JP3181029B2 - Manufacturing method of laminated core - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a laminated core such as a motor and a transformer.

[0002]

2. Description of the Related Art Since a conventional laminated core is generally of an integral type, winding is difficult and a large number of coils cannot be arranged in a limited space. A strip-shaped connecting stator core in which the magnetic pole block is formed to be bendable through the thin portion has been proposed. After winding the winding, the thin portion is bent to form an annular shape, thereby facilitating the winding operation. Is becoming

[0003]

In manufacturing a laminated core, the magnetic member is divided into a portion that can be effectively used as the core and a portion that is discarded as scrap. And
In the case of an induction machine, an armature motor, or a transformer, the rotor is also formed of a laminated core, in the case of a band-shaped connecting core configured as described above, a larger portion is discarded as scrap than an integrated core. Therefore, there is a problem that the material cost is increased and the cost increases accordingly.

Further, as shown in FIG. 19, it is necessary to arrange the connecting core 1 to increase the width of the mold to the developed length, or to increase the pitch feed (not shown) to the developed length. is there. When the mold width is increased, the equipment becomes expensive because it is necessary to select a progressive feed press having a large bed size for mounting the mold, and when the pitch feed is increased, the time required for the pitch feed increases, and As shown in FIG. 20, the rotor 2 has to be punched in another step, and there is a problem that productivity is reduced.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and has as its object to provide a method of manufacturing a laminated core with low cost and high productivity.

[0006]

According to a first aspect of the present invention, there is provided a method for manufacturing a laminated core, comprising: forming a magnetic member in a direction corresponding to a thin connecting portion having an assumed contour of an annular magnetic member; Forming a pair of holes at positions near the outer edge and at positions deviated from the inner edge of the magnetic member,
The step of forming a slit connecting each pair of holes and the step of sequentially forming a magnetic member are performed by punching in a die of a progressive press, and a predetermined number of magnetic members are sequentially stacked to form a laminated core. The laminated core is developed in a belt shape by forming and expanding each slit, and after performing a predetermined operation process, the laminated core is returned to the original ring shape.

According to a second aspect of the present invention, there is provided a method for manufacturing a laminated core according to the first aspect, wherein a hole formed at a position near the outer edge of the inner magnetic member of the pair of holes is formed in a direction orthogonal to the slit. It is a long, elongated hole.

According to a third aspect of the present invention, there is provided a method for manufacturing a laminated core according to the first aspect, wherein the pair of holes is orthogonal to the slit instead of the hole formed at a position near the outer edge of the inner magnetic member. And a pair of cut portions disposed at predetermined intervals in a direction in which the cut portions are formed, and a recess interposed between the cut portions.

According to a fourth aspect of the present invention, there is provided a method of manufacturing a laminated core according to the first aspect, wherein a coil is formed by applying a winding as a predetermined operation step.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiment 1 FIG. FIG. 1 is a front view showing a configuration of a laminated core of an armature motor used in, for example, a vacuum cleaner or an electric tool according to Embodiment 1 of the present invention, and FIG. 2 shows a process of forming a pair of holes in a magnetic member. FIG. 3 is a front view schematically showing a step of forming a slit for connecting a pair of holes in FIG. 2 to a magnetic member, and FIG. 4 is a step of forming a stator core into a predetermined shape. 5, FIG. 5 is a cross-sectional view showing a mold applied to the slit formation in FIG. 3, and FIG. 6 shows a stator core formed in a predetermined shape in FIG. FIG. 7 is a cross-sectional view showing the overlapping step, and FIG. 7 is a plan view showing a state where the core in FIG. 1 is punched out of the magnetic member.

In the drawing, reference numeral 3 denotes an annular yoke portion formed of a magnetic member, and reference numerals 4 and 5 denote magnetic pole teeth projecting oppositely at symmetrical positions on the inner peripheral side of the yoke portion 3.
These three, four, and five constitute a stator core 6. Reference numeral 7 denotes a rotor core disposed at the center between the magnetic pole teeth 4 and 5, reference numeral 8 denotes a hole formed at a position near the outer edge of each corner of the yoke 3, and reference numeral 9 denotes each of the holes 8 to each corner. A slit 10 formed to extend to the inner edge side of the portion is a cut portion formed to cross one of the corners. Then, a predetermined number of the stator cores 6 and the rotor cores 7 are stacked to form a laminated core.

