JPH10271772A - Laminated sheet without burr, and its manufacture and device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a laminated sheet product at low cost without burrs at a key part, by stamping out strip sheets along the external form after stamping them out from below for the first to the Lth and from above for the L+1th to the nth, and then, integrating them. SOLUTION: A laminated rotor core 20 is constituted by stacking three sheets of rotor core elements, and the rotor core 15 positioned in the lowermost position is a rotor core element stamped with a lower die, and other rotor cores 16 and 17 are rotor core elements stamped with upper dies. Then, the upward burrs 35 produced at the topside of the element 15 stamped with a lower die and the downward burrs 36 produced at the bottom of the rotor core element 16 stamped with an upper die are press-fitted and united with each other in a state of facing, so they do not project out of a winding part. Moreover, the burrs 36 at the downside of the uppermost rotor core element 17 with an upper die are abutted against and suck fast to the shear drop at the topside of the rotor core element 16 stamped with an upper die right below it, so they do not project out of the winding part. As a result, a laminated core without burrs at the winding can be manufactured at low cost.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated sheet product and a method and apparatus for producing the same. In particular, a laminated thin plate component (for example, a laminated core) having no burr in the main part, and an in-die laminated composite processing method and a progressive composite die capable of manufacturing such a laminated thin plate component at low cost were used. The present invention relates to a laminated sheet component manufacturing apparatus.

[0002]

2. Description of the Related Art In manufacturing laminated sheet metal parts, composite molds are awarded. In this type of composite mold, a pressing step and an assembling step after the pressing are sequentially or simultaneously processed. This eliminates the need for a large number of single-function facilities, reduces the installation space and personnel required for them, dramatically improves work efficiency, and greatly improves product accuracy and product life. A typical laminated sheet metal component is a laminated core. For manufacturing the laminated core, a dedicated composite mold is used. As an example of a laminated core manufacturing apparatus using a composite mold of this type, an article entitled "Laminated core automatic caulking rotary mold" in "Technical Magazine Press Technology Vol. 21 No. 10" (pp. 38-43). There is something introduced by.

A plan view of a laminated rotor core manufactured by such a laminated core manufacturing apparatus is the same as that shown in FIG. The cross section of the winding part w of the laminated rotor core is as shown in FIG. In FIG. 6, reference numeral 20 denotes a thin laminated rotor core, and first, three rotor core elements 5, 5,
5 are sequentially laminated, pressed and caulked. The swaged state is caused by the static friction force generated between the swaged hole 45 (or the measurement hole h) of the lower rotor core element 5 and the cut-and-raised (projection) p of the upper rotor core element 5. Will be maintained. Three rotor core elements 5,
As is well known to those skilled in the art, Nos. 5 and 5 are separately punched from separate portions of a long strip-shaped steel plate (strip) using a punch and a die.

[0004] The winding portion w of each rotor core element 5 is formed by punching the left and right sides thereof downward with slot punches before punching the outer shape. 10 is
11 is the cut generated by this, and 11 is the cut 10
The sagging surface 12 generated at the upper end of the cut 10 is a burr generated at the lower end (ridge line) of the cut 10. FIG. 9 is a plan view of a winding portion of another conventional laminated rotor core. The laminated rotor core 20 of FIG. 9 includes only two rotor core elements.
Further, w is a winding portion having no cut and raised, and 13 is a winding portion w.
This is the winding applied to. As is well known, the winding w is coated with an insulating coating. FIG. 10 is a cross-sectional view of a winding portion of the laminated rotor core of FIG. This cross section is indicated by line A in FIG.
-A. In FIG.
5 is a rotor core element, 12 and 12 are burrs, and 13 is a covered winding. (In general, the cuts generated by punching are "drain,""shear(shear),""fracture," and "burr."
(Burr). Burrs are burrs (warpage) around a cut edge caused by a blade. And its occurrence is generally unavoidable. In this context, burrs are also part of the product structure. As described above, each rotor core element 5 is inevitably attached to the burr 12.
Occurs. According to the conventional in-mold composite machining method, the burrs 12, 12 remain at the lower ends of the cuts of the respective winding portions of the laminated rotor core 20, as shown in FIG.

[0005] In the conventional laminated core manufacturing apparatus, all kinds of punches are arranged in an upper mold, and all corresponding dies are arranged in a lower mold. That is, the mold arrangement is of a sequential arrangement type. The reason is to keep up with gravity. FIG. 7 is a strip layout (process setting) diagram of a progressive composite mold in a conventional laminated core manufacturing apparatus. In FIG. 7, 1 is a strip-shaped steel plate (strip), 38
Is the upper surface, and ph is the pilot hole (the hole penetrating the bottom). A large number of pilot holes ph are formed at regular intervals in the longitudinal direction and in pairs in the short direction. Then, two pairs (four) of pilot holes (p
h, ph) and (ph, ph) are all processed areas. For convenience of explanation, the rightmost processed area is referred to as a “first processed area”, and hereinafter, in the order from right to left, the “second processed area”, “ .., “N-th processed area”, “N + 1-th processed area”,. From the inside of each processing area, the rotor core element, from the outside, the stator core element,
Can be cut out. In FIG. 7, black portions indicate punched portions, and thick lines indicate cut portions.

[0006] The position of each processing area during the processing of the strip-shaped steel sheet 1 can be corrected by inserting a sharp-pointed pilot (pin) into the pilot hole ph. (The tip shape of the pilot (pin) is preferably a bullet shape or a conical shape.) The work area in the press machine is machined by a composite mold every stroke of the press machine, and a progressive mechanism is provided. , The document is sequentially advanced from left to right (in the direction of the arrow). The processed state of the strip-shaped steel sheet 1 shown in FIG. 7 is a processed state after the processing has progressed 10 strokes or more after the start of the processing. A series of dies for processing the strip-shaped steel sheet 1 are disposed above and below the passage of the strip-shaped steel sheet 1, respectively. In FIG. 7, the positional relationship between the symbols a to j arranged at equal intervals symbolically represents the positional relationship between the dies inside the press machine. In other words, different molds A to J are arranged at positions a to j in the press machine. In addition, a punch and a die (not shown) for punching a pilot hole are arranged in front of the mold A.

[Working on the first work area] When the first work area of the strip-shaped steel sheet 1 arrives at the position a in FIG. 7, the first step of the press machine is performed. That is, all the slots (see 44 in FIG. 2) of the desired rotor core element in the processing area are completely punched out by a slot punch for rotor (not shown; the same applies hereinafter). FIG. 7a shows only three rotor slots as a representative of the whole. The first processed area processed in the first step is then advanced to position b. When the first work area arrives at the position b, the first step of the press machine is performed. That is, a desired slot portion of the stator core element 5 (not shown).
The same applies hereinafter) are completely punched out by the slot punch for stator. In FIG. 7B, only six status lots are shown as a representative of the whole. The first processed area processed in the second stroke is then advanced to position C.

When the first work area arrives at the position c, a third stroke of the press machine is performed. That is, the measuring punch for the rotor core element (not shown) pops out and becomes the same height as the other punch surfaces, whereby the desired caulking position of the rotor core element 5 is completely punched out and the measuring hole h is formed there. Is formed (the predetermined swaging positions are, for example, three). When the metering hole h having no convex portion is provided, the metering hole h is not coupled to the rotor core element 5 immediately below but separated. (For the second to N-th processing areas (where N is a predetermined number of stacked layers), the measuring core punch for the rotor core element is not extruded and, therefore, is not perforated.) The third processing performed in the third step The first work area is then advanced to position d.

When the first work area arrives at the position d, a fourth stroke of the press machine is performed. That is, a desired inner shape (inner area) of the rotor core element 5 is completely punched out by the inner punch for the rotor core element. However, the cut-and-raised forming punch for the rotor core element is not extruded to a predetermined position, and therefore, is not perforated. (However, this does not apply to the (N-1) -th processed areas from the second to the N-th.) The first processed area processed in the fourth step is located next to the position e. It is forwarded toward.

When the first work area arrives at the position e, the fifth step of the press machine is performed. That is, the outer shape (outer outline) of the desired rotor core element 5 is cut by the rotor core element outer shape punch, and the first rotor core element 5 is cut off. The cut-out first rotor core element 5 is held in the lower die as shown in FIG. (Incidentally, the cut-off rotor core element 5 is often required to be rotated and placed at every stroke of the press machine, or smaller or larger. For example, the rotation of the rotor is improved, the thickness deviation is removed, In such a case, it is desirable to minimize the deflection of the inner and outer shape, in which case, for example, the cylindrical rotating body (squeeze ring) 53 shown in FIG.
At the same time, the lower mold may be rotated. As a result, only the area for manufacturing the stator core element remains in the first processed area. The first processed area (remaining processed area) processed in the fifth step is then advanced to the position f.

