JP3180687B2 - Laminated core and method of manufacturing the laminated core - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to an electric motor,
The present invention relates to a method for manufacturing a laminated core of electromagnetic application equipment such as a generator, a transformer, and a magnetic head.

[0002]

2. Description of the Related Art As a conventional laminated core of this kind, for example, disclosed in Japanese Patent Application Laid-Open No. 1-273628, a core is pulled out of a magnetic material into a desired shape by means of a mold, and at the same time, a ring-like shape is formed in the mold. A core material is successively caulked and laminated and integrated with a preceding punched core material held by a tube using a caulking projection.
No. 6,019,067, a laser beam generator is built in an iron core press, and a core material extracted from a magnetic material into a desired shape and a core material previously extracted are separated. The lamination is performed by laser welding automatically in a mold.

[0003] Furthermore, Japanese Unexamined Patent Publication (Kokai) No. 6-165449 discloses a method of obtaining a laminated core free from caulking which causes an increase in iron loss. After the rotor core and shaft hole are temporarily dropped in the mold, they are temporarily fixed again by the method of returning to the mold, and then the shaft hole is removed from the mold. The part is removed in a lump.

[0004]

According to the method of manufacturing a laminated core disclosed in Japanese Patent Application Laid-Open No. 1-273628 as described above, in the case of a laminated core formed by laminating a large number of magnetic materials, a crimping process is performed. Even if the accuracy is increased, slight displacement of the magnetic material in the longitudinal direction due to punching occurs,
Further, the errors accumulate in proportion to the number of stacked layers. For example, when a laminated core having a thickness of about 100 mm is obtained by stacking 200 pieces of magnetic material having a thickness of 0.5 mm, it is assumed that the precision of one stage of punching can be achieved with a high precision of 0.001 mm. The total deviation is simply 0.001
mm × 200 = 0.2 mm, and as a result, the laminated core has a shape inclined by 0.2 mm as a whole with respect to the laminating direction. When applied to a rotating machine due to this inclination, the air gap between the rotor and the stator becomes non-uniform, resulting in noise and vibration and deterioration of characteristics. However, when applied to a magnetic field, there is a problem that an unbalance or a gap is generated in a magnetic path, which causes deterioration of characteristics and generation of a beat.

Further, as disclosed in Japanese Patent Application Laid-Open No. Sho 62-171436, in a method in which a laser device is incorporated in a metal mold and fixedly integrated by laser welding, a lamination constituted by laminating a large number of magnetic materials is performed. In the case of a core, welding distortion due to slight imbalance of multiple lasers and misalignment due to slight clearance between the mold and the core material occur, and these errors accumulate according to the number of laminated layers, and the laminated core is The laminated end face is inclined or has a large undulation.

[0006] When this inclination or undulation is applied to a rotating machine, the air gap between the rotor and the stator becomes non-uniform, so that noise and vibration are generated and characteristics are deteriorated. When applied to a transformer, it causes an unbalance or a gap in the magnetic path, which causes deterioration of characteristics and generation of a beat. In addition, since the laser device is built into the mold, the tip of the laser light emitting portion becomes dirty with the press lubricating oil, making welding unstable and causing trouble in the laser oscillation portion due to press vibration. In addition, there is a problem in that the number of laser devices incorporated in the mold is limited due to the space in the mold layout, so that it cannot be applied to a laminated core that requires a large number of fixed locations. There was a point.

Further, in the structure disclosed in Japanese Patent Application Laid-Open No. 6-165449, since the scrap portion and the core portion are temporarily fixed by a method of pulling back, there is no limitation on the shape that can be held by pulling back. Yes, it is limited to the shaft hole. In addition, in such a method, there is a possibility that the part that has been withdrawn during the feeding of the magnetic material in the press mold may be disjointed, and the end surface of the magnetic material that has been withdrawn may be smaller than the end surface that is simply pulled out. However, since the accuracy is deteriorated due to the large amount of deformation and distortion, excessive force is applied at the time of press-fitting the shaft, deforming the shaft and lowering the coaxiality, causing problems such as noise and vibration. there were.

