combination of the concavo-convex of the caulking projections, the internal residual stress due to fitting fixation The generation can be suppressed, and the adhesion between the laminated foil plate core pieces is improved by eliminating the gaps between the core pieces.

Further, the plurality of shape processing stations of the progressive die apparatus are divided die apparatuses divided for each shape processing station, and these are attached to a press station having an independent press function. A press working process is arranged in which the above are arranged in a tandem through a loop device in an appropriate order. As a result, the plate pressing pressure suitable for each shape processing station can be made as strong as possible, and the highly accurate punching die device can be easily manufactured, and highly accurate punching can be performed.

Further, the pressing station is provided with a pair of punching devices arranged vertically, and by using a conventional vertical punching method, one of the foil plate portions of the laminated foil plate is alternately alternated from the top and bottom a plurality of times. Give shearing deformation to part or all,
A pushback function of pushing this back to the punching hole of the laminated foil plate and a function of removing the punched piece are provided. With this configuration, it is possible to prevent the fatigue fracture of the strip material and the occurrence of punch burrs.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION In the present invention, a plurality of amorphous alloy foil sheet materials are laminated and integrated via a heat resistant adhesive layer,
A laminating step for forming a laminated strip of the amorphous alloy foil plate, and a first laminated foil plate core piece in which caulking projections and through holes into which caulking projections are inserted are alternately arranged downstream thereof. A required shape is formed with a second laminated foil plate iron core piece in which a through hole is formed at the position of the caulking projection of the first laminated foil plate iron core piece and the caulking projection is alternately arranged at the position of the through hole. Arranging a plurality of shape processing stations including a shape processing station and a lamination processing station for fitting the first laminated foil plate iron core piece and the second laminated foil plate iron core piece with the combination of the caulking protrusion and the through hole. And a press working process using the progressive die device.

Further, the progressive die apparatus is divided into a plurality of divided die apparatuses for each shape processing station, and a plurality of divided die apparatuses are provided, each having an independent press function and both ends thereof or an intermittent conveying function at one or both of them. Each press station is equipped with a press working step in which the press stations are arranged in tandem in an appropriate order directly or through a loop. Here, as the pressing function, a conventional vertical punching method can be used.

As the amorphous alloy foil sheet material, one having a heat-resistant organic or inorganic insulating coating layer on one or both sides can be used.

[0014]

EXAMPLE A manufacturing process of a laminated stator core of an electric motor using a laminated foil sheet material of an amorphous alloy will be described below with reference to the accompanying drawings. FIG. 1 is an explanatory view showing an outline of a manufacturing process of a laminated stator core of an electric motor which is an example of an embodiment of the present invention. Here, the example shown in the figure shows the case where two strips of amorphous alloy foil plate are laminated to form a laminated stator core of an electric motor.

According to FIG. 1, the steps of manufacturing the laminated stator core 100 (see FIG. 3) of the electric motor, which is an example of the embodiment of the present invention, are as follows. A laminating step 12 in which 10b is pressure-bonded via an insulating adhesive layer 11 to form a laminated foil sheet material 10, and the laminated stator core 1 is provided downstream of the laminating step 12.
The laminated foil plate core piece 13a for separation, which is a component of No. 00, and the required shape of the laminated foil plate core piece 13 of the first and second laminated foil plate core pieces 13b and 13c (see FIGS. 2 and 3) are formed. The first to sixth shape processing stations 14 of the progressive die device 14
a, 14b, 14c, 14d, 14e, 14f (see FIG. 2) are divided into plural shape forming stations, each of which is provided with an independent pressing function, which is provided in an appropriate order. First to sixth press stations 1 arranged in tandem via the loop device 14h
5a, 15b, 15c, 15d, 15f and the press working step 16 mounted. Hereinafter, details of the configurations of the laminating step 12 and the pressing step 16 will be described.

First, referring to FIG. 1, a laminating step 12 for forming the laminated foil sheet material 10 by pressure bonding the amorphous alloy foil sheet materials 10a and 10b will be described.