When the first work area arrives at the position f, the sixth step of the press machine is performed. That is, a desired inner shape (inner area) of the stator core element is completely punched by the inner punch for the stator core element. The first processed area processed in the sixth step is then advanced to position g. Position g
When the first work area arrives, the seventh step of the press machine is performed. In other words, the caulking position for the stator core element in the same area is completely punched out by the stator core element measuring punch, and the measuring hole h is formed. (This does not apply to the (N-1) processing areas from the second to the N-th processing area.) The first processing area processed in the seventh step is then moved to the position h. Are forwarded.

When the first work area arrives at the position h, an eighth stroke of the press machine proceeds. At this time, the stator core element / cut-and-raised forming punch is not pushed out to a predetermined position, so that the cut-and-raised punch is not formed. (However, the second to Nth
This does not apply to the (N-1) processed areas up to the first. ) The first processed area processed in the eighth stroke is then advanced to position i.

When the first work area arrives at the position i, the ninth stroke of the press machine proceeds. No special processing is performed here. The first work area is then advanced to position j. When the first work area arrives at the position j, the first of the press machine
Zero strokes are performed. That is, the outer shape (outer outline) of the desired stator core element in the processing area is cut by the stator core element outer shape punch, and the first stator core element is cut off from the inside of the processing area. The cut stator core element is held in a stator core element outer die (lower die) as shown in FIG. (Incidentally, the cut-off stator core element 6 is also often required to be rotated or placed small or large for each stroke of the press machine. In such a case, for example, a cylindrical rotating body shown in FIG. 8 is used. (The lower die may be rotated by rotating the (squeeze ring) 53.)

[Processing of the 2nd to Nth Workpieces] The second to Lth workups on the strip-shaped steel sheet 1 are the first in the position a. All the slots (44) of the desired rotor core element 5 are completely punched out by the rotor core element slot punch, and at the position b, as in the first processed area, All the portions corresponding to the slots of the stator core element 6 are completely punched out by the stator core element slot punch, and the position c
Is not processed in

At the position d, the inner shape (inner area) of the desired rotor core element 5 is the same as in the first processed area.
The portion is completely punched out by the internal punch for the rotor core element, but different from the first processed area, at each caulking position between the inner diameter and the outer shape (outer outline) of the element 5. Forming downward cut-outs, each of which has a crimp hole on its upper surface side and each crimp convex portion on its lower surface side. The outer (outer contour) portion of the rotor core element 5 is cut by a rotor core element outer shape punch, and the internal rotor core element 5 is cut off. As shown in FIG. While being stacked, unlike the first processed area, each of the caulking holes on the upper surface side of the rotor core element 5 that has just been dropped is pressed downward by a press-fit pin (not shown), and Direction Are pressed into the respective measurement holes (separation and caulking holes) or the caulking holes of the rotor core element 5 immediately below, and the upper and lower rotor core elements 5 and 5 are brought into close contact with each other by the frictional force of the cut surfaces thereof ( In other words, at the position f, the desired inner shape (inner area) of the stator core element 6 is completely punched out by the inner punch for the stator core element at the position f, similarly to the first processed area.

At the position g, no machining is performed, and at the position h, unlike the first work area, the punching and punching forming punches for the stator core element are provided at the respective swaging positions within the desired stator core elements. Thereby, for example, eight cut-and-raised portions are formed, and a caulking hole is formed on the upper surface side thereof.
On the lower surface side, a downwardly protruding portion appears, and at the position j, the outer shape (outer outline) of the desired stator core element is cut by an outer shape punch for the stator core element as in the first processed area. Then, the internal stator core element is cut off and stacked in the outer shape cutting die (lower die) for the stator core element, as shown in FIG. 8, while being different from the first processed area, the upper stator core element 6
Are pressed from above by respective push pins (not shown), and the protruding portions of the respective cut and raised portions are pressed into the respective swaged holes of the lower stator core element 6. (I.e., caulked). The swaged state is maintained by the frictional force generated at the joint between each swaged hole (or measuring hole) of the lower stator core element 6 and each cut-out (projection) of the upper stator core element 6. .

[Working on the (N + 1) th work area] The first work area on the (N + 1) th work area of the strip-shaped steel sheet 1 at the positions a to j. The same processing as described above is performed. At the position e, the (N + 1) th rotor core element 5 cut off from the strip-shaped steel sheet 1 is superimposed on the Nth rotor core element 5 cut off earlier, but they are not joined. . The (N +
1) The first rotor core element is already completely punched at the position c to be cut and raised, and therefore does not have the cut and raised (projection) p for caulking / coupling.
At the position j, the (N
+1) The Nth stator core element 6 is superimposed on the N-th stator core element 6 cut off earlier, but the two are not joined. The (N + 1) -th rotor core element 6 is already punched out at the position g at a position to be cut and raised, and thus is cut and raised (projection) for caulking and coupling.
This is because p does not have p.

[Processing of (N + 2) -th to (N + 2) -th processing zone of strip-shaped steel sheet 1], (N + 2) -th of the strip-shaped steel sheet 1
Processing of the 2Nth work area is performed by
This is the same as the processing for the Nth processed area. Thus, a laminated rotor core composed of N rotor core elements is
From the lower mold at the position e, it is generated every 10 strokes after the 14th stroke of the press machine. The generated multiple laminated rotor cores are taken out of the lower mold in a separated state without being bonded to each other. The laminated rotor core taken out of the lower mold does not need to be repressurized. Also, a laminated stator core composed of N pieces of stator core elements is generated from the lower mold at the position j every 10 strokes after the 19th stroke of the press machine. The generated large number of laminated stator cores are taken out of the lower mold in a separated state without being connected to each other. The laminated rotor core taken out of the lower mold similarly does not need to be repressurized.

[0019]

2. Description of the Related Art In the conventional laminated core manufacturing apparatus, as described above, all the various punches are arranged in the upper die holder, and all the corresponding dies are all arranged in the lower die holder. Therefore, the operating direction of the punch with respect to the thin plate to be processed is
That is, always from above to below. Therefore, the thin burr generated by the punching operation of the thin plate is always generated at the lower end (lower ridge line) of one of the thin plate portions left on the die, and the other thin plate portion dropped into the die is formed. Then, it always occurs at the upper end (upper ridge) of the cut. Moreover, such a burr generation phenomenon
It becomes remarkable as the number of punches increases, and eventually grows over the entire periphery of the cut.

All of the winding portions w of the rotor core element 5 formed by the conventional in-mold laminating / combining process are formed by punching downwardly the predetermined slot sections (cass portions) 44 (see FIG. 2) on both right and left sides thereof. Therefore, all the burrs 12 of the winding part w generated by this are present at the lower end of the cut as shown in FIG. 6 or FIG. As described above, the conventional laminated rotor core 20 is manufactured by laminating N (N ≧ 2) rotor core elements 5 as they are (that is, without reversing the upper and lower surfaces), and pressing and caulking. Therefore, the burrs 12 generated at the lower ends of the left and right cuts of the winding portion w of the first rotor core element 5 remain on the lower ridge portion (corner portion) of the winding portion w as it is. Projecting downward is inevitable. Such burrs 12 remaining at and protruding from the lower ridges (corners) of the winding portion w of the laminated rotor core 20 are used to insulate the winding 13 applied to the winding portion w. The coating may be damaged, causing an electrical short circuit accident through the burr itself, which may also cause a fire. That is, the performance, durability, and safety of the motor may be impaired.

To avoid such a risk, the remaining burr 1
In particular, the paint must be so thick that it fills in 2. In that case, a coating film having a thickness of about 0.2 to 0.3 mm must be formed on one side. However, even if such measures are taken, it is still not possible to completely wipe out the risk of short-circuiting or fire at the time of the unstable electric withstand voltage test or at the customer after delivery. . First, increasing the thickness of the coating film results in a corresponding increase in cost. Therefore, the conventional laminated core manufacturing apparatus
While providing a number of benefits as described above, the laminated core 20 manufactured therefrom has the above-mentioned hidden problems. (Note that the burrs 12 generated on the second to Nth rotor core elements 5, 5,... There is no particular problem because it is almost in contact with the sagging surface.)

