JP2008061315A - Manufacturing method of laminated iron core and manufacturing apparatus thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of industrially manufacturing a laminated iron core with high-density winding on a magnetic pole and manufacturing a laminated iron core from an undivided iron core piece with high productivity, and a manufacturing apparatus of the laminated iron core. <P>SOLUTION: Each slot 20 is separated in a circumferential direction, one half 27 thereof is punched and formed using a first punch and a die, the other half 28 is punched and formed using a second punch and a die. Further, the slots 20 are formed on regular positions where the distance among the first and second punches and the die is gradually narrowed from a position of the wider distance in the lower part of the laminated iron core 10, and formed while gradually widening the distance from the regular position on the upper part of the laminated iron core 10. The widths of magnetic pole pieces 16 of iron pieces 14 on an upper and lower layers of the laminated iron core 10 are each gradually made small toward upper and lower ends. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

The present invention relates to a method and an apparatus for manufacturing a laminated core (stator or rotor) used for a motor or a generator by effectively using a core material.

As shown in FIG. 4A, the winding of the laminated core to the magnetic pole part 70 is facilitated by making the annular laminated core into a divided laminated core 72 in which the yoke part 71 is divided for each magnetic pole part 70. In addition, it can be wound with high density. However, as shown in FIG. 4B, which is a YY cross section of FIG. 4A, the winding 73 is workable, but when it is wound around the magnetic pole portion 70, the magnetic pole upper end portion 74 and Clearances 76 and 77 are formed in the magnetic pole lower end 75, and the winding density cannot be further increased. In particular, there is a problem that when the thick winding is wound around the magnetic pole portion 70 so as to reduce the copper loss of the motor, the gap is generated wider.
As a technique for coping with this problem, Patent Document 1 discloses a magnetic pole portion 78 of a laminated iron core as shown in FIG. 5 (B), and an upper end portion 79 and a lower end portion as seen from a cross section as shown in FIG. 5 (A). The width of 80 is gradually reduced. According to this, the winding to the magnetic pole part 78 can be wound without generating a gap in the upper end part 79 and the lower end part 80.

JP 2005-348553 A

However, Patent Document 1 does not clearly disclose the industrial manufacturing method of the laminated core, and there is a problem to develop a method for industrially manufacturing at low cost. In addition, since the laminated core is configured by connecting the divided laminated cores, it is necessary to assemble using a special jig or the like, and punching out the core pieces with a press mold apparatus to directly manufacture the laminated core. There is a problem that cannot be done.

The present invention has been made in view of such circumstances, and industrially manufactures a laminated core capable of high density winding to a magnetic pole part, and manufactures a laminated core with high productivity from undivided core pieces. And an apparatus for manufacturing the laminated core.

According to the first aspect of the invention, there is provided a method for manufacturing a laminated iron core, wherein a workpiece plate is sequentially passed through a press mold line having a plurality of processing stations, and a plurality of magnetic poles having both sides formed by adjacent slots. In the manufacturing method of the laminated core, in which the iron core piece provided with one piece at an equal angular position in the circumferential direction is extracted, and the iron core piece is formed by caulking and laminating via a pre-formed caulking part,
The slots are divided in the circumferential direction, half slots on one side thereof are punched and formed with a first punch and die, and half slots on the other side are punched and formed with a second punch and die. 1. The slot between the second punch and the die is gradually widened from a regular position gradually narrowed from the widened position on the lower side of the laminated core, and is gradually widened from the regular position on the upper side of the laminated core. The widths of the upper and lower layers of the laminated core are gradually narrowed toward the upper end and the lower end, respectively.
The circumferential widths of the first and second punches and dies forming one side of each slot preferably have a circumferential width that is at least half that of the largest circumferential width slot.

A method for manufacturing a laminated core according to a second aspect of the invention is a method for manufacturing a laminated core according to the first aspect of the invention, wherein the first and second punches and dies are used to punch and form the slots. The radial outer contours of the half slots on the one side and the other side at the positions where the first and second punches and the die are at the maximum distance at the positions corresponding to the radially outer sides at the central positions of the slots. A connecting slot for connecting the lines is formed.

A method for manufacturing a laminated core according to a third invention is the method for producing a laminated core according to the first and second inventions, wherein the first punch and die, and the second punch and die are the core pieces. , And the distance between the first and second punches and the die is increased or decreased.

