JP2008113498A - Laminated iron core, and manufacturing method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a laminated iron core which has a wiring wire capable of being wound around a magnetic pole axis portion with the density being as high as possible, has high electromagnetic characteristics and can prevent generation of noise, and to provide a manufacturing method therefor. <P>SOLUTION: The laminated iron core has a structure, in which a plurality of split laminated iron cores 10 are coupled via coupling portions 35, 36 on its both ends and formed into a circle; the iron cores are formed by caulking and laminating a plurality of split iron core pieces 15, 16 obtained by splitting a yoke for each magnetic pole and by gradually decreasing the widths of a laminate upper-end side of a magnetic pole portion 13 and a laminate lower end portion toward the laminate upper end and laminate lower end and rounding the corners of the polar axis portion 13; and the width of the magnetic pole portion 13 becomes gradually wider from the laminate upper end side and the laminate lower end side, while the width of an intermediate portion 24 of a laminate thickness direction is a maximum. In the manufacturing method therefor, a slot portion punching device is gradually retracted to the intermediate portion 24, to punch the iron core while increasing the widths of the magnetic pole axis piece portion 18 of the split iron core pieces 15, 16, the slot portion punching device is gradually advanced, when the punching device has passed through the intermediate portion 24 and the iron core pieces are formed by punching, and the width of the magnetic pole axis piece portion 18 is reduced. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

The present invention relates to a laminated core that can be wound around a magnetic pole without damaging the insulating coating and the winding itself, and a method for manufacturing the same.

Nowadays, the winding of the laminated iron core to the magnetic pole is facilitated by being performed on the divided laminated iron core in which the yoke is divided for each magnetic pole, and can be wound at high density. However, although the winding is workable, a gap is generated between the upper end of the magnetic pole and the lower end of the magnetic pole when winding the magnetic pole, and the density of the winding cannot be further improved.
As a technique for coping with this problem, for example, in Patent Document 1, as shown in FIGS. 4A and 4B, a magnetic pole shaft portion 90 of a laminated iron core (divided laminated iron core) is viewed from a cross-section with its upper end portion. The width of 91 and the lower end 92 is gradually reduced. According to this, the winding around the magnetic pole shaft portion 90 can be wound without causing a gap between the upper end portion 91 and the lower end portion 92 of the magnetic pole shaft portion 90.

JP 2005-348553 A

The winding to the magnetic pole shaft portion 90 is performed at high speed while applying tension to the winding, but the magnetic pole shaft portion 90 is thick and the upper end portion 91 and the lower end portion of the magnetic pole shaft portion 90 are thick. Since the side surface of the portion excluding the portion 92 is planar (the width of the magnetic pole shaft portion 90 is the same), the winding may not be in close contact with the side surface. In particular, as the thickness of the laminated iron core (divided laminated iron core) increases, this tendency tends to occur, and it is difficult to increase the space factor of the windings to the limit, and this may contribute to noise generation.

SUMMARY OF THE INVENTION The present invention has been made in view of such circumstances, and provides a laminated iron core capable of winding a winding around a magnetic pole shaft portion at as high a density as possible, having excellent electromagnetic characteristics and preventing noise generation, and a method for manufacturing the same. The purpose is to provide.

In the laminated core according to the first aspect of the present invention, a plurality of divided core pieces obtained by dividing the yoke for each magnetic pole are caulked and laminated, and the width of the laminated upper end side and the laminated lower end side of the magnetic pole shaft portion is set to the upper end of the laminated In a laminated core in which a plurality of divided laminated cores that are gradually decreased toward the lower end of the laminated layer and rounded the four corners of the magnetic pole shaft portion are connected to each other via connecting portions formed at both ends of the divided laminated core. ,
The width of the magnetic pole shaft portion is gradually increased from the upper end side of the stack and the lower end side of the stack with the intermediate portion in the stacking thickness direction as the maximum width.

In the laminated iron core according to the first invention, the width of the intermediate portion in the laminated thickness direction of the magnetic pole shaft portion is relative to the average width of the magnetic pole shaft portion excluding the laminated portion on the laminated upper end side and laminated lower end side with rounded corners. It is preferable to increase in the range of 0.5 to 8%.