[0022]

SUMMARY OF THE INVENTION Therefore, a first object of the invention of the present application is to provide a novel in-mold laminating / combining method capable of producing a laminated thin plate product having no burrs at a main portion at a low cost. To provide. A second object of the invention of the present application is to provide a laminated core manufacturing apparatus using a novel progressive composite mold, which can produce a laminated thin plate product having no burrs in the main part at a low cost. is there. A third object of the invention of the present application is to provide a low-cost laminated thin plate product having no burrs at its main part. A fourth object of the invention of the present application is to realize a laminated thin plate product having no burrs in a main part, thereby simplifying and facilitating a subsequent coating process. A fifth object of the invention of the present application is to realize a laminated thin plate product having no burr in a main part, thereby further improving the performance, durability and safety of a motor using the product.

[0023]

[Means for achieving the object]
In order to achieve the above object, the method of manufacturing an N-sheet (N ≧ 2) burr-free laminated thin plate according to the invention of the present application is based on the first to L-th strip-shaped thin plates 1. The inside of each of the L processed areas (N> L ≧ 1) is
L upward punching step of completely punching upward from below with an upward punch 29 to form a space 44 of a predetermined pattern 46 inside each of the L processed areas; 1, M (L + 1) -th to N-th processed areas (M = NL,
Each interior of M ≧ 1) is completely punched downward from above by the downward punching punch 30 of the predetermined pattern 46, and the space 44 of the predetermined pattern 46 is formed inside each of the M processing areas. Forming M downward punching steps, and completely punching one or a plurality of predetermined caulking positions in the first processed area downward from above by a lamination number determining punch, A separating and crimping hole punching step for forming a plurality of separating and crimping holes h, and one or more crimping schedules in each of the (N-1) second to N-th (N-1) processing areas At the position, forming a cut and raised by a cut and formed forming punch,
(N-1) cut-and-raise forming steps for exposing the crimping holes 45 on the upper surface side and the crimping convex portions p on the lower surface side, and the internal space of each of the N number of processing areas. A contour 48 of a predetermined shape that surrounds 44
By the outer shape punch 41 having the same shape,
Cut completely, pull out the thin plate element in the same contour 48,
Stack as it is without turning over the top and bottom, N
Each time the outer shape extracting step and the above-mentioned thin plate elements are pulled out and stacked, each caulking hole 45 on the upper surface side of the thin plate element is formed.
By pressing down from above with a press-fit pin, the projections p on the lower surface side are separated and swaged holes h in the thin plate element immediately below.
Or (N-1) crimping steps for press-fitting into the crimping hole 45, thereby bringing the two into close contact, joining and integrating.

The manufacturing apparatus of the present invention for producing an N-sheet (N ≧ 2) burr-free laminated thin plate includes a progressive mechanism for sequentially feeding a long strip-shaped thin plate 1, and a first feed mechanism on the strip-shaped thin plate 1. The inside of each of the L processed areas (N> L ≧ 1) up to the L-th is punched upward from below to form a space 44 of the predetermined pattern 46 in each of the L processed areas. Upward punch 29 of the predetermined pattern 46
Upward punch punching-in / out means connected to the lower surface of the upward punch 29 and capable of pushing or retracting the tip of the punch 29 to a predetermined height in the vertical direction; A downward punching die 32 having a predetermined negative pattern and cooperating with the belt-like thin plate 1 above the punch 29 and the passing area of the above-mentioned ribbon-like thin plate 1, and a puncher punched into the downward punching die 32. A scrap removing means for removing the scrap, and M (L + 1) -th to N-th processing areas (M = M) on the strip-shaped thin plate 1 at a stage subsequent to the downward punching die 32; NL, M ≧ 1) is completely punched downward from above to form a predetermined pattern forming a space 44 of a predetermined pattern 46 in each of the M processing areas. Downward punching punch 30 of 46,
A downward punch punching-in / out means connected to the upper surface of the downward punch 30 and capable of pushing or retracting the tip of the punch 30 to a predetermined height in the vertical direction; 30 and an upward punching die 31 having a predetermined negative pattern and cooperating with the punching punch 30 below the passage area of the strip-shaped thin plate 1; and one or a plurality of punching dies in the first processed area. The punching position is completely punched downward from above to form one or a plurality of separating and caulking holes h. Extruded to the height of
A stacking number determining punch entering / exiting means that can be retracted, a stacking number determining die below the passing area of the stacking number determining punch and the band-shaped thin plate 1 and cooperating with the stacking number determining punch, At the one or more predetermined swaging positions inside each of the (N-1) processing areas from the second to the N-th, crimping cut-and-raised portions are formed downward, and their upper surface sides are formed. To form a crimping hole 45 and a crimping convex portion p on the lower surface side, a cut-and-raised forming punch, the cut-and-raised forming punch, and the strip-shaped thin plate 1.
And a cutting and forming die which cooperates with the cutting and forming punch and a predetermined shape which is at the last stage and surrounds the predetermined space 44 in each of the processing areas. The contour 48 is completely cut in sequence, and
An external punch 41 having a predetermined shape, which pulls out the thin plate element inside and stacks it without inverting the upper and lower surfaces,
An outer shape die 4 below the outer shape punch 41 and the band-shaped thin plate 1 and cooperating with the outer shape punch 41.
2 and inside the outer shape punch 41, projecting slightly below the lower end surface of the outer shape punch 41, and each of (N-1) pieces to be processed from the second sheet to the N-th sheet. From the inside of the area, the thin plate elements are sequentially cut into the outer die 42, and each time they are stacked, the caulking hole 45 on the upper surface side of each cut and raised formed in the thin plate element is pressed from above. Then, each of the convex portions p on the lower surface side is press-fitted into each of the separating and caulking holes h or the caulking holes 45 in the thin plate element immediately below, so that the press-fit pin and the press-fitting pin make the two close contact, join and integrate. A lower die holder 28 for holding the upward hole punch 29, the upward hole punch in / out means, the upward hole die 31, the lamination number determining die, the cut-and-raised forming die, and the outer shape die 42; , The downward punching die 32, above The scrap removal means, the downward punching punch 30, the downward punching punch and out means, the stacked number determination punch, the laminated number determination punch and out means, the cut-and-raised form punch and the outer punch 4
1, and an upper die holder 27 for holding the press-fit pin;
An upper die holder driving mechanism connected to the upper die holder 27 and driving the holder 27 downward;
A control device for giving an operation timing to each of the upper die holder driving mechanism, the upward punch punching in / out means, the downward punching punching in / out means, and the lamination number determining punch in / out means. .

The burr-free laminated thin plate of N sheets (N ≧ 2) according to the invention of the present application is composed of L to L-th processing zones (N> L) on a long strip-shaped thin plate. ≧ 1) is completely punched upward from below with a predetermined pattern 46 upward punch to form a space 44 of the predetermined pattern 46 in each of the L processed areas. , And for the first processed area,
Separating and caulking holes h are respectively formed at one or a plurality of caulking scheduled positions inside, and the second to L-th (L
-1) For each of the processed areas, a downward crimping cut-and-raise is formed at one or a plurality of scheduled crimping positions inside each, and a crimping hole 45 is formed on the upper surface side, and the lower surface side is formed. Then, a caulking convex portion p is made to appear, and thereafter, a predetermined contour 48 having a predetermined shape surrounding the internal space 44 of each of the processed areas is formed by an external punch having the same shape.
In order, the thin plate elements in the same contour 48 are cut out completely, the thin plate elements in the same contour 48 are dropped out, and the upper and lower surfaces are stacked as they are without being inverted, and the L thin plate elements and the (L +
1) M processed areas from the (N) th to the (N) th (M = N
−L, M ≧ 1) is completely punched downward from above by a downward punching punch of the predetermined pattern 46, and the space of the predetermined pattern 46 is provided inside each of the M processing areas. 44, and at each of one or a plurality of scheduled swaging positions inside each of these processed areas, a downwardly directed swaging portion is formed, and a swaging hole 45 is formed on the upper surface side, and a lower surface is formed. On the side, a caulking convex portion p is made to appear, and thereafter, a predetermined contour 48 having a predetermined shape surrounding the space 44 is formed by an external punch having the same shape.
Sequentially, complete cutting is performed, the thin plate element within the same contour 48 is dropped out, and the above L
M thin plate elements stacked above the two thin plate elements,
The first thin plate element and the second thin plate element are each formed by a swaging hole 45 on the upper surface side of the second thin plate element.
Are pressurized from above, and each caulking projection p
Are pressed and inserted into the respective separating and caulking holes h of the first thin plate element immediately below, so that they are brought into close contact with each other and joined together, and the ith thin plate element (i = 2, 3,..., N− 1) and the (i + 1) th thin plate element, each of the swaging holes 45 on the upper surface side of the (i + 1) th thin plate element is pressed from above, and each of the swaging convex portions p on the lower surface side thereof Press-fit into each of the caulking holes 45 on the upper surface side of the i-th thin plate element immediately below, so that they are brought into close contact with each other.
The thin plate elements are tightly joined, joined and integrated as a whole.