Next, a method of manufacturing the laminated core configured as described above will be described with reference to the drawings. First, as shown in FIG. 2, an assumed contour 1 of a stator core 6 made of a magnetic member is used.
A pair of holes 8, 8 ′ are formed at positions corresponding to the respective corners of the stator core 1 at positions near the outer edge of the yoke portion 3 of the stator core 6 and at positions inside the inner edge of the yoke portion 3. Form. At this time, the size of each of the holes 8 and 8 'is suitably about 2 to 5 times the thickness of the magnetic member, but the hole 8' on the side located outside the contour 11 of the yoke portion 3 is slightly larger. No problem.

Next, as shown in FIG. 3, a slit 9 is formed so as to connect both holes 8, 8 '. At this time, the slit 9 is formed by the upper mold 12 as shown in FIG.
Is inserted into the opening 13a of the lower mold 13 on which the magnetic member is placed.
The step H of the projection 12a differs depending on the material of the magnetic member, and the step H needs to be small as the material is hard and brittle, and the step H is large as the material is soft and sticky. About 2 times is appropriate. The holes 8, 8 'can be made smaller as the step H is smaller.
As shown by the broken line in FIG. 5, the magnetic member is bent when the slit 9 is formed. However, when the upper mold 12 is raised, the magnetic member returns to its original state by springback and becomes flat. If the plastic deformation remains and does not become flat, it may be flattened by bending in the next step in the progressive die in the reverse direction.

Finally, the stator core 6 is formed by removing the scrap portion along the contour 11 as shown in FIG. As is clear from the figure, one hole 8 ′ is not present on the yoke part 3 because it is removed together with the scrap part. In addition, since the hole 8 is formed at a position near the outer edge of the corner of the yoke 3, it can be seen that the thin connecting portion 14 is formed between the hole 8 and the outer edge of the yoke 3.
As shown in FIG. 6, a predetermined number of the stator cores 6 thus formed are stacked in a mold to complete a laminated coil. Although only the formation of the stator core 6 has been described in the above description, the rotor core 7 is formed by punching together with the stator core 6 as shown in FIG.

The stator cores 6 stacked in this manner are taken out of the mold, and first, as shown in FIG.
After removing 0, each slit 9 is sequentially expanded and developed into a band as shown in FIG. Next, as shown in FIG. 10, windings are wound around the pole teeth 4, 5 of the stator core 6 to form coils 15. Then, when the winding is completed, it is returned to the original ring shape again, and as shown in FIG. 11, the stator 17 is formed by press-fitting into the motor frame 16, and the armature motor is completed by being combined with the rotor 18.

As described above, according to the first embodiment, the portion corresponding to the corner of the assumed contour 11 of the stator core 6 made of the magnetic member is located in the vicinity of the outer edge of the yoke 3 in the direction crossing the same. A pair of holes 8 and 8 ′ are formed at positions and inside the inner edge of the yoke portion 3, and after connecting the holes 8 and 8 ′ with slits 9, the scrap portion is cut along the contour 11. By removing the stator core 6, the slits 9 are expanded, and the thin connecting portion 14 formed between the hole 8 and the outer edge of the yoke portion 3 is extended. Since the coil 15 was developed in a band shape and the magnetic pole teeth 4 and 5 were wound in this state to form the coil 15 and then returned to the original annular shape to form the stator 17, it is apparent from FIG. The material width of the magnetic member and the feed pitch Both can be reduced to a size almost the same as the external dimensions of the stator core 6, and can be obtained at a low cost without the need for a large progressive press and with a reduced amount of scrap to obtain a laminated core with high productivity. It is possible to provide a method of manufacturing a laminated core that can perform the above.

Embodiment 2 FIG. FIGS. 12, 13 and 14 are front views schematically showing different steps of a part of the method of manufacturing a laminated core according to the second embodiment of the present invention. In the figure, the same parts as those in the first embodiment are denoted by the same reference numerals, and description thereof will be omitted. 19, 1
9 'is an assumed contour 1 of the stator core 6 made of a magnetic member.
A pair of holes formed at positions near the outer edge of the yoke portion 3 of the stator core 6 and at positions deviated inward from the inner edge of the yoke portion 3 in a direction crossing the portions corresponding to the respective corners of the stator core 6. The one hole 19 is an elongated hole long in a direction orthogonal to a slit described later. 20 is these two holes 19,
This is a slit formed so as to connect 19 '.