According to a fourth aspect of the present invention, there is provided a laminated iron core manufacturing apparatus that sequentially passes a workpiece plate through a plurality of processing stations, and has a plurality of magnetic pole piece portions formed on both sides by adjacent slots at an equal angle on the circumference. In the manufacturing apparatus of the laminated core, the outer shape of the iron core piece provided at the position is removed, and the iron core piece is caulked and laminated via the caulking portion formed in advance.
Each slot is divided in the circumferential direction, and the processing station is provided with a first punch and die for punching and forming each half slot on one side, and is rotatable about the axis of the iron core piece A first slot punching station for forming the half slot on the one side, and a second punch and die for punching and forming each half slot on the other side, and rotatable about the axis of the core piece. A second slot punching station forming the other half slot,
In punching formation of a desired number of the core pieces at the initial and final stages of stacking the core pieces, the circumferential positions of the first punch and die and the second punch and die are shifted, the one side and Each half slot on the other side is formed, and the widths of the magnetic pole piece portions in the upper layer portion and the lower layer portion of the laminated core are gradually narrowed toward the upper end and the lower end, respectively.

The laminated core manufacturing apparatus according to a fifth aspect of the present invention is the laminated core manufacturing apparatus according to the fourth aspect of the present invention, wherein the slot is inserted into the processing station in the previous process of the first and second slot punching stations. A connecting slot forming station is provided at a position corresponding to the radially outer side at a central position to form a connecting slot for connecting the half slots at positions where the first and second punches and dies are at a maximum distance.

In the method of manufacturing a laminated core according to any one of claims 1 to 3, the half slots on one side and the other side that determine the widths on both sides of the magnetic pole part of the laminated core are formed by punching with the first and second punches and the die, respectively. The interval between the first and second punches and dies is gradually narrowed from the widened position on the lower side of the laminated core to the normal position, and gradually widened from the regular position on the upper side of the laminated core. Each slot consisting of half-slots is formed, and the width of the magnetic pole pieces of the upper and lower layers of the laminated core is gradually narrowed toward the upper and lower ends, respectively. The corners on both sides in the width direction on the upper side and the lower side of each magnetic pole part can be smoothly rounded.
Furthermore, the positions of the first and second punches and dies can be determined while intermittently passing each core piece through the press mold line. Can be given to.

In particular, in the method for manufacturing a laminated core according to claim 2, in the first step of punching and forming the half slot with the first and second slots and the punch, the first position is a position corresponding to the radially outer side at the center position of the slot. The second punch and the die form a connecting slot that connects the half slots at the position where the maximum distance is reached, so that the radially outer positions (ie, contours) of the half slots on one side and the other side are connected. Connect smoothly with slots.

In the method for manufacturing a laminated core according to claim 3, the first punch and the die and the second punch and the die are rotated about the axis of the core piece as a center of rotation. Since the distance between the punch and the die is increased or decreased, the plurality of slots in the circumferential direction can be simultaneously processed to control the width of the magnetic pole portions on the lower layer side and the upper layer side.

The laminated core manufacturing apparatus according to claim 4 and 5 includes a first punch and a die that form a half slot on one side of the slot of the core piece from the workpiece plate and that can rotate around the axis of the core piece. A first slot punching station, and a second slot punching station having a second punch and die that are formed by punching the other half slot of each slot and rotatable about the axis of the core piece. Since it is provided separately, the first and second punches and dies forming the half slots on one side and the other side are arranged without interfering with each other, and the circumference is provided by these first and second punches and dies. Slots having different widths in the direction can be formed.
Further, since the first and second punches and the die for punching the slot are separated, the press load can be dispersed.

In particular, the laminated iron core manufacturing apparatus according to claim 5 is provided in the first and second slot punching stations at a position corresponding to the radially outer side at the center position of the slot. Since the connecting slot forming station for forming the connecting slot for connecting the half slots at the positions where the punches and the die are at the maximum distance is provided, the radial positions of the first and second punches and the die are very small. Even if they are different in range, the contours of the formed slots are smoothly and accurately connected.