[0026]

BEST MODE FOR CARRYING OUT THE INVENTION

[Points of Embodiment of the Invention] Generally, a laminated thin plate is made of N
It is formed by laminating two thin plate elements. Where N
Is an arbitrary integer of 2 or more. A feature of the laminated sheet of the invention of this application is that there are no outwardly projecting burrs as far as the spaces or slots formed in the profile are concerned. The method for manufacturing a laminated thin plate according to the present invention has the following characteristics in order to produce such a burr-free laminated thin plate at a low cost. (1) Space or slot to be formed within the outer shape of each thin plate element In the case of punching, a lower die punching step contrary to the usual method is introduced, and the lower die punching step is performed for the first L sheets.
For the subsequent M sheets, an upper die-cutting step is performed.
(2) An outer shape removing step is arranged after the lower die removing step and the upper die removing step relating to the space or slot in the outer shape of each thin plate element. (3) The outer shape is extracted (L + M =
N) Laminate and integrate the thin plate elements in this order and without inverting them. The production of the laminated sheet of the invention of this application also naturally has the above-mentioned features.

[First embodiment of laminated thin plate without burrs] A first embodiment of a laminated thin plate (for example, a laminated rotor core) of the present invention will be described. FIG. 2 is a plan view of the laminated rotor core according to the invention of this application. In the figure, 20 is a laminated rotor core, s is a slot,
4 is a slot punching portion or punching waste, 47 is an inner shape,
48 is an outer shape. The laminated rotor core 20 is generally formed by laminating N (here, three) rotor core elements. Reference numeral 45 denotes a predetermined number of caulking holes (holes with a bottom) formed on the uppermost rotor core element. Although not shown, the planar shape of the swaging hole 45 is a rectangle here, and its long side direction matches the radial direction of the rotor. (In other places, the long side direction of the rectangle can be designed to match the circumferential direction of the core. Further, the planar shape can be a sector shape or an arc shape.)
FIG. 2 is a partial cross-sectional view of the laminated rotor core according to the invention of the present application, and shows a cross section taken along a cutting line (BB) shown in FIG. In the same figure, 20 is a laminated rotor core, w is its winding part, 37 is its lower surface, and 38 is its upper surface. The laminated rotor core 20 according to the first embodiment includes one lower die-cut rotor core element 15 and two upper die-cut rotor core elements 16 and 17.

In FIG. 1, h is a separation and caulking hole (a hole without a bottom) formed in a predetermined winding portion W of the lowermost rotor core element 15, and 45 is a winding of the other rotor core elements 16 and 17. The swaging holes (holes with a bottom) formed on the upper surfaces of the portions, and p is a convex portion formed on the lower surfaces thereof. Hereinafter, the whole including the swaged hole 45 and the convex portion p is referred to as “cut and raised”. 10 vertical cut occurring in the left and right sides of the winding part w, 10 ₁ are perpendicular cut occurred with reference to the long side of the isolation and the caulking hole h (radial direction of the rotor), 10 ₃
Is a vertical wall formed along the long side of the caulking hole 45. The wall surface generated along the short side direction does not need to be a vertical surface, and may be a slope. Furthermore,
Vertical wall surface 10 formed along the long side of caulking hole 45
₃ may be cut in some cases. Each downward convex portion (not shown in the figure) of the immediately upper rotor core element 16 is press-fitted and caulked in each of the separation and caulking holes h of the lowermost unmolded rotor core element 15, and each caulking hole (not shown) of the rotor core element 16 is provided. (Not shown), the downwardly projecting portions p of the uppermost die-cut rotor core element 17 are press-fitted and caulked, and thus three rotor core elements 1 are formed.
5, 16, and 17 are integrated. Coupling state between the two rotor core elements 15 and 16 in contact phase, a perpendicular cut 10 ₁ of each separation and caulking hole h of the element 15, vertical sides of each convex portion of the element 16 (unsigned) and It is held by the static frictional force generated at the press contact portion, and the connection state between the two rotor core elements 16 and 17 is also determined by the swaged hole 4 of the element 16.
5 is held by a similar static friction force generated at the press-contact portion between the vertical wall surface (no symbol) of the element 17 and the vertical side surface of the downward convex portion p of the element 17.

The laminated rotor core 20 of FIG. 1 contains three rotor core elements as described above, but one rotor core element 15 located at the lowest position among the three rotor core elements is a lower die-cut rotor core element. Other two rotor core elements 1
Each of 6 and 17 is a rotor core element without an upper die.
The rotor core element 15 from which the lower mold is removed has a sag surface 4 on the lower surface side.
0 and a burr 35 on the upper surface side.
Each of the upper die-cut rotor core elements 16 and 17 has sag surfaces 39 and 39 on the upper surface side, and burrs 36 and 36 on the lower surface side.
Having. In general, the laminated sheet contains N rotor core elements, but the laminated sheet of the invention of the present application is such that the lower L (L ≧ 1) of the N sheets are the lower die-cut sheet elements, and are above them. The remaining M (M ≧ 1) sheets are thin plate elements without an upper die.

The upward burrs 35 generated on the upper surface of the lower die-cut rotor core element 15 and the downward burrs 36 generated on the lower surface of the upper die-cut rotor core element 16 are pressed into each other in a state where they face each other. Therefore, the burrs 35 and 36 do not protrude outside the winding part. Also, a burr 36 on the lower surface side of the uppermost upper punched rotor core element 17 is provided.
The burr 36 does not protrude outwardly (in the direction normal to the cut 10) of the winding portion because it is brought into contact with and adheres to the sagging surface on the upper surface side of the upper die-cut rotor core element 16 immediately below.
Thus, the lower surface 37 and the upper surface 38 of the winding portion w of the laminated rotor core 20 have no burrs at all, and no burrs are present on the left and right side surfaces. Therefore, the upward burrs 35 of the rotor core element 15 formed by the lower punching of the slot s and the downward burrs 36, 36 of the rotor core elements 16 and 17 formed by the upper punching of the slot s are formed on the winding portion w. There is no risk of damaging the applied insulation coating of the winding 13. The basic effect of the laminated rotor core 20 is as follows.
Even if the number of elements, the outer shape of the element, the inner diameter or the shape of the slot, or the type of the material is changed, it can be stored without change. Therefore, the basic configuration of the laminated rotor core 20 can be applied to the laminated stator core and also to the laminated thin plate in general.

[First Embodiment of a Method for Producing a Laminated Thin Plate Without Burrs] A first embodiment of a method for producing a laminated thin plate of the present invention will be described. FIG. 3 is an explanatory diagram of the first embodiment. In the figure, 1 is a long strip-shaped steel plate (in-process state), 38 is an upper surface thereof, and ph is a number of pilot holes (a hole penetrating the bottom). The pilot holes ph are formed so as to be equidistant in the longitudinal direction and to form a pair in the transverse direction. The leftmost three pairs (6
) Of the pilot holes are drawn narrower in the longitudinal direction for the sake of space, but are actually the same as the longitudinal intervals of the other pilot holes. As a result, the inside of each of the two pairs (four) of pilot holes ph is each processed area. The left and right sides of each processed area are “edge” (bridge), and the space between the processed areas is “feed”. The role of the pilot hole ph is to correct the position of the work area by allowing a sharp pilot (pin) to enter therein. It is desirable that the tip shape of the pilot (pin) is bullet-shaped or conical. Counting from the rightmost end (most extreme) of the strip-shaped steel sheet 1, for example, the first to third processed areas produce the first laminated rotor core,
A second laminated rotor core is produced from the sixth to sixth processed areas. The same applies hereinafter. Generally, a first laminated rotor core is obtained from the first to N-th processed areas (N is the number of laminated layers), and the first to the (N + 1) -th to (2N) -th processed areas are obtained. Produces a second laminated rotor core, and in the same manner as above,
-1) From the (N + 1) th to the (jN) th processed areas (j = 3, 4,...), A j-th laminated rotor core is produced.