[0008] The present invention has been made to solve the above problems, and is not limited by its shape.
It is an object of the present invention to provide a laminated core having excellent productivity and high assembling accuracy, and a method of manufacturing the laminated core.

[0009]

According to a first aspect of the present invention, there is provided a method for manufacturing a laminated core, comprising the steps of: forming a magnetic member having a posture holding portion connected via a core portion and a thin connecting portion by press punching; Forming and sequentially laminating in a mold;
A step of integrating each magnetic member by successively caulking the posture holding parts at the time of lamination, a step of positioning each core part of each integrated magnetic member, and a step of fixing the positioned core parts to each other Is included.

According to a second aspect of the present invention, there is provided a method for manufacturing a laminated core, comprising: forming a magnetic member having a posture holding portion connected by a press punching via a core portion and a thin connecting portion; A step of sequentially laminating, a step of integrating each magnetic member by sequentially caulking a posture holding part at the time of laminating, a step of positioning each core part of each integrated magnetic member, and a step of positioning each core The method includes a step of fixing the parts, and a step of separating each posture holding part from each core part by cutting the thin connecting part.

According to a third aspect of the present invention, there is provided a method for manufacturing a laminated core, comprising the steps of: holding a posture holding portion connected via a core portion and a thin connecting portion by press punching; Forming a magnetic member having a shape having projections and depressions, and sequentially stacking them in a mold while fitting the projections and recesses, and sequentially crimping a posture holding portion during stacking to integrate the respective magnetic members. Positioning each core portion of each magnetic member, and fixing the positioned core portions to each other, and detaching each posture holding portion from each core portion by cutting the thin connecting portion. Is included.

According to a fourth aspect of the present invention, there is provided a method for manufacturing a laminated core, comprising: a first portion having a shape having a posture holding portion connected via a core portion and a thin connecting portion by press punching.
Forming a second magnetic member having the same shape as the posture holding portion and a third magnetic member having the same shape as the core portion by press punching. A step of sequentially laminating a predetermined number of sheets on one magnetic member, a step of forming a first magnetic member and sequentially laminating a predetermined number of sheets on the second and third magnetic members,
Integrating the first, second and third magnetic members by successively caulking the attitude holding portion of the magnetic member and the second magnetic member, and the core of each integrated first magnetic member Positioning the portion and the third magnetic member, fixing the core portion and the third magnetic member of each of the positioned first magnetic members, and cutting the thin connecting portion of the first magnetic member. Thereby separating each of the posture holding sections from each of the core sections.

According to a fifth aspect of the present invention, there is provided a method of manufacturing a laminated core according to any one of the first to fourth aspects, wherein each of the positioned core portions or the predetermined portions of the side surfaces of the core portions and the third magnetic member are provided. Are welded to each other by laser welding, or each core and the third magnetic member are fixed to each other.

According to a sixth aspect of the present invention, there is provided a method of manufacturing a laminated core according to any one of the first to fourth aspects, wherein each of the positioned core portions or the predetermined portions of the side surfaces of the core portions and the third magnetic member are provided. The cores are fixed to each other or the cores and the third magnetic member are fixed to each other by adhering a resin to the region.

According to a seventh aspect of the present invention, in the method for manufacturing a laminated core according to any one of the first to fourth aspects, the thin connecting portion is connected to the core at a position depressed from the outer shape of the core. It was done.

According to a eighth aspect of the present invention, there is provided a method of manufacturing a laminated core according to any one of the second to fourth aspects, wherein a notch is provided in the thin connecting portion.

According to a ninth aspect of the present invention, there is provided a method of manufacturing a laminated core according to any one of the second to fourth aspects, wherein the thin connecting portion is provided with a crack which cannot be broken by half-retraction. is there.

A laminated core according to a tenth aspect of the present invention is constituted by stacking a large number of magnetic members having a core portion formed by press punching and a posture holding portion connected via a thin connecting portion. It was done.