According to a second aspect of the present invention, there is provided a method of manufacturing a laminated core according to a second aspect of the present invention, wherein a slot punching device that is movable forward and backward with respect to the center of the press working line is advanced and retracted from a work plate passed through the press working line. The core pieces that have been punched by changing the width of the shaft piece as needed are caulked and stacked, and the widths of the bottom end and top end of the stacked magnetic pole shafts are stacked toward the bottom and top of the stack, respectively. In the method of manufacturing a laminated core in which a plurality of the laminated cores are annularly connected to each other through a connecting part formed at both ends, and the divided laminated cores are formed by rounding the four corners of the magnetic pole shaft portion. ,
Formation of the divided core pieces constituting the laminated core excluding the laminated upper end side and the laminated lower end laminated portion with rounded corners is performed by gently retracting the slot punching device up to the middle portion in the laminated thickness direction. Punching is performed by increasing the width of the magnetic pole shaft piece portion, and punching by reducing the width of the magnetic pole shaft piece portion by slowly advancing the slot punching device from the time when the intermediate portion in the stacking thickness direction is exceeded. The center of the magnetic pole shaft portion in the thickness direction was expanded.

In the method for manufacturing a laminated core according to the second aspect of the invention, the width of the intermediate portion in the laminated thickness direction of the magnetic pole shaft portion is an average of the magnetic pole shaft portions excluding the laminated portion on the laminated upper end side and laminated lower end side with rounded corners. It is preferable to increase in the range of 0.5 to 8% with respect to the width.

In the laminated core according to claim 1 and 2, and the method of manufacturing the laminated core according to claims 3 and 4, the width of the magnetic pole shaft is gradually increased from the upper end side and the lower end side of the stack, with the intermediate portion in the stacking thickness direction being the maximum width. Therefore, the winding of the winding around the magnetic pole shaft portion can be adapted to the whole magnetic pole shaft portion without gaps. As a result, it is possible to obtain a laminated iron core that can wind the winding around the magnetic pole shaft portion at as high a density as possible, has excellent electromagnetic characteristics, and can prevent generation of noise by such winding.
Moreover, even if it is a thick winding, it can be wound without generating a gap, thereby reducing the copper loss, and for example, the efficiency of a rotating machine (motor and generator) can be increased.

In particular, the method of manufacturing the laminated core according to claim 2 and the laminated core according to claim 4 defines the width of the intermediate portion in the laminated thickness direction of the magnetic pole shaft portion, so that the winding density of the winding can be improved, Excessive swelling of the width of the magnetic pole shaft can also be prevented.
According to the method for manufacturing a laminated core of claim 3, since the slot punching device can be moved forward or backward with respect to the center of the press working line, and the split core pieces having different widths of the magnetic pole piece can be manufactured industrially. Efficient production is possible.

Next, embodiments of the present invention will be described with reference to the accompanying drawings for understanding of the present invention.
First, a stator laminated core that is an example of a laminated core according to an embodiment of the present invention will be described with reference to FIGS. 1 (A), 1 (B), and 2 (A) to 2 (C).
A stator laminated iron core (not shown) has a plurality of, for example, 8 to 16 magnetic poles 11 inside an annular yoke iron core. The divided laminated iron core 10 formed by dividing the yoke (yoke iron core) of the stator laminated iron core for each magnetic pole 11 has a yoke portion 12 and a magnetic pole 11 which are divided yoke iron cores, respectively. 12 includes a magnetic pole shaft portion 13 whose base portion is connected to 12 and a tooth portion 14 provided at the tip of the magnetic pole shaft portion 13.