Each work area of the strip-shaped steel sheet 1 is processed by a series of punches and dies for each stroke of the press machine, and is sequentially fed from left to right by a progressive mechanism. Therefore, if attention is paid to an arbitrary one and the same processing area, which is sequentially fed from the left to the right, the in-mold lamination and complex processing for that is as follows from the first step to the eleventh step. , 11 steps. That is, the first step is a pilot hole punching step (step number not shown), the second step is a lower die punching step, the fourth step is an enlarged pilot hole punching step (step number not shown), and the fifth step is a matching mark. A punching step (step number not shown), a seventh step is an upper die removing step of the slot, an eighth step is an inner punching step, a ninth step is a step of determining the number of laminations (step number is not shown), and a tenth step is cut and raised. The forming process and the eleventh process are an outer shape removing process and a caulking process. The third step,
The sixth step is an idle step (the punching step is not performed).

First, for manufacturing the laminated rotor core 20 shown in FIGS. 1 and 2 comprising three rotor core elements,
The main steps will be described. The remaining steps and details of each step will be described later. In the first step (pilot hole punching step), a pair of pilot holes ph, ph to be positioned on the short-side straight line are punched out for all the processing areas of the strip-shaped steel sheet 1. Here, a pair of pilot punches and pilot dies located near the left end of the strip-shaped steel plate 1 and a pair of pilot punches and pilot dies (not shown; the same applies hereinafter) located near the right end of the belt-shaped steel plate 1 cooperate. . In the second step (slot lower punching step) 22, lower punching of a predetermined slot pattern 46 is performed only on the first processed area. In this step, an upward punch having a predetermined slot pattern 46 (lower die) and a downward punching die having a predetermined negative slot pattern (upper die) are used. In the seventh step (upper die removing step of the slot), only the two to second processing areas are processed,
The upper die of the predetermined slot pattern 46 is removed. Here, a downward punch (upper die) having a predetermined slot pattern 46 and an upward punch die (lower die) having a predetermined negative slot pattern cooperate.

In the ninth step (step of determining the number of stacked layers), the first
-Th, fourth, (4 + 3i) -th (i = 1, 2, 2,
…)), Only at the to-be-processed area, the intended swaging position is completely punched downward from above to form a separation and swaging hole h. Here, the stacked number determining punch and the stacked number determining die cooperate. In the tenth step (cut-and-raise forming step), the second to third steps are performed.
For only the individual processing areas, a crimping cut-and-raise is formed at the predetermined crimping position. The upper surface side of the cut-and-raised portion for caulking is a caulking hole 45, and the lower surface side is a caulking convex portion p. Here, the cut-and-raised forming punch and the cut-and-raised forming die cooperate. In the eleventh step (outer shape removing step and crimping step), the outer shape surrounding the above-mentioned slot group is completely cut downward in all the processing areas of the strip-shaped steel sheet 1, and the rotor core elements are dropped out and stacked. Each time the rotor core element is pulled out and stacked, pressure is applied from above to each of the swaging holes 45 on the rotor core element to separate the projections p on the lower surface side of the rotor core element from the immediately lower rotor core element. The crimping hole h or the crimping hole 45 is press-fitted, and the two are closely contacted and joined. In this step, a contour punch, a contour die, and a press-fit pin are used.

[Second Embodiment of a Method for Producing a Burr-Free Laminated Thin Plate] The above-mentioned production method for a three-layer laminated burr-free laminated rotor core is composed of any number of two or more burr-free laminated thin plates. Can be extended to the manufacturing method.
Therefore, next, the main steps for manufacturing an N-piece laminated thin plate without burrs (N is an arbitrary integer of 2 or more) will be described. The remaining steps, as well as details of each step, will also be described later. The first step is the same as in the case of the three-sheet configuration. In the second step (the lower die removing step of the space), the first to L-th L processed areas (L
Is an arbitrary integer that satisfies the condition L ≧ 1), and the lower die of the predetermined space pattern is removed. In this step,
An upward punching hole of a predetermined space pattern and a downward punching die of a predetermined negative space pattern,
used. In the seventh step (upper die removing step of the space), the (L + 1) -th to (L + M) -th M processed areas (M is an arbitrary one satisfying the condition M = NL and M ≧ 1) The upper die of the predetermined pattern is removed only for (integer). In this step, a predetermined pattern of downward punches and a predetermined negative pattern of upward punch dies are used.

In the ninth step (step of determining the number of stacked layers), the first
For only the (1 + N) -th and (1 ++ N + iN) -th (i = 1, 2,...) Processing areas, the caulking expected position is completely punched downward from above,
The separation and swaging hole h is formed. Here, a stacked number determining punch and a stacked number determining die are used. In the tenth step (cut-and-raise forming step), only the (N-1) -th to (N-1) -th to-be-processed areas are formed with the crimp-and-raise at the crimp-scheduled portions. The upper surface side of the cut-and-raised portion for caulking is a caulking hole 45, and the lower surface side is a caulking convex portion p. Here, a cut-and-raised punch and a cut-and-raised die are used. In the eleventh step (outer shape removing step and crimping step), the element contour of the predetermined shape surrounding the space of the predetermined pattern is completely cut downward for all the processing areas of the strip-shaped steel sheet 1 to form the inner thin plate. The elements are pulled out and stacked without being turned over. Each time, each of the caulking holes 45 on the thin plate element is pressurized from above, so that the respective convex portions p on the lower surface side are separated and crimped holes h in the thin plate element immediately below.
Alternatively, they are press-fitted into the caulking holes 45, and the two are closely contacted and joined. Here, the external punch, the external die, and the press-fit pin cooperate or cooperate.

[Third Embodiment of Burr-Free Laminated Thin Plate Manufacturing Method] A third embodiment of the burr-free laminated thin plate manufacturing method of the present invention will be described. In the third embodiment, the ninth step (the number-of-laminations determining step), the tenth step (the cut-and-raise forming step), and the caulking step in the eleventh step can be omitted. Instead, the first
A tightening step of bringing the N thin plate elements stacked in one step (outer shape removing step) into close contact with each other and integrating them must be arranged after the same step. Other items in the third embodiment of the method for manufacturing a laminated thin plate without burrs are the same as those in the second embodiment.

[First Embodiment of Laminated Sheet Manufacturing Apparatus] A first embodiment of a laminated thin sheet manufacturing apparatus according to the present invention will be described. FIG. 4 is a vertical sectional view of the left half of the laminated core manufacturing apparatus according to the first embodiment of the present invention, and FIG. 5 is a vertical sectional view of the right half of the laminated core manufacturing apparatus. . 4 and 5, reference numeral 50 denotes a lower die assembly;
26 is a die plate group and 28 is a lower die holder. 29
Upward drilling punch having a predetermined slot pattern 46 (see FIG. 3), 29 ₂ is upward movable stripper plate. The upward punch 29 includes a plurality of (for example, 24) punch bodies and an upward punch plate 29.
_{And 1} . 49 is a top die assembly 27 is upper holder 27 ₁ is downward movable stripper. 32 is
A downward punching die having a predetermined negative pattern, which opposes and cooperates with an upward punching punch 29. The lower surface of the upward drilling punch 29 (i.e. the lower surface of the upward punch plate 29 ₁₎ are connected upward drilling punch and out means. The punch punching in / out means comprises, for example, an air cylinder and a cam.
To the vicinity of the lower surface of the strip-shaped steel plate 1 (that is, to the same position as the tip surface of the die plate group 26),
You can withdraw. The operation timing is L times (1 ≦ L) for N strokes of the press machine.
<N) and is provided by a controller (not shown). The slot punching die 32 is combined with slot punching scrap removing means (not shown) in order to remove slot punching scraps cut off inside the die 32. The slot removing debris removing means is constituted by a mechanical type (for example, a knockout pin), a pneumatic type (for example, an air blow), or a combination thereof.

[0039] 30 is a downward punching punch having a predetermined slot pattern 46, a plurality of punch body (e.g. 24) consists of a downward punch plate 30 ₁ Tokyo. On the upper surface of the downward punching punch 30 (i.e. downward punch plate 30 ₁ of the upper surface), which is connected downward drilling punch and out means. The punch punching-in / out means comprises, for example, an air cylinder and a cam, and pushes or retracts the distal end face of the downward punch 30 to a predetermined position (that is, to the same position as the distal end faces of other punches). I can do it. The operation timing is given by a control device (not shown) at a rate of M times (M = NL) for N strokes of the press machine. 31
Are upward facing punching dies having a predetermined negative pattern that cooperates and cooperates therewith.