[0019]

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiment 1 FIG. 1 is a perspective view showing a configuration of a laminated core of a stator of a rotating electric machine obtained by a manufacturing method according to Embodiment 1 of the present invention, and FIG. 2 is a state in which the laminated core of FIG. 1 is incorporated in a bracket of the rotating electric machine. FIG. 3 is a perspective view showing a state immediately after forming a magnetic member of a predetermined shape by press-punching a large number of magnetic materials and stacking them in a mold, and FIG. 5 and 6 are a plan view and a front view, respectively, showing a process of positioning the core portions of the magnetic members and fixing the core portions to each other in FIG. 3. is there.

In the drawing, reference numeral 1 denotes a number of magnetic members formed in a predetermined shape by press punching in a mold (not shown), and a central portion having a shape of a stator of a rotating electric machine is provided at a central portion. 2 and both sides of the core portion 2, for example, a magnetic member 1
Is 0.5 mm, it is formed by a posture holding part 4 connected via a thin connecting part 3 having a width of 1 mm. These magnetic members 1 are sequentially stacked in a mold, and at the same time, as shown in FIG.
Each magnetic member 1 is integrated as shown in FIG. 3 to form a laminated core 10 of the stator.

At this time, a slight error accumulates in the staked portion 4a, causing a tilt as shown in FIG.
0 is slightly inclined. Next, after taking out the laminated core 10 from the mold, the corner portion of the core portion 2 was positioned by the jig 5 to correct the overall shape as shown in FIG. 5, and then the positioning was performed as shown in FIG. Core part 2
By performing laser welding 6 on the side surface of each of the core portions 2, the core portions 2 are fixed to each other to perform the main fixing, thereby completing the laminated core 10. Then, the laminated core 10 thus completed is bent as shown in FIG. 1 by bending the thin-walled connecting portion 3 so that the posture holding portion 4 is along the side surface of the core portion 2. As shown, it is stored in the bracket 7 and fixed at a predetermined position.

As described above, according to the first embodiment, the posture holding unit 4 connected to the core unit 2 via the thin connecting unit 3 is used.
A large number of magnetic members 1 composed of the following are stacked, and the respective magnetic members 1 are integrated by performing crimping 4a on the attitude holding unit 4, so that the core members 2 are taken out from the press die and positioned. Process can be handled as one part, so that productivity can be improved without being restricted by the shape, and the core portion 2 is fixed by laser welding 6 after positioning. Therefore, the distortion between the core portion 2 and the posture holding portion 4 generated at the time of positioning is absorbed by the deformation of the thin connecting portion 3 having relatively low strength, so that the laminated core 10 having high accuracy is obtained. Can be obtained.

In the above description, the case where the respective core portions 2 are fixed to each other by the laser welding 6 has been described. However, the present invention is not limited to this. For example, a resin is adhered to a predetermined region on the side surface of each of the core portions 2. Alternatively, the same effect as described above can be obtained.

Embodiment 2 FIG. 7 is a perspective view showing a state immediately after forming a magnetic member having a predetermined shape by punching out a large number of magnetic materials and stacking them in a mold, and FIG. 8 is a core portion of each magnetic member in FIG. FIG. 9 is a plan view showing a process of positioning and fixing the core portions to each other, and FIG. 9 is a perspective view showing the configuration of the laminated core according to the second embodiment of the present invention together with the detached attitude holding portion.

In the drawing, reference numeral 8 denotes a number of magnetic members formed into a predetermined shape by press punching in a mold (not shown), and a central portion having a shape of a stator of a rotating electric machine is provided at a central portion. 9 and both sides of the core 9, for example, the magnetic member 1
Is 0.5 mm, it is formed by a posture holding part 12 connected via a thin connecting part 11 having a width of 1 mm. These magnetic members 8 are sequentially stacked in a mold, and at the same time, the posture holding portion 12 is crimped 12a in the same manner as in the first embodiment, and each magnetic member 8 is shown in FIG. Thus, the laminated core 20 of the stator is constituted.