According to the drawing, the laminating process 12 is performed in two steps.
The foil plate strips 10a, 10b are unwound from each of the first and second unwinding devices 17, 18 which have wound the amorphous alloy foil plate strips 10a, 10b. Then, the insulating adhesive 11 is applied to the back surface of the foil strip material 10a by the application roller group 20 of the conventional adhesive application device 19 provided on the back surface side of the unwound foil strip material 10a. The thin film layer 21 of the insulating adhesive is formed and the foil strip 10 is formed.
a is processed by aligning the foil strip 10b with the aligning roller group 22, and then the foil strips 10a, 10b are pressure bonded by the pressure roller group 23 via the thin film layer 21 of the adhesive. Is performed to form the laminated foil strip 10 of the foil strips 10a and 10b.

Next, the pressing step 16 will be described with reference to FIGS. FIG. 2 is a punching process drawing of a laminated foil plate core piece which is a component of a laminated stator core of an electric motor which is sequentially formed in the press station shown in FIG. 1, and FIGS. 3 (a), 3 (b) and 3 (c) are It is a schematic explanatory drawing which shows the state which fitted and fixed the laminated foil board piece which is a component of the laminated stator core of the electric motor which shows an example of embodiment of this invention.

In the first pressing station 15a, the laminated foil sheet material 10 supplied from the laminating step 12 is applied to the laminated foil sheet core piece 1 at each pressing station.
3 is formed, the pilot holes 24 functioning for positioning are formed separately in the width direction of the strip, and the inner diameter hole 25 of the laminated foil plate core piece 13 which is a component of the laminated stator core 100 of the electric motor is formed. The partial shape processing of the laminated foil plate iron core piece 13 for punching is performed. Here, the inner diameter hole 25 is an inner diameter hole in which a connecting ring is left so as to connect the tips of the magnetic pole teeth formed in the next step, and the connecting ring is removed after performing the required shape processing. It is also possible to do so. The laminated foil plate core piece 13 referred to here is a general term for the separating laminated foil plate core piece 13a, the first laminated foil plate core piece 13b, and the second laminated foil plate core piece 13c.

In the second pressing station 15b, a required number of winding slots 26 are punched out and a plurality of magnetic pole teeth 27 are laminated on the laminated foil sheet material 10 formed in the first pressing station 15a. It is configured to be punched along the inner diameter hole 25 of the foil plate core piece 13.

In the third press station 15c, the caulking projections 28 (books) are formed on the laminated foil sheet material 10 formed in the second press station 15b for every required number of laminated stator cores 100. In the embodiment, a predetermined number of through holes 29 (4 places in the present embodiment) into which 4 places are fitted are intermittently punched and formed.
It is configured to perform an intermittent process to form the required shape. Here, when the third press station 15c is operating, the fourth press station 15d and the fifth press station 15e are not operating.
The caulking protrusion 28 here is a general term for the caulking protrusions 28a and 28b.

In the fourth press station 15d, the laminated foil plate strip 10 formed in the third press station 15c is provided with through holes for laminated foil plate core pieces which are components of the laminated stator core 100. A predetermined number of first through holes 29a into which the first caulking protrusions 28a (four places in this embodiment) and the second caulking protrusions 28b to be fitted with 29 are fitted.
(4 locations in this embodiment) are arranged alternately so that the required shape of the first laminated foil plate core piece 13b, which is a component of the laminated stator core 100 of the electric motor, is intermittently formed. There is. Here, the fourth press station 15d
Third press station 15 when the
c and the fifth press station 15e are not operating.

In the fifth pressing station 15e, the laminated foil plate material 10 formed in the fourth pressing station 15d and the first caulking projection 28a formed in the laminated foil plate material 10 are attached. A laminated stator of an electric motor in which the second through holes 29b are aligned at aligned positions and the second caulking protrusions 28b are alternately aligned at aligned positions with the first through holes 29a formed in the laminated foil sheet material 10. The required shape of the second laminated foil plate iron core piece 13c, which is a component of the iron core 100, is intermittently formed. Here, when the fifth press station 15e is operating, the third press station 15c and the fourth press station 15d are not operating.