Reference numeral 51 denotes a downward internal punch, 52 denotes an upward internal die that cooperates and cooperates with the punch, 41 denotes a hollow cylindrical downward external punch, and 42 denotes an opposing and cooperates upward. Die. The upward punch 29, the movable upward stripper plate 29 ₂ , the upward punch die 31, the inner punching die 52, and the outer die 42 are all held by the lower die holder 28.
A pair of pilot hole punching dies is arranged in front of the upward punching punch 29 having a predetermined slot pattern 46 (see FIG. 3), and a pair of pilot punching dies is provided between the upward punching die 29 and the upward punching die 31. , An enlarged pilot hole punching die and a matching mark punching die are arranged,
Between the outer die 2 and the outer die 42, a die for determining the number of stacked layers and a cut-and-raised forming die are arranged, and the lower dies thereof are all supported by the lower die holder 28. The lower die holder 28 is provided with a scrap drop hole below each punching die.

Downward punching die 32, slot removing scrap removing means (all or a part thereof), downward punching punch 3
0, the inner punch 51, and the outer punch 41 are all supported by the upper die holder 27. A pair of pilot hole punching punches are disposed in front of the downward punching die 32, and the downward punching die 32 and the downward punching punch 3 having the predetermined slot pattern 46 are provided.
0, an enlarged pilot hole punch and a matching mark forming punch are arranged.
A punch for determining the number of laminations and a punch for forming a cut-out are arranged between the outer shape punch 41 and the outer shape punch 41. The stacking number determining punch is combined with a stacking number determining punch in / out means capable of extruding or retracting the leading end surface of the punch to the same position as the leading end surface of another punch. The access means comprises, for example, an air cylinder and a cam. The operation timing is given by a control device (not shown) at a rate of once per N strokes of the press machine. The above upper molds are all supported by the upper mold holder 27.

The upper die holder 27 is attached to a slide or a ram (neither is shown) in the press machine.
The slide is connected to a slide drive mechanism. Here, the slide drive mechanism is of a mechanical type, but may be of a hydraulic type or a pneumatic type. Upward hole punching in / out means,
The operation timings of the slide drive mechanism and the progressive feed mechanism, the number of stacked sheets determining punch, the slot removing scrap removing means, etc.
Provided by a controller (not shown). The strip-shaped steel plate 1 is fed forward from the left to the right through the space between the upper die and the lower die.

[Details of In-Mold Lamination Composite Processing] Details of the in-mold lamination composite processing according to the invention of this application will be described. In the first step, pilot holes ph, ph are punched in all the processing areas on the long strip-shaped steel sheet 1. In other words, a pair of pilot holes ph, p
When h is formed, one processing area is determined.
Regarding three pairs (six) of pilot holes shown at the left end of FIG. 3, their longitudinal intervals are drawn narrow for convenience of drawing, but actually, the longitudinal intervals of the other pilot holes are different from those of the pilot holes. Are identical. In the second step 22, at the timing before and after the first, fourth,..., (3j + 1) -th processed areas (j ≧ 2) on the strip-shaped steel sheet 1 arrive, the leading end face of the upward punch 29 is It is projected to the same position as the upper surface of the die plate group 26 by the upward punch. When the downward punching die 32 descends, it is punched upward from below by an upward punching punch 29 to form 24 slots as shown in FIG.

In general, the first (1-L),
The (N + 1 to N + L),..., (Nj + 1 to Nj + L) th processing areas (j ≧ 2) are punched upward from below by the upward punch 29 of the slot pattern 46, and the slot punching scum is removed from the punching die. It remains in 32 holes. The slot scrap left in the hole of the punching die 32 is removed out of the hole by, for example, a lockout pin, and subsequently discharged out of the mold by means such as an air blow. In the fourth step, the diameter of the pilot hole ph is enlarged. In the fifth step, three matching marks are formed. The alignment mark is used for alignment and angle adjustment between the rotor core elements.

In the seventh step, the (2, 3), (5,
6),..., {(3j + 2), (3j + 3)} th processed area (j ≧ 2) is punched upward from below by the downward punch 30 of the slot pattern 46;
As shown, 24 slots are formed. Generally,
(L + 1 to N), (N + L + 1 to 2) on the strip steel plate 1
The (N),..., {(Nj + L + 1) to (N + 1) j} th processed area (j ≧ 2) is punched downward from above by the downward punch 30 of the slot pattern 46. In an eighth step 43, an inner shape (outline) 47 is punched out of a predetermined area of each rotor core element 10 by an inner shape punch 51. In the ninth step, the first, fourth,..., (3j + 1) th regions to be cut and cut on the strip-shaped steel sheet 1 are punched by the lamination number determination punch. In the tenth step 24, the second (2,
3), (5, 6), ..., ｛(3j + 2), (3j +
3) The cut-and-raised p is formed in the｝ th work area.

In the eleventh step 25, the outer shape (outline) of the rotor core element planned area in each processing area on the strip-shaped steel sheet 1 is sheared by the outer shape punch 41, and the rotor core element 15 is cut off from the processing area. As shown in FIG. 8, the cut-off rotor core element 15 is stacked in an outer die (lower die) 42, and a crimping hole 45 (concave side of the cut and raised p) is pressed by a downward press-fit pin. As a result, the downwardly protruding portion p of the upper rotor core element (for example, 16) is press-fitted into the crimping hole 45 of the lower rotor core element (for example, 15), and both are brought into close contact with each other. That is, it is caulked. Caulked state, as described above, the incision 10 _first separation and the caulking hole h or caulking holes 45, occurs between the side surface (or cut) of the cut-and-raised p, it is held by static friction force. In the first embodiment, as described above, three rotor core elements are integrated. That is, the first to third sheets, the fourth to sixth sheets,..., {(3j + 1) to (3j + 3)}.
The second rotor core element (j ≧ 2) is integrated. In other words, between the third and fourth rotor core elements, between the sixth and seventh rotor core elements,..., The third j-th and the (3
No connection is made during the (j + 1) th sheet. What is the fourth
As described above, none of the seventh, seventh, and (3j + 1) th rotor core elements have the cut-and-raised p.
This is because there is no mere surface contact between the (3j) th and (3j + 1) th rotor core elements.

[Second Embodiment of Burr-Free Laminated Thin Sheet Manufacturing Apparatus] A second embodiment of the burr-free laminated thin sheet manufacturing apparatus of the present invention will be described. In the second embodiment, two or more composite dies used in the first embodiment are arranged in parallel. Then, the progressive feeding mechanism for the parallel sheets (materials) is united. In this case, the composite molds may be the same or different. The individual molds are uniformly controlled by an electronic control device so as to operate in synchronization with each other. Other configurations of the second embodiment of the burr-free laminated sheet manufacturing apparatus of the invention of this application are the same as those of the first embodiment. Second
According to the embodiment, a plurality of rows of punching can be performed simultaneously and in parallel on one long strip-shaped steel plate. Therefore, productivity can be improved.

[Third Embodiment of Burr-Free Laminated Thin Sheet Manufacturing Apparatus] A third embodiment of the burr-free laminated thin sheet manufacturing apparatus of the present invention will be described. In the third embodiment, two or more composite dies used in the first embodiment are arranged in series. Then, the sheet (raw material) forward feed mechanism at the very beginning and the last end is left, and the intermediate forward feed mechanism is omitted. In this case, it is desirable that the composite molds be of different types. The individual molds are uniformly controlled by an electronic control device so as to operate in synchronization with each other.
The remaining configuration of the third embodiment is the same as that of the first embodiment. According to the third embodiment of the burr-free laminated sheet manufacturing apparatus, two or more kinds of laminated sheet products can be produced simultaneously and in parallel from one long strip-shaped sheet.