Next, a method and apparatus for manufacturing a laminated core according to an embodiment of the present invention will be described with reference to the accompanying drawings to provide an understanding of the present invention.
1A is a plan view of the laminated core manufactured by the manufacturing method according to the embodiment of the present invention, FIG. 1B is a cross-sectional view taken along the line XX, and FIG. FIG. 2 is an explanatory view showing the steps of the manufacturing method of the laminated core, and FIGS. 3A and 3B are explanatory views of a method of forming slots of the laminated core.

First, a stator laminated iron core (an example of a laminated iron core) 10 to which a manufacturing method according to an embodiment of the present invention is applied will be described. As shown in FIG. 1 (A), the stator laminated core 10 has six magnetic pole portions 12 that are equally arranged in the circumferential direction inside an annular yoke portion 11. A rotor hole 13 into which the rotor is fitted is formed inside the magnetic pole portion 12. The laminated core 10 has a yoke piece 15 formed of a core piece 14 formed by stamping a magnetic strip 24 (see FIG. 2), which is an example of a processed plate having a thickness of 0.2 to 0.6 mm, by a press die. And a plurality of caulking portions (in this embodiment, V-shaped caulking is used) 17 formed in the magnetic pole piece portion 16 for caulking and lamination.

The cross section of the magnetic pole portion 12 is shown in FIG. 1B. The upper and lower corners of the magnetic pole piece 16 become narrower and the upper and lower corners of the magnetic pole portion 12 become round with the stacking direction as the top. Yes. As is clear from FIG. 1C, the inner end of the magnetic pole portion 12 has a magnetic pole tooth portion 18 that is widened. The magnetic pole tooth portion 18 also has a narrow width in the upper layer portion and the lower layer portion, and is adjacent to the magnetic pole tooth portion 18. The gap 19 of the magnetic pole tooth portion 18 is structured to gradually widen up and down.
In addition, a notch 21 is formed at the center in the circumferential direction outside the slot 20 forming the magnetic pole portion 12 in the radial direction. When the magnetic pole portion 12 is formed in this way, windings (that is, copper wires) can be smoothly applied to the magnetic pole portion 12, and the winding length can be saved with respect to the same number of windings.

Then, the manufacturing method and manufacturing apparatus of the laminated core which concern on one embodiment of this invention are demonstrated, referring FIG. 2, FIG.
This laminated core manufacturing apparatus 23 has a plurality of processing stations (A) to (J) that constitute a press mold line, and each processing station excluding an idle station includes a punch and a die paired with the punch. A die means comprising the combination of the above is provided, and a predetermined pressing process is performed on the magnetic sheet material 24 that is intermittently conveyed.

Pilot holes 25 are formed at predetermined intervals on both sides. Although this processing station is not shown in this embodiment, it is preferable to provide a station for punching and forming pilot holes 25 in a process preceding the processing station (A) of the manufacturing apparatus 23.
The processing station (A) is a connection slot forming station, and forms a connection slot 26 remaining as a notch 21 formed in the center in the circumferential direction on the radially outer side of the slot 20 of each core piece 14. It is sufficient that the width of the connecting slot 26 is 1 to 2 times the circumferential direction (maximum width−minimum width) of the magnetic pole portion 12 of the stator laminated core 10. The width in the radial direction is, for example, 0.05 to 0.5 mm with respect to the radially outer contour line 29 (see FIG. 1) of the slot 20 to be finally formed. The processing station (B) is an idle station.

In the processing station (C) serving as the first slot punching station, punching of the half slot 27 on one side which has about half the area of each slot 20 and forms one side (clockwise direction) of the magnetic pole piece 16 is performed. Processing is performed using a first punch and die (not shown). When punching out the core piece 14 on the lower layer side in the initial stage of lamination of the stator laminated core 10 and the upper layer side in the final stage of lamination, it is necessary to narrow the width of the magnetic pole piece 16 toward the lower end side and the upper end side, respectively. Since each core piece 14 is stacked from bottom to top, punching of the bottommost core piece 14 on the lower layer side causes the first punch and die to center on the axis of the core piece 14 and the pole piece 16 The rotation is performed counterclockwise by an angle θ degrees from the normal position. Here, as shown in FIG. 1A, θ degrees is, for example, an angle α of the angle α where the arc angle at the position of the average radius r1 of one magnetic pole portion 12 excluding the magnetic pole teeth 18 is α degrees. 1/20 to 1/6 times is preferable. The regular position refers to a position where the half slot 27 on one side of the magnetic pole piece 16 having the normal width is formed.