As described above, according to the second embodiment,
Since the hole 19 formed at a position near the outer edge of the yoke portion 3 is an elongated hole that is long in a direction orthogonal to the slit 20, it is possible to prevent the magnetic flux flowing through the yoke portion 3 from being an obstacle, and to reduce the performance as a motor. Drop can be prevented.

Embodiment 3 15, 17, and 18 are front views schematically showing different steps of a part of a method of manufacturing a laminated core according to Embodiment 3 of the present invention.
FIG. 6 is a cross-sectional view showing a cross-section along line XVI-XVI in FIG. In the figure, the first and second embodiments are described.
The same reference numerals are given to the same parts as those in and the description is omitted. Reference numerals 21 and 22 denote predetermined intervals at positions near the outer edges of the yoke portion 3 of the stator core 6 in directions crossing the corners of the assumed contour 11 of the stator core 6 made of a magnetic member. And a pair of cut portions formed through.

Reference numeral 23 denotes a portion between these two cutting portions 21 and 22 in FIG.
As shown in FIG. 6, the recess 24 is formed in a V-shape, and like the recess 23, an assumed contour 1 of the stator core 6 is formed.
1, a hole formed at a position corresponding to each corner of the yoke 3 at a position deviated from the inner edge of the yoke 3 in a direction crossing the corner;
5 is a slit formed to connect the depression 23 and the hole 24. The two cut portions 21 and 22 and the depression 23 can be easily formed by a mold.
It is considered that the interval between the first and the second 22 is two to three times the thickness of the magnetic member, and the length is appropriately four to ten times the thickness.

As described above, according to the third embodiment, a pair of cut portions 21 and 22 are formed at a position near the outer edge of the yoke portion 3 at a predetermined interval, and a pair of cut portions 21 and 22 are formed between the cut portions 21 and 22. As in the second embodiment, the recesses are formed, so that the magnetic flux flowing through the yoke portion 3 is prevented from becoming an obstacle, and the performance of the motor can be prevented from lowering.

In each of the above embodiments, a method of manufacturing a laminated core of an armature motor has been described as an example. However, the present invention is not limited to this, and is applicable to a method of manufacturing a laminated core such as a transformer. Needless to say, the same effect as described above can be obtained.

[0023]

As described above, according to the first aspect of the present invention, the position near the outer edge of the magnetic member in the direction crossing the portion corresponding to the thin connecting portion of the assumed contour of the annular magnetic member. A step of forming a pair of holes at positions deviated from the inner edge of the magnetic member to the inside, a step of forming a slit connecting each of the pair of holes, and a step of sequentially forming the magnetic member. After punching in a mold, a predetermined number of magnetic members are sequentially stacked to form a laminated core, and each slit is expanded to expand the laminated core into a band shape, and after performing a predetermined work process, the original work is performed. Since the annular core is returned to the annular shape, it is possible to provide a method of manufacturing a multilayer core that can obtain a multilayer core with low cost and high productivity.

According to a second aspect of the present invention, in the first aspect, a hole formed at a position near the outer edge of the inner magnetic member of the pair of holes is formed as an elongated hole elongated in a direction orthogonal to the slit. Therefore, it is possible to provide a method of manufacturing a laminated core that can prevent a decrease in electromagnetic performance, as well as being able to obtain a laminated core with high productivity with inexpensive equipment. .

According to a third aspect of the present invention, in the first aspect, instead of a hole formed at a position near the outer edge of the inner magnetic member of the pair of holes, a predetermined direction is defined in a direction orthogonal to the slit. Since a pair of cut portions arranged at intervals and a recess intervening between both cut portions are formed, it is of course possible to obtain a laminated core with high productivity with inexpensive equipment, It is possible to provide a method for manufacturing a laminated core that can prevent a decrease in electromagnetic performance.

According to a fourth aspect of the present invention, in the first aspect, the operation of forming the coil by applying the winding as a predetermined operation step is performed, so that the armature can be manufactured with low cost and high productivity. A method for manufacturing a laminated core capable of obtaining a laminated core for a motor can be provided.