[Fourth Embodiment of Burr-Free Laminated Sheet Manufacturing Apparatus] A fourth embodiment of a burr-free laminated sheet manufacturing apparatus of the present invention will be described. In the fourth embodiment, among the individual dies in the third embodiment, any one of the dies capable of performing simultaneous and parallel processing on the same region to be processed is used as much as possible. It is a summary of the processing points. The remaining configuration of the fourth embodiment is the same as that of the third embodiment. According to the fourth embodiment of the burr-free laminated sheet manufacturing apparatus, two or more kinds of burr-free laminated sheet products are simultaneously and concurrently produced from one long strip-shaped sheet. , The number of steps can be reduced, and space can be saved. In addition, when the above two kinds of burr-free laminated sheet products have an interlocking relationship (for example, a rotor core and a stator core), they can be cut out from the same work area, so that sheet material can be saved. Becomes

[0050]

Since the invention of this application is configured as described above, the following remarkable effects can be obtained. (1) Since the laminated core according to the invention of this application has no burrs in the winding portion, there is no possibility of damaging the insulating-coated winding applied thereto. Therefore, it is possible to eliminate the possibility of an electric short circuit via a burr, and to improve the performance, durability and safety of the motor. (2) The laminated core manufacturing apparatus according to the invention of the present application has a simple structure, simple handling, and low cost. (3) The laminated core manufacturing apparatus according to the invention of the present application can produce a laminated core having no burrs in the winding portion at low cost. (4) Similarly, there is no burr in the main part, and the cost is low.
Laminated sheet products can be manufactured. (5) By manufacturing a laminated sheet product having no burrs in the main part, it is possible to contribute to simplifying the subsequent coating process. (6) According to the invention of this application, the productivity of the laminated thin plate without burrs is improved.

[Brief description of the drawings]

FIG. 1 is a partial cross-sectional view of a first embodiment of a laminated rotor core of the present invention.

FIG. 2 is a plan view of the first embodiment of the laminated rotor core of the present invention.

FIG. 3 is an explanatory view of a first embodiment of a method for manufacturing a laminated rotor core according to the present invention;

FIG. 4 is a longitudinal sectional view of the left half of the first embodiment of the laminated core manufacturing apparatus of the present invention.

FIG. 5 is a vertical sectional view of the right half of the first embodiment of the laminated core manufacturing apparatus of the present invention.

FIG. 6 is a partial sectional view of a conventional laminated rotor core.

FIG. 7 is a strip layout diagram of a progressive composite mold of a conventional laminated core manufacturing apparatus.

FIG. 8 is an explanatory diagram of a laminating / caulking process for a laminated rotor core and the like.

FIG. 9 is a plan view of a winding portion of another conventional laminated rotor core.

FIG. 10 is a cross-sectional view of a winding portion of another conventional laminated rotor core.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS ₁ Strip-shaped steel plate (strip-shaped metal thin plate) 5 Conventional rotor core 6 Conventional stator core 10 Slot cutout 10 ₁ Wall surface of caulking hole 45 ₃ Cutoff of separable and caulking hole h 11 Drip surface 12 Burr 13 Rotor winding 15 Lower die-cut rotor core Element 16 Upper die-cut rotor core element 17 Upper die-cut rotor core element 20 Laminated rotor core 22 Second step 23 Seventh step 24 Tenth step 25 Eleventh step 26 Die plate group 27 Upper die holder 27 ₁ Downward movable stripper 28 Lower die holder 29 Upward punch (lower type) 29 ₁ Upward punch plate 29 ₂ Upward movable stripper plate 30 Downward punch (upper type) 31 Upward punching die (lower type) 32 Downward punching die (upper type) 35 Upward burr 36 Downward burrs 37 Lower surface of strip steel plate 38 Upper surface 39 Upper sagging surface 40 Lower sagging surface 41 Outer punch 42 Outer die 43 Eighth process 44 Slot punching part or scrap 45 Caulking hole 46 Slot pattern (space pattern) 47 Inner shape 48 Outer shape 49 Upper die assembly 50 Lower die Assembly 51 Internal punching die 52 Internal punching die 53 Cylindrical rotating body (squeeze ring) h Separation and crimping hole p Caulking protrusion s Slot (space) ph Pilot hole

Claims (7)