Next, the laminated core 20 is taken out of the mold, and the entire shape is corrected by positioning the corner portion of the core portion 9 with the jig 13 as shown in FIG. By performing the laser welding 14, the core portions 9 are fixed to each other and fixed, and the laminated core 20 is completed. Then, the laminated core 20 thus completed is cut at its root portion on the core portion 9 side of the thin connecting portion 11 by performing thermal processing such as laser irradiation or mechanical processing such as bending or shearing. After the attitude holding unit 12 is detached from the core unit 9 as shown in FIG. 9, the attitude holding unit 12 is housed in a bracket (not shown) and fixed at a predetermined position.

As described above, according to the second embodiment, similarly to the first embodiment, a large number of components including the core portion 9 and the attitude holding portion 12 connected via the thin connecting portion 11 are provided. Since the magnetic members 8 are integrated by stacking the magnetic members 8 and performing crimping 12a on the posture holding unit 12, the process until the core unit 9 is taken out from the press die is performed. Since it can be handled as a single part, it is possible to improve productivity without being restricted by the shape, and since the core portion 9 is positioned and fixed by laser welding 14. Since the distortion between the core portion 9 and the posture holding portion 12 caused at the time of positioning is absorbed by the deformation of the thin connecting portion 11 having relatively low strength, it is possible to obtain a highly accurate laminated core 20. Further, after the core portion 9 is positioned and fixed, the posture holding portion 12 is detached from the core portion 9 by cutting the thin-walled connecting portion 11, so that the external dimensions can be reduced by the amount of unnecessary portions eliminated. For,
The storage in the bracket is easy, and the assembling work is simplified.

In the above, the case where the respective core portions 9 are fixed to each other by the laser welding 14 has been described. However, the present invention is not limited to this. For example, as in the case of the first embodiment, the respective core portions 9 are fixed. The resin may be adhered to a predetermined region on the side surface of the substrate.

If a crack 13 that does not break due to half-removal is formed at the base of the thin connecting portion 11 on the side of the core 9, the thin connecting portion 11 can be easily cut, and the posture holding portion 12 can be detached. Work becomes easier. Hereinafter, a method for forming the crack 13 will be described with reference to FIG. First, an upper mold 1 having a projection 14a protruding by a dimension h at a predetermined position on the lower surface.
4 and a projection 1 of the upper mold 14 which is disposed below the upper mold 14.
A first press die 16 including a lower die 15 having a recess 15a that can be fitted with the projection 14a at a position corresponding to the lower die 4a.
In between, the thin connecting portion 11 of the magnetic member 8 is inserted.

Next, the upper die 14 is lowered to bring the lower surface into contact with the upper surface of the lower die 15, and then the upper die 14 is raised and returned to its original state. You. Next, the thin connecting portion 11 is inserted and the upper die 18 is lowered between the second press die 21 composed of the upper die 18 having a flat lower surface and the lower die 19 having a flat upper surface. When the upper die 18 is raised and returned to its original position after being brought into contact with the upper surface of 19, the half blanking portion 17 formed by the first press die 16 is returned to its original position as shown in FIG. As schematically shown in detail, a crack 13 that does not break is formed. FIG. 12 shows that the projection 14
FIG. 4 is a characteristic diagram showing a relationship between a half withdrawal amount d determined by the protrusion dimension h of a and the strength K of the magnetic member 8. As is clear from the drawing, the strength K decreases as the half withdrawal amount d increases. Therefore, by appropriately selecting the half withdrawal amount d, the cutting of the thin connecting portion 11 becomes more effective.

FIG. 13A and FIG.
As shown in FIG. 13A, if notches 22 are provided on one or both sides of the base portion of the thin connecting portion 11 on the core portion 9 side, as shown in FIGS. 13B and 14B, respectively. ,
By alternately bending the notch 22 on both sides, as shown in FIGS. 13C and 