In this processing station (C), the half slot 27 of the next core piece 14 is also punched. If n is the number of the lower-layer core pieces 14 that reduce the width of the magnetic pole piece 16, the number of θ / n degrees is 1 punch and die are returned (that is, rotated clockwise) to perform press working. The punching operation is performed on the iron core pieces 14 from the bottom to the nth while returning the first punch and die by θ / n degrees. In the n + 1-th core piece 14 from the bottom, the positions of the first punch and the die are the normal positions. Here, n is usually about 3 to 10 sheets, and the core piece 14 (that is, the core piece 14 excluding the upper layer portion and the lower layer portion) of the intermediate layer is in the normal position (that is, θ = 0) and the half slot 27 Punching is performed.

For the upper-layer core piece 14, at this processing station (C), gradually move the first punch and die from the normal position to θ / m degrees (m is the number of the upper-layer core pieces 14, and usually m is n. Rotate in the counterclockwise direction (that is, the direction in which the width of the magnetic pole piece portion 16 is narrowed) by the same amount, but may be different, and finally punch the half slot 27 of the uppermost iron core piece 14 at a position of θ degrees. Finish processing.
Even if the half slot 27 punched and formed by the first punch and die is moved from the normal angular position to the maximum offset position (that is, θ-degree rotation), the outer edge in the radial direction becomes the connection slot 26. The size is determined so as to overlap. The details of the processing station (C) are shown in FIG.

The next station (D) is an idle station. In the processing station (E) serving as the second slot punching station, as shown in FIG. 3B, a second punch and die (not shown) are used to halve the slot 20 of the core piece 14 in the circumferential direction. Punching of the other half slot 28 having the area is performed. In this case, the n-th lower-layer core pieces 14 from the lowermost part are biased by θ degrees in the clockwise direction from the normal position around the axis of the core piece 14 in the first core piece 14. The half-slot 28 is punched by moving the second punch and the die to the position where the magnetic pole piece 16 is finally narrowed to the smallest width. In the second core piece 14 from the bottom, the second punch and the die are moved in the normal position direction (that is, counterclockwise direction) by θ / n degrees, and the half slot 28 is punched. When the above process is applied to the nth core piece 14 from the bottom, the half slot 28 of the (n + 1) th core piece is in the normal position. Here, the positions of the second punch and the die are fixed, and the half slot 28 of the core piece 14 of the intermediate layer of the required number is punched as it is.

With respect to the m core pieces 14 in the upper layer portion, the second punch and die in the normal position are moved eccentrically by θ / m degrees (that is, rotated in the clockwise direction), and the half-slot 28 is gradually moved. Move the cut position clockwise. The second punch and die are symmetrical with the first punch and die. One slot 20 is formed by the two half slots 27 and 28. Then, both sides of the magnetic pole piece 16 are formed by the adjacent slots 20. The lower layer portion and the upper layer portion iron core piece 14 constituting the stator laminated iron core 10 have the slot 20 wider toward the lower end side and the upper end side, respectively, whereby the width of the magnetic pole piece portion 16 is reduced.

The station (F) is an idle station, and the next processing station (G) is a station for forming a caulking hole 17a in the lowermost iron core piece 14. The processing station (G) is an idle station for the second and subsequent iron core pieces 14.
The next processing station (H) is a station for forming the caulking portion 17 (V-shaped caulking) on the second and subsequent iron core pieces 14 from the bottom. The first iron core piece 14 is an idle station.
The processing station (I) is a processing station for punching out the rotor hole 13, and this punch and die are formed between adjacent magnetic pole tooth pieces 30 formed at the tip of the magnetic pole piece 16 of each iron core piece 14. A blade for punching the gap 19 is also provided.
The processing station (J) is an outer shape removal station, in which the iron core pieces 14 are punched from the magnetic sheet material 24 and are caulked and laminated in a lower mold. The stator laminated core 10 is formed through the above processing stations (A) to (J).