The divided laminated core 10 includes divided core pieces 15 and 16 in which an annular yoke piece is divided for each magnetic pole piece, a magnetic pole shaft having a base piece connected to a yoke piece portion 17 of each of the divided core pieces 15 and 16. It is caulked and laminated via a caulking part 19 having a well-known shape formed on the piece part 18. Note that the caulking portion of the lowermost divided core piece 16 is a through hole (caulking hole 54, see FIG. 3).
The width of the magnetic pole shaft portion 13 of the divided laminated core 10, that is, the laminated portion on the lower end side of the laminated layer, from below the laminated divided core pieces 15 and 16 (first laminated layer) to n1th (for example, about 3 to 10). Is gradually shortened symmetrically with respect to the center line L of the magnetic pole shaft portion 13 in the downward direction. Further, the magnetic pole shaft 13 from the top of the divided core pieces 15 and 16 to the (n3-n2) -th sheet, that is, the stacked portion on the upper end side of the stacked layer, is gradually shortened in the left-right symmetrical manner toward the upper side. Note that n3 is the final number of laminated core pieces.
As described above, the widths of the upper end side and the lower end side of the magnetic pole shaft 13 are gradually reduced toward the upper end and the lower end of the stack, respectively, and the corners 20 to 23 at the four corners of the magnetic pole shaft portion 13 are rounded (for example, (Arc shape or elliptical arc shape), the winding bends along the magnetic pole shaft portion 13 more smoothly.

Further, the width of the central portion excluding the remaining n2-n1 magnetic pole shaft portions 13 of the divided laminated core 10, that is, the laminated portions on the laminated upper end side and the laminated lower end side, is the maximum width W1 of the laminated thickness direction intermediate portion 24. Are gradually widened from the upper end side (n2-1 sheet) and the lower end side (n1 + 1 sheet). That is, the width of the central portion of the magnetic pole shaft portion 13 is gradually shortened in the vertical direction with respect to the center line of the intermediate portion 24 in the stacking thickness direction.
Here, the width W1 of the magnetic pole shaft portion 13 positioned at the intermediate portion 24 in the stacking thickness direction is set such that the central portion of the magnetic pole shaft portion 13 (n2) excluding the stacking portion on the stacking upper end side and stacking lower end side with rounded corners 20-23. 0.5 to 8% (preferably lower limit is 1% and upper limit is 5%) with respect to the average width W of the magnetic core pieces 18 of the divided core pieces 15 and 16 from the -1st sheet to the (n1 + 1) th sheet ).

By configuring as described above, the contour of the cross section of the magnetic pole shaft portion 13 becomes an arc shape or an elliptical arc shape, and has a shape in which the center of the magnetic pole shaft portion 13 in the thickness direction is expanded. As a result, winding of the winding around the magnetic pole shaft portion 13 can be adapted to all of the peripheral surface (upper surface, side surface, and lower surface) of the magnetic pole shaft portion 13 and there is no gap.
Note that the bulging shape of the magnetic pole shaft portion 13 is determined according to, for example, the thickness (diameter) of the winding to be used, the material characteristics (elastic modulus), or the laminated thickness of the divided core pieces.

Further, in the split laminated core 10, the radially inner sides 25 and 26 of the yoke portion 12 to which the base portion of the magnetic pole shaft portion 13 is coupled are linear, and the radially inner side 25 and the radially inner side 26 are straight. It is on the line (on the same straight line). For this reason, the magnetic pole shaft portion 13 is placed on the yoke portion 12 so that the center line L formed from the center in the width direction of the magnetic pole shaft portion 13 is perpendicular (right angle) to the radially inner sides 25 and 26 of the yoke portion 12. Are connected.
The radial outer sides 27 and 28 of the tooth portion 14 to which the tip portion of the magnetic pole shaft portion 13 (that is, the inner side in the radial direction) is connected have an obtuse angle (for example, an angle θ with respect to the center line L of the magnetic pole shaft portion 13). It is formed to be in the range of 100 degrees to 130 degrees.

For this reason, the same mold (an example of a slot punching device) (not shown) is used in a shape in which the width of the magnetic pole shaft piece 18 of the divided core piece 15 is different as shown in FIGS. In the case of punching out, the mold is moved to the center line L along the radially inner sides 25 and 26 of the yoke piece portion 17 (the same name and number are used because they are at the same position as the divided laminated core 10). Move forward and backward. As a result, the radial width of the tooth portion 14 of the divided laminated core 10 gradually increases from the upper end side and the lower end side of the stack, with the intermediate portion 24 in the stacking thickness direction being the maximum width.
Accordingly, also in the divided core pieces 15 and 16 constituting the divided laminated core 10, the magnetic pole shaft piece 18 is formed perpendicular to the radially inner sides 25 and 26 of the yoke piece 17. In addition, the radially outer sides 27 and 28 of the tooth piece 29 are formed at an angle θ with respect to the magnetic pole piece 18.