[Brief description of the drawings]

FIG. 1 is a front view showing a configuration of a laminated core of an armature motor according to Embodiment 1 of the present invention.

FIG. 2 is a front view schematically showing a step of forming a pair of holes in a magnetic member.

FIG. 3 is a front view schematically showing a step of forming a slit for connecting a pair of holes in FIG. 2 to a magnetic member.

FIG. 4 is a front view schematically showing a step of forming a stator core into a predetermined shape.

FIG. 5 is a cross-sectional view showing a mold used for forming a slit in FIG.

FIG. 6 is a cross-sectional view showing a step of sequentially stacking stator cores formed in a predetermined shape in a mold in FIG.

FIG. 7 is a plan view showing a state where the core in FIG. 1 is punched out of a magnetic member.

FIG. 8 is a front view showing a step of developing a laminated core of the stator into a belt shape.

FIG. 9 is a front view showing a laminated core of the stator developed in a belt shape in FIG. 8;

FIG. 10 is a front view showing a step of forming a coil by winding a winding around the magnetic pole teeth of the laminated core of the stator which is developed in a belt shape as shown in FIG. 9;

FIG. 11 is a front view showing a configuration of an armature motor to which the laminated core manufactured by the method according to the first embodiment is applied;

FIG. 12 is a front view schematically showing one step of a method for manufacturing a laminated core according to Embodiment 2 of the present invention.

FIG. 13 is a front view schematically showing a step subsequent to the step in FIG. 12 of the method for manufacturing a laminated core according to the second embodiment of the present invention.

FIG. 14 is a front view schematically showing a step subsequent to the step in FIG. 13 of the method for manufacturing a laminated core according to the second embodiment of the present invention.

FIG. 15 is a front view schematically illustrating one step of a method of manufacturing a laminated core according to Embodiment 3 of the present invention.

FIG. 16 is a sectional view showing a section taken along line XVI-XVI in FIG. 15;

FIG. 17 is a front view schematically showing a step subsequent to the step in FIG. 15 of the method for manufacturing a laminated core in the third embodiment of the present invention.

FIG. 18 is a front view schematically showing a step subsequent to the step in FIG. 17 of the method for manufacturing a laminated core in the third embodiment of the present invention.

FIG. 19 is a plan view showing a state of arrangement of a conventional stator-side connecting core at the time of punching.

FIG. 20 is a plan view showing a state of arrangement of a conventional rotor-side core at the time of punching.

[Explanation of symbols]

3 Yoke part, 4,5 magnetic pole taste, 6 stator core, 7 rotor core, 8, 8 ', 19, 19', 24
Hole, 9, 20, 25 slit, 10, 21, 22 cut part, 11 contour, 12 upper mold, 12a projection, 13
Lower die, 13a opening, 14 thin connecting part, 15 coil, 16 motor frame, 17 stator, 18 rotor, 23 hollow.

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-8-317579 (JP, A) JP-A-9-308143 (JP, A) JP-A-8-196061 (JP, A) JP-A-1- 264548 (JP, A) JP-A-50-133407 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) H02K 15/00-15/16

Claims (4)

(57) [Claims] 1. A pair of a portion corresponding to a thin connecting portion of an assumed contour of an annular magnetic member is located at a position near an outer edge of the magnetic member in a direction crossing the portion and at a position inside the inner edge of the magnetic member. The step of forming each of the holes, the step of forming a slit connecting each of the pair of holes, and the step of sequentially forming the magnetic member are performed by punching in a die of a progressive press, and the magnetic member is formed. A predetermined number of sheets are sequentially stacked to form a laminated core, and the slits are expanded to expand the laminated core into a band shape, perform a predetermined work process, and then return to an original ring shape. A method for manufacturing a laminated core. 2. The manufacturing method of a laminated core according to claim 1, wherein a hole formed at a position of the pair of holes near the outer edge of the inner magnetic member is an elongated hole elongated in a direction orthogonal to the slit. Method. 3. A pair of cut portions and a pair of cut portions arranged at a predetermined interval in a direction orthogonal to the slit in place of a hole formed at a position near the outer edge of the inner magnetic member of the pair of holes. The method for manufacturing a laminated core according to claim 1, wherein depressions interposed between the cut portions are formed. 4. The method according to claim 1, wherein the predetermined operation step is an operation of applying a winding to form a coil.