In the above-described embodiment, the upper and lower iron core pieces 14 of the magnetic pole part 12 are formed at the same angle (that is, θ / n or θ / m) by the first and second punches. Since the die is moved, the four corners of the cross section of the magnetic pole portion 12 are linearly chamfered. However, when the arc portion is formed, the first and second punches with respect to the thickness of the iron core piece and Arbitrary cross-sectional shapes can be obtained by placing the movement amount of the die on a circle function or an ellipse function.
Moreover, in the said embodiment, although the number of magnetic poles was 6, it is applicable also to the laminated iron core which has the magnetic pole of the number of other than that.

(A) is a top view of the laminated iron core manufactured by the manufacturing method which concerns on one embodiment of this invention, (B) is arrow XX sectional drawing, (C) is arrow A figure. It is explanatory drawing which shows the process of the manufacturing method of the same laminated iron core. (A), (B) is explanatory drawing of the formation method of the slot of the same laminated iron core, respectively. (A), (B) is explanatory drawing of the laminated iron core which concerns on a prior art example. (A), (B) is explanatory drawing of the laminated iron core which concerns on a prior art example.

Explanation of symbols

10: Stator laminated iron core, 11: Yoke part, 12: Magnetic pole part, 13: Rotor hole, 14: Iron core piece, 15: Yoke piece part, 16: Magnetic pole piece part, 17: Caulking part, 17a: Caulking hole, 18 : Magnetic pole tooth part, 19: gap, 20: slot, 21: notch, 23: laminated core manufacturing device, 24: magnetic strip material, 25: pilot hole, 26: connecting slot, 27, 28: half slot, 29: Outline, 30: Magnetic pole piece

Claims (5)

The workpiece plate is sequentially passed through a press mold line having a plurality of processing stations, and a plurality of magnetic pole pieces formed on both sides by adjacent slots are provided at equal angular positions in the circumferential direction. In the method for manufacturing a laminated core in which the iron core piece is formed by caulking and laminating via a pre-formed caulking portion,
The slots are divided in the circumferential direction, half slots on one side thereof are punched and formed with a first punch and die, and half slots on the other side are punched and formed with a second punch and die. The slot between the first and second punches and the die is gradually widened from a regular position gradually narrowed from the widened position on the lower side of the laminated core, and is gradually widened from the regular position on the upper side of the laminated core. A method of manufacturing a laminated core, characterized in that the width of the magnetic pole piece portions of the upper layer portion and the lower layer portion of the laminated core are gradually narrowed toward the upper end and the lower end, respectively. 2. The method of manufacturing a laminated core according to claim 1, wherein, in the step before punching and forming each of the slots with the first and second punches and the die, at a position corresponding to a radially outer side at a central position of each of the slots. The laminated iron core is characterized in that a connecting slot is formed to connect the radially outer contour lines of the half slots on the one side and the other side at a position where the first and second punches and dies are at a maximum distance. Manufacturing method. 3. The method of manufacturing a laminated core according to claim 1, wherein the first punch and the die and the second punch and the die rotate around the axis of the core piece as a rotation center. A method of manufacturing a laminated iron core, wherein the interval between the first and second punches and the die is enlarged or reduced. A plate to be processed is sequentially passed through a plurality of processing stations, a core piece having a plurality of magnetic pole piece portions formed on both sides by adjacent slots at equal angular positions on the circumference is extracted, and the core piece In a manufacturing apparatus for a laminated iron core for caulking and laminating via a caulking portion formed in advance,
Each slot is divided in the circumferential direction, and the processing station is provided with a first punch and die for punching and forming each half slot on one side, and is rotatable about the axis of the iron core piece A first slot punching station for forming the half slot on the one side, and a second punch and die for punching and forming each half slot on the other side, and rotatable about the axis of the core piece. A second slot punching station forming the other half slot,
In punching formation of a desired number of the core pieces at the initial and final stages of the stacking of the core pieces, the circumferential positions of the first punch and die and the second punch and die are shifted so that the one side and the other The laminated core manufacturing apparatus is characterized in that each half-slot is formed and the widths of the upper and lower layers of the laminated core are gradually narrowed toward the upper end and the lower end, respectively. 5. The laminated core manufacturing apparatus according to claim 4, wherein the first and second slot punching stations have a first step, a center position of the slot, and a position corresponding to the radially outer side. An apparatus for manufacturing a laminated core, comprising: a connection slot forming station for forming a connection slot for connecting the half slots at positions where the second punch and die are at a maximum distance.

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