In the sixth pressing station 15f, first, the laminated foil plate material 13 for separation is first separated from the laminated foil plate material 10 formed in the fifth pressing station 15e.
The outer shell is punched out to form the laminated foil strip for separation 13a. Then, on this separation laminated foil plate piece 13a, the outer hole is punched out in the through hole 29 of the separation laminated foil plate piece 13a to form the first caulking protrusion 2 of the first lamination foil plate piece 13b.
8a is fitted, and the separating laminated foil plate piece 13a and the first laminated foil plate piece 13b are fitted and fixed. Next, the first through hole 29a of the first laminated foil plate piece is punched out to fit the second caulking projection 28b of the second laminated foil plate piece 13c, and the first laminated foil is formed. Plate piece 13b and second laminated foil plate piece 13c
Fit and fix and. Similarly, the first caulking protrusion 28a of the first laminated foil plate piece 13b is fitted into the second through hole 29b of the second laminated foil plate piece 13c, and the first laminated foil plate piece 13c and the first laminated foil plate piece 13c are joined together. Then, the laminated foil plate piece 13b is fitted and fixed. This is sequentially performed, and the first laminated foil plate piece 13b is placed on the separation foil plate piece 13a.
And the second laminated foil plate pieces 13c are alternately laminated and laminated to have a predetermined stacking thickness, and then the separation laminated foil plate pieces 13a are punched to form the predetermined laminated stator core 100 separately. It is configured to perform processing. Here, the shape of the caulking projection 28 is V-shaped shown in FIG. 3A or FIG.
The tongue shape shown in FIG. 3B or the cut and bent shape shown in FIG. 3C may be used, and it is particularly preferable to use the cut and bent shape shown in FIG. 3C. This can suppress the generation of internal residual stress.

As described above, as a preferred embodiment of the method for forming the laminated iron core of the stator of the electric motor, a plurality of split mold devices divided for each shape processing station are attached to each of a plurality of press stations, and the die units are attached to each of the plurality of press stations. Although the description has been given as to the configuration including the pressing step in which the tandem arrangement is performed in an appropriate order, the first laminated foil plate core piece in which the crimping projections and the through holes into which the crimping projections are inserted are alternately arranged, and the first Forming station for forming a required shape with a second laminated foil plate iron core piece in which through holes are arranged at the positions of the caulking projections of the laminated foil plate iron core piece and the crimping projections are alternately arranged at the positions of the through holes. It is also possible to adopt a configuration including a press working process using a progressive die apparatus in which a plurality of shape working stations including and are arranged.

[0026]

According to the present invention, even if the laminated iron core of the electric component is made of the amorphous alloy foil strip material, a step of forming the laminated foil strip material of the amorphous alloy foil sheet is provided. It is possible to secure the material conveyance strength and to smoothly perform intermittent conveyance. As a result, productivity can be improved.

Further, since the constituent parts of the first laminated foil plate piece and the second laminated foil plate piece in which the caulking projections and the through holes are alternately arranged are alternately formed, the through holes of the above-mentioned constituent parts Polymerization can be performed with a combination of protrusions for tightening,
As compared with the conventional combination of the concavities and convexities of the caulking projections, it is possible to suppress the generation of internal residual stress due to fitting and fixing, and it is possible to improve the adhesion by eliminating the gap between the laminated foil plates. As a result, the magnetic characteristics of the laminated core can be improved.

Further, since the plurality of shape processing stations of the progressive die apparatus are divided into the respective die forming stations, the press stations equipped with the divided die apparatuses are arranged in tandem. The plate pressing pressure suitable for the shape processing station can be made as strong as possible, and the high-precision punching die can be easily manufactured, and high-precision punching can be performed.

Further, since the press station is constructed by using the vertical punching method, it is possible to prevent the punching burr from being generated due to the fatigue fracture of the strip material.

[Brief description of drawings]

FIG. 1 is a schematic diagram illustrating a manufacturing process of a laminated foil plate core according to an embodiment of the present invention.

FIG. 2 is a press punching process diagram showing a process of forming a laminated foil sheet core piece according to an embodiment of the present invention.

FIG. 3 is a schematic explanatory view showing a form of fitting and fixing the laminated foil plate core pieces according to the embodiment of the present invention.

[Explanation of symbols]

 100 Electric Motor Laminated Stator Core 10 Laminated Foil Sheet Strip 10a Amorphous Alloy Foil Sheet Strip 10b Amorphous Alloy Foil Sheet Strip 11 Insulating Adhesive Layer 12 Laminating Process 13 Laminated Foil Sheet Core Piece 13a Separation Laminate Foil plate iron core piece 13b First laminated foil plate iron core piece 13c Second laminated foil plate iron core piece 14 Progressive die device 14a First shape processing station 14b Second shape processing station 14c Third shape processing station 14d Fourth 4 shape processing station 14e 5th shape processing station 14f 6th shape processing station 15 press processing apparatus 15a 1st press station 15b 2nd press station 15c 3rd press station 15d 4th press station Station 15e Fifth Press Station 15f 6 Press station 16 Pressing process 17 First unwinding device 18 Second unwinding device 19 Adhesive applying device 20 Coating roller group 21 Heat-resistant insulating thin film layer 22 Aligning roller group 23 Crimping roller Group 24 Pilot hole 25 Inner diameter hole 26 Winding slot 27 Magnetic pole tooth 28 Caulking protrusion 28a First caulking protrusion 28b Second caulking protrusion 29 Through hole 29a First through hole 29b Second through hole 30 Outer shell

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI technical display location H01F 41/02 H01F 41/02 C

Claims (5)

[Claims] 1. Forming a foil plate piece by press working using a progressive feeding die apparatus in which a plurality of shape processing stations are appropriately arranged, and successively laminating the foil sheet pieces in the die apparatus. In the method for producing a laminated electric component using an amorphous alloy foil strip material, a plurality of amorphous alloy foil strip materials are laminated and integrated via a heat-resistant adhesive layer, and the amorphous alloy foil Laminated foil of a plate Laminating process for forming a strip material, and a first laminated foil plate piece in which a caulking projection and a through hole into which the caulking projection is inserted are alternately arranged downstream thereof, and the first laminated sheet. Sequential feed including a plurality of shape processing stations for forming a required shape of a second laminated foil plate piece in which a through hole is provided at the position of the caulking projection of the foil plate piece and the caulking projection is alternately arranged at the position of the through hole. Pressing process with mold equipment And a shape processing for forming a required shape of the first laminated foil sheet piece and the second laminated foil sheet piece while intermittently conveying the laminated foil sheet material through the progressive die device. A method for manufacturing a laminated core using a foil sheet material of an amorphous alloy, characterized in that the above are alternately laminated. 2. A foil plate piece is shaped by press working using a progressive die apparatus in which a plurality of shape working stations are appropriately arranged, and the foil sheet pieces are successively laminated in the die apparatus. In the method for producing a laminated electric component using an amorphous alloy foil strip material, a plurality of amorphous alloy foil sheet strips are laminated upstream of the press working step via a heat-resistant adhesive material layer. A laminating step of integrating to form a laminated foil plate material of the amorphous alloy foil plate,
The shape processing mold device, which is obtained by dividing the progressive mold device for each shape processing station, is equipped with an independent press function, and is attached to a plurality of press stations arranged in a tandem through a loop device in an appropriate order. A method for manufacturing a laminated iron core using a foil sheet material of an amorphous alloy, characterized in that it comprises a pressing step. 3. The laminated strip material of a foil plate of an amorphous alloy has a three-layer structure in which a heat resistant adhesive material layer is sandwiched between foil strip materials of an amorphous alloy. A method for manufacturing a laminated core using a foil strip material of an amorphous alloy. 4. The press station has a pair of punching blades arranged one above the other, and alternately alternates a predetermined number of times from the upper and lower surfaces of the laminated foil sheet material to form one of the foil sheets of the laminated foil sheet material. Press function to give shearing deformation to part or all,
The amorphous alloy foil strip material according to claim 2 or 3, characterized in that a pushback function of pushing this back into the punching hole of the laminated foil sheet and a function of removing the punched piece are provided. Manufacturing method of laminated core. 5. The strip-shaped amorphous alloy foil plate,
The method for producing a laminated core using a foil sheet material of an amorphous alloy according to claim 1, characterized in that a heat resistant insulating coating layer is provided on one side or both sides thereof.