Engagement portions 30 each having a dovetail-shaped notch are formed on the rear surface portions of the divided core pieces 15 and 16 on the radially outer side. The engaging portion 30 is used when the divided laminated core 10 is fixed to a jig (not shown). Thereby, this part can be latched to a jig and assembled easily and accurately.
The split core piece 15 has a protruding portion 31 on one side of the yoke piece portion 17 and a notch portion 32 on the other side, and the split core piece 16 has a notch portion 33 on one side of the yoke piece portion 17. A protrusion 34 is provided on the other side. In this embodiment, connecting portions 35 and 36 each including a concave portion and a convex portion are formed on both sides of the yoke portion 12 of the divided laminated core 10 in which three divided iron core pieces 15 and 16 are alternately and continuously laminated. ing. And the connection parts 35 and 36 of the adjacent division | segmentation laminated | stacked iron core 10 are meshed | engaged, and it is set as the cyclic | annular stator lamination | stacking iron core laminated | stacked the desired number (for example, about 50 or more and 300 or less). In this embodiment, three divided core pieces are continuously laminated. However, for example, the present invention is applied to a case where two or four or more pieces are continuously laminated.

Then, the manufacturing method of the laminated iron core which concerns on one embodiment of this invention is demonstrated, referring FIG.
First, a strip material (for example, a silicon steel plate having a thickness of 0.15 to 0.5 mm) 40, which is an example of a processed plate having a length from which the divided core pieces 15 and 16 are collected, is prepared, and at least the step is performed. It is introduced into a press processing facility that sequentially performs the press processing of steps 1 to 10. The strip 40 is intermittently conveyed in steps 1 to 10 by a conveying means (not shown) with reference to the pilot holes 41 and 42.

In step 1, pilot holes 41 and 42 are formed on both sides of the strip 40 in the width direction. In step 2, a first hole 44 is formed that forms one radial outer side 28, one radial inner side 26 of each of the divided core pieces 15 and 16, and one contour line 43 of the magnetic pole piece 18 connected thereto. Form. A first die (an example of a slot punching device) composed of a punch and a die for forming the first punching hole 44 (the same applies to the following die) moves along the radially inner side 26. The width of the magnetic pole piece 18 can be adjusted. In step 3, the second radial hole 46 that forms the other radially outer side 27, the radially inner side 25, and the other contour line 45 of the magnetic pole piece 18 connected to each of the divided core pieces 15, 16. Form. The second die (an example of the slot punching device) that forms the second punch hole 46 moves along the radially inner side 25 so that the width of the magnetic pole piece 18 can be adjusted. Yes.

Therefore, when forming the n1st divided core pieces 15 and 16 from the lowermost layer constituting the divided laminated core 10, the first and second molds are connected to the press processing reference line (the center of the press processing line, that is, the center of the press processing line). The first and second punched holes 44 and 46 are punched while being gradually retracted with respect to the center line of the strip 40 and also the center line of the magnetic pole piece 18. When forming the divided core pieces 15 and 16 from the (n1 + 1) th to the laminated thickness direction intermediate portion 24 constituting the divided laminated core 10, the first and second molds are moved with respect to the press working reference line. The first and second punching holes 44 and 46 are punched while gradually retracting and increasing the width of the magnetic pole piece 18.

In forming the divided core pieces 15 and 16 from the time when the intermediate thickness 24 in the laminated thickness direction constituting the divided laminated core 10 is exceeded to the (n2-1) th divided core pieces 15, 16, the first and second molds are The first and second punched holes 44 and 46 are punched while being gradually advanced with respect to the press working reference line and reducing the width of the magnetic pole piece 18. Then, in the manufacture of the split core pieces 15 and 16 from the n2th to the final stack number n3 constituting the split laminated core 10, the first and second molds are gradually advanced with respect to the press working reference line. Thus, the width of the magnetic pole piece piece 23 is gradually reduced.

In Steps 4 and 5, third to sixth punched holes 47 to 50 that form the outlines of the protruding portions 31 and 34 that become the connecting portions 35 and 36 and the cutout portions 32 and 33 with respect to the divided core pieces 15 and 16. Are punched by the third to sixth molds.
Here, when the divided core piece 16 passes through the process 4, the movement of the third and fourth molds is stopped, and when the divided core piece 15 passes through the process 5, the fifth and sixth molds are stopped. Stop the movement of the mold.

In step 6, the contours of both end portions of the tooth piece portion 29 of each of the divided core pieces 15 and 16 are formed by punching the seventh and eighth punch holes 51 and 52 with the seventh and eighth molds. Do it. In step 7, a ninth punching hole 53 that forms an engaging portion 30 (groove) formed at the back portion (radially outer center) of each of the divided core pieces 15 and 16 is formed by punching with a ninth die. In step 8, the three caulking holes 54 to be caulked portions of the lowermost divided core pieces 16 are formed by the tenth to thirteenth molds.

In step 9, three caulking projections 55 that form the caulking portions of the divided core pieces 15 and 16 excluding the lowermost layer are formed by the fourteenth to sixteenth molds. In step 10, punching of the radially inner contour line 56 and the radially outer contour line 57 of the divided core pieces 15, 16 is performed by punching with a seventeenth mold.
In addition, although the case where the division | segmentation iron core piece 16 is formed is demonstrated in the process 6 and the process 7, the division | segmentation iron core piece 15 is processed by the same process. Moreover, although the process 9 demonstrated the case where the division | segmentation iron core piece 15 was formed, the division | segmentation iron core piece 16 is processed by the same process. And the 17th metal mold | die used for the process 10 becomes a shape which includes both the division | segmentation iron core pieces 15 and 16. FIG.

The divided core pieces 15 and 16 that have been removed from the outer die of the mold in step 10 are sequentially caulked and stacked to form the divided laminated core 10 shown in FIGS. 1 (A) and 1 (B). In the lamination of the divided core pieces 15 and 16, it is preferable that a plurality of (for example, 2 to 6) divided core pieces 15 and 16 are alternately stacked as shown in FIG. Thereby, even when the split core pieces 15 and 16 are extremely thin, the meshing portions of the connecting portions 35 and 36 have a constant thickness, and the assembly efficiency of the split laminated core 10 is improved. As a matter of course, a predetermined coil is wound around each magnetic pole shaft portion 13 of the divided laminated core 10 and then assembled.

In the present embodiment, the first die is used in step 2 and the second die is used in step 3 to form the first and second punch holes 44 and 46, respectively. The first mold and the second mold may be simultaneously used in the same process, and the first and second punch holes 44 and 46 may be punched. In this case, the first and second molds are structured to advance and retract in synchronization with the center of the press working line. Thereby, the split core piece 15 (16 is also the same) having a narrow pole shaft piece portion 18 shown in FIG. 2A, and the split core piece 15 having a wide pole shaft piece portion 18 shown in FIG. The intermediate divided core piece 15 shown in FIG. 2B can be formed in one process, and the process can be shortened.

As described above, the present invention has been described with reference to one embodiment. However, the present invention is not limited to the configuration described in the above embodiment, and is described in the claims. Other embodiments and modifications conceivable within the scope of the above are also included. For example, the case where the laminated core of the present invention and the manufacturing method thereof are configured by combining some or all of the above-described embodiments and modifications are also included in the scope of the right of the present invention.
In the embodiment described above, the number of magnetic poles of the laminated core is specified and described. However, the number of magnetic poles and the shape of the laminated core can be arbitrarily selected within a range not changing the gist of the present invention.

In addition, in the method of manufacturing a laminated core, when forming magnetic pole piece pieces having different widths, the mold is moved in one step and the width of the formed magnetic pole piece portion is changed. The mold may be moved, or in the case of mass production, a plurality of processes (stations) in which the position of the mold is fixed may be used to process the divided core pieces.
Further, by changing the distance to move the mold according to the position of the divided core pieces to be laminated, the upper and lower laminated parts of the magnetic pole shaft part, and the cross-sectional shape of the part excluding these laminated parts can be changed to an arc shape or Not only the elliptical arc shape but also other shapes can be changed.
Furthermore, in the said embodiment, the 7th, 8th metal mold | die which forms the outline of the both-sides edge part of the tooth piece part 29 of the division | segmentation iron core pieces 15 and 16 is advanced / retreated with respect to the center of a press work (reference | standard) line. Then, by changing the positions of the punched holes 51 and 52, a configuration in which the tooth piece portion 29 is skewed can be obtained.

(A) is a top view of the division | segmentation laminated | stacked iron core which comprises the laminated iron core which concerns on one embodiment of this invention, (B) is an aa arrow directional cross-sectional view of (A). (A)-(C) is a top view of the division | segmentation iron core piece which comprises the division | segmentation laminated | stacked iron core, respectively. It is explanatory drawing of the process of the manufacturing method of the laminated iron core which concerns on one embodiment of this invention. (A), (B) is sectional drawing and the top view of the magnetic pole axial part of the division | segmentation laminated | stacked iron core which respectively relate to a prior art example.

Explanation of symbols

10: split laminated iron core, 11: magnetic pole, 12: yoke portion, 13: magnetic pole shaft portion, 14: tooth portion, 15, 16: split iron core piece, 17: yoke piece portion, 18: magnetic pole shaft piece portion, 19: caulking Part, 20-23: corner part, 24: lamination thickness direction middle part, 25, 26: radial inner side, 27, 28: radial outer side, 29: tooth piece part, 30: engagement part, 31: protrusion Part, 32, 33: notch part, 34: projecting part, 35, 36: connecting part, 40: strip material (processed plate), 41, 42: pilot hole, 43: contour line, 44: first extraction Hole: 45: contour line, 46: second hole, 47: third hole, 48: fourth hole, 49: fifth hole, 50: sixth hole, 51: first hole 7 holes, 52: 8th hole, 53: 9th hole, 54: caulking hole, 55: caulking projection, 56, 57: contour line

Claims (4)

A plurality of divided core pieces each having a yoke divided for each magnetic pole are caulked and laminated, and the widths of the upper end side and the lower end side of the magnetic pole shaft are gradually reduced toward the upper end and lower end of the stack, respectively. In the laminated iron core in which two corners are rounded by connecting a plurality of the laminated iron cores with rounded corners via connecting portions formed at both ends of the divided laminated iron cores,
The laminated core is characterized in that the width of the magnetic pole shaft portion is gradually widened from the upper end side and the lower end side of the stack, with the intermediate portion in the stacking thickness direction being the maximum width. 2. The laminated core according to claim 1, wherein the width of the intermediate portion in the laminated thickness direction of the magnetic pole shaft portion is relative to the average width of the magnetic pole shaft portion excluding the laminated upper end side and the laminated lower end side laminated portion with rounded corners. A laminated iron core characterized by increasing in a range of 0.5 to 8%. A split iron core punched from a work plate passed through a press processing line by moving a slot punching device that can move forward and backward with respect to the center of the press processing line and changing the width of the magnetic pole piece as required. Divided lamination in which pieces are caulked and laminated, and the width of the lower end side and the upper end side of the magnetic pole shafts stacked as many as desired are gradually reduced toward the lower end and upper end of the stack, respectively, so that the four corners of the magnetic pole shaft portion are rounded. In the manufacturing method of a laminated core that forms an iron core and connects the divided laminated iron cores to each other through a connecting portion formed at both ends to form an annular shape.
Formation of the divided core pieces constituting the laminated core excluding the laminated upper end side and the laminated lower end laminated portion with rounded corners is performed by gently retracting the slot punching device up to the middle portion in the laminated thickness direction. Punching is performed by increasing the width of the magnetic pole shaft piece portion, and punching by reducing the width of the magnetic pole shaft piece portion by slowly advancing the slot punching device from the time when the intermediate portion in the stacking thickness direction is exceeded. A method of manufacturing a laminated iron core, wherein the center of the magnetic pole shaft portion in the thickness direction is expanded. 4. The method of manufacturing a laminated core according to claim 3, wherein the width of the intermediate portion in the laminated thickness direction of the magnetic pole shaft portion is an average width of the magnetic pole shaft portion excluding the laminated upper end side and the laminated lower end side laminated portion with rounded corners. The manufacturing method of the laminated iron core characterized by having increased in 0.5 to 8% of range.

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