[Claims] 1. A method for manufacturing a burr-free laminated thin plate having N sheets (N is an integer and N ≧ 2), wherein the first to the L-th L on a long strip-shaped thin plate (1). The inside of each of the processed areas (L is an integer and N> L ≧ 1) is inserted into an upwardly directed punch (2) of a predetermined pattern (46).
According to 9), the blank is completely punched upward from below to form a space (s) of a predetermined pattern (46) inside each of the L processed areas, and L upward punching steps; (1) The inside of each of the M (L + 1) -th to N-th work areas (M = NL, M ≧ 1) is inserted into a downward hole punch (3) of a predetermined pattern (46).
0), punching completely downward from above to form a space (s) of a predetermined pattern (46) inside each of the M processing areas, and performing M downward punching steps; One or a plurality of predetermined swaging positions in the first processed area are completely punched downward from above by a stacking number determination punch to form one or a plurality of separation and swaging holes (h). Separating and caulking hole punching process, and caulking by a cut-and-raised forming punch at each of one or a plurality of predetermined caulking positions in the (N-1) second to N-th work areas. (N-1) cut-and-raising forming steps to form a crimping hole (45) on the upper surface side and a crimping convex portion (p) on the lower surface side. The space (s) inside each of the N processed areas is The contour (48) of a predetermined shape to be surrounded is sequentially and completely cut by an outer shape punch (41) of the same shape, the thin plate element in the contour (48) is pulled out, and the upper and lower surfaces are not inverted. Each time when the thin plate element is pulled out and stacked, each of the caulking holes (45) on the upper surface side of the thin plate element is pressed downward from above by a press-fit pin. Lower side convex part (p)
Into the separation and crimping hole (h) or the crimping hole (45) in the thin plate element immediately below.
And (N-1) crimping steps to be integrated. 2. A method for producing a burr-free laminated thin plate having N sheets (N is an integer and N ≧ 2), wherein the first to the L-th L on a long strip-shaped thin plate (1). The inside of each of the processed areas (L is an integer and N> L ≧ 1) is inserted into an upwardly directed punch (2) of a predetermined pattern (46).
According to 9), the blank is completely punched from below to above to form a space (s) of a predetermined pattern (46) inside each of the L pieces of processing areas, and L upward punching steps; (1) The inside of each of the M (L + 1) -th to N-th work areas (M = NL, M ≧ 1) is inserted into a downward hole punch (3) of a predetermined pattern (46).
0), punching completely downward from above to form a space (s) of a predetermined pattern (46) inside each of the M processing areas, and performing M downward punching steps; A predetermined contour (48) of a predetermined shape surrounding the internal space (s) of each of the N processing areas is sequentially and completely cut by an external punch (41) of the same shape,
A thin plate element in the same contour (48) is dropped out, and the upper surface and the lower surface are stacked without inverting, and the outer shape removing process is performed N times; and the N stacked thin plate devices are tightly integrated with each other, and a tightening process is performed. A method for producing a laminated thin plate without burrs. 3. A manufacturing apparatus for a burr-free laminated thin plate having N pieces (N is an integer and N ≧ 2), comprising: a progressive feeding mechanism for sequentially feeding a long strip-shaped thin plate (1); 1) L from 1st to Lth above
The inside of each of the plurality of processing areas (L is an integer and N> L ≧ 1) is punched out from the bottom to the top, and the space (s) of the predetermined pattern (46) is provided in each of the L processing areas. ) To form a predetermined pattern (46), which is connected to an upward punch (29), and a lower surface of the upward punch (29). An upwardly perforated punching-in / out means capable of being extruded or retracted; and a band-shaped thin plate (1) above the upwardly-perforated punch (29) and a passing area of the band-shaped thin plate (1).
A downward drilling die (32) having a predetermined negative pattern, cooperating with the above, a punching die removing means for removing a punching dust dropped inside the downward punching die (32); and the downward punching die. In the stage subsequent to (32), the inside of each of the (L + 1) -th to N-th M processed areas (M = NL, M ≧ 1) on the strip-shaped thin plate (1) is described. , Downward punching (30) of the predetermined pattern (46) forming a space (s) of the predetermined pattern (46) inside each of the M processing areas by completely punching from the upper side to the lower side. And a downward punch punching-in / out means connected to the upper surface of the downward punch (30) and capable of vertically extruding or retracting the tip of the punch (30) to a predetermined height in the vertical direction. , The above downward hole An upward punching die (31) having a predetermined negative pattern, which is located below a passage area of the punch (30) and the band-shaped thin plate (1) and cooperates with the punch (30); Completely punching one or a plurality of caulking positions within the processing area of
Alternatively, a stacking number determining punch forming a plurality of separation and caulking holes (h), and a tip of the stacking number determining punch can be extruded or retracted to a predetermined height in a vertical direction.
A stacking number determining punch in / out means, a stacking number determining die below the passage area of the stacking number determining punch and the band-shaped thin plate (1), and cooperating with the stacking number determining punch; At one or more predetermined swaging positions inside each of the (N-1) processing areas up to the N-th, swaging cut-and-raising is formed downward, and swaging holes ( 45), a cut-and-raised forming punch for exposing a crimping convex portion (p) on the lower surface side, and the cut-and-raised forming punch and the cut-and-formed punch below the passing area of the strip-shaped thin plate (1). A cutting and forming die which cooperates with the forming and forming punch, and a predetermined contour (48) of a predetermined shape in the last stage and surrounding a predetermined space (s) in each of the processing areas are sequentially and completely formed. And remove the thin plate element in the same contour (48) An external punch (41) having a predetermined shape, which is dropped and stacked as it is without inverting the upper and lower surfaces. A cooperating outer die (42), inside the outer punch (41), projecting slightly below the lower end surface of the outer punch (41), from the second to the Nth sheet Each time the thin plate element is cut off from the inside of each of the (L + 1) processed regions to be cut into the outer shape die (42) and stacked, each of the cut and raised portions formed in the thin plate element is cut. Crimp hole on top side (45)
Are pressed from above, and each convex portion (p) on their lower surface side is pressed.
Is pressed into each of the separating and caulking holes (h) or the caulking holes (45) in the thin plate element immediately below.
A press-fit pin to be joined / integrated; the upward punch; the upward punch; the upward punch; A lower die holder (28) for holding an outer shape die (42); a downward punching die (32); a scrap removing means; a downward punching punch (30); An upper die holder (27) for holding the number-of-laminations determining punch, the punching-in / out means for determining the number of laminations, the cut-and-raised forming punch, the outer shape punch (41), and the press-fit pin, and the upper die holder (27) And the holder (27)
To the upper die holder driving mechanism, the forward feed mechanism, the upper die holder driving mechanism, the upward punch punching in / out means, the downward punching punch in / out means, and the stacking number determining punch in / out means. And a control device for giving an operation timing, respectively. 4. The apparatus for producing a laminated thin plate without burrs according to claim 3, wherein the tip of the cutting and raising punch can be pushed out and retracted to a predetermined height in a vertical direction. The lower die holder (27) also holds the cut-and-punch punching-in / out means, and the control device also gives an operation timing to the cut-and-punching punch-in / out means. Equipment for manufacturing laminated sheets. 5. A manufacturing apparatus for a burr-free laminated thin plate having N sheets (N is an integer and N ≧ 2), comprising: a progressive feeding mechanism for sequentially feeding a long band-shaped thin plate (1); 1) L from 1st to Lth above
The inside of each of the plurality of processing areas (L is an integer and N> L ≧ 1) is punched out from the bottom to the top, and the space (s) of the predetermined pattern (46) is provided in each of the L processing areas. ) To form a predetermined pattern (46), which is connected to an upward punch (29), and a lower surface of the upward punch (29). An upwardly perforated punching-in / out means capable of being extruded or retracted; and a band-shaped thin plate (1) above the upwardly-perforated punch (29) and a passing area of the band-shaped thin plate (1).
A downward drilling die (32) having a predetermined negative pattern, cooperating with the above, a punching die removing means for removing a punching dust dropped inside the downward punching die (32); and the downward punching die. In the stage subsequent to (32), the inside of each of the (L + 1) -th to N-th M processed areas (M = NL, M ≧ 1) on the strip-shaped thin plate (1) is described. , Downward punching (30) of the predetermined pattern (46) forming a space (s) of the predetermined pattern (46) inside each of the M processing areas by completely punching from the upper side to the lower side. And a downward punch punching-in / out means connected to the upper surface of the downward punch (30) and capable of vertically extruding or retracting the tip of the punch (30) to a predetermined height in the vertical direction. , The above downward hole An upward punching die (31) having a predetermined negative pattern and cooperating with the punch (30) below the punching punch (30) and the band-shaped thin plate (1). Then, predetermined contours (48) of a predetermined shape surrounding the predetermined space (s) in each of the above-mentioned processing areas are sequentially and completely cut, and thin plate elements in the contours (48) are pulled out. Are stacked as they are without being inverted, and cooperate with the outer shape punch (41) having a predetermined shape, and the outer shape punch (41) and the outer shape punch (41) below the passage area of the strip-shaped thin plate (1). An outer die (42), the upward punch (29), the upward punch punch in / out means, the upward punch die (31), and the lower die holder (28) for holding the outer die (42).
An upper die holder (27) for holding the downward punching die (32), the scrap removal means, the downward punching punch (30), and the outer shape punch (41); and the upper die holder (27). And an upper die holder driving mechanism for driving the holder (27) downward, the forward feed mechanism, the upper die holder driving mechanism, the upward punch punching in / out means, and the downward punch punching in / out means. And a control device for giving an operation timing, respectively. 6. A lamination-free laminated thin plate of N pieces (N is an integer, N ≧ 2), wherein L to-be-processed areas (1 to L-th) on a long strip-like sheet are provided. L is an integer, and N> L ≧ 1) is completely punched from the bottom to the top by an upward punch in a predetermined pattern (46), and inside each of the L processed areas, A space (s) of a predetermined pattern (46) is formed, and a separation and caulking hole (h) is formed at one or a plurality of caulking scheduled positions inside the first processed area. For each of the (L-1) pieces to be processed from the second to the L-th, each downward or downward caulking cut-and-raise is formed at one or a plurality of caulking scheduled positions inside each, and their upper surfaces are formed. The side has a swaged hole (4
5), a crimping convex portion (p) is exposed on the lower surface side, and then a predetermined contour (48) of a predetermined shape surrounding the internal space (s) of each of the processed areas is formed. An L-shaped thin plate element, which is completely cut in sequence by the same shape outer punch, pulls out thin plate elements within the same contour (48), and is stacked as it is without inverting the upper and lower surfaces, and Of the (L + 1) -th to N-th processed areas (M = NL, M ≧ 1) are formed from above to below by a predetermined pattern (46) downward punch. To form a space (s) of a predetermined pattern (46) in each of the M processing areas, and to form one or a plurality of spaces in each of these processing areas. Form a downwardly oriented swaging for each swaging at the expected swaging position, On the top side of them are swaged holes (4
5), a crimping convex part (p) is exposed on the lower surface side, and then a predetermined contour (48) surrounding the space (s) is formed by an external punch having the same shape as the predetermined contour (48).
The sheet elements in the same contour (48) are sequentially cut completely, and the sheet elements in the same contour (48) are dropped out, and M sheet elements stacked above the L sheet elements without reversing the upper and lower surfaces. The first thin plate element and the second thin plate element are configured such that each of the swaging holes (45) on the upper surface side of the second thin plate element is pressurized from above, and the lower surface side thereof is closed. Each caulking convex part (p)
Are pressed and inserted into the respective separating and caulking holes (h) of the first thin plate element immediately below, so that they are brought into close contact with each other and joined together, and the ith thin plate element (i = 2, 3,...) (N-1) and the (i + 1) th thin plate element, each of the swaging holes (45) on the upper surface side of the (i + 1) th thin plate element is pressurized from above, and each of the swaging holes on the lower surface side thereof. The protrusions (p) are pressed into the respective caulking holes (45) on the upper surface side of the i-th thin plate element immediately below, so that they are brought into close contact with each other, so that the N thin plate elements are joined together. A burr-free laminated sheet that is closely adhered, joined and integrated as a whole. 7. A lamination-free laminated thin plate having an N-piece configuration (N is an integer, N ≧ 2), wherein L to-be-processed areas (first to L-th) on a long strip-shaped thin plate are provided. L is an integer, N> L
≧ 1) is completely punched upward from below with a predetermined pattern (46) upward punch, and a space of the predetermined pattern (46) is formed in each of the L processed areas. (S), and then a predetermined contour (48) of a predetermined shape surrounding the space (s),
An L-shaped thin plate element, which is sequentially cut completely by an outer shape punch having the same shape, pulls out thin plate elements within the same contour (48), and is stacked as it is without inverting the upper and lower surfaces; The inside of each of the M (L + 1) -th to N-th work areas (M = NL, M ≧ 1) is formed from above by a downward punch in a predetermined pattern (46). The blank is completely punched downward to form a space (s) of a predetermined pattern (46) inside each of the M processing areas, and then has a predetermined shape surrounding the space (s). The predetermined contour (48) is sequentially and completely cut by an outer shape punch having the same shape as above, the thin plate element in the same contour (48) is pulled out, and the L thin plates are left as they are without inverting the upper and lower surfaces. Stacked above the element , M thin plate elements, and the N thin plate elements are brought into close contact with each other by fastening means.
A laminated thin plate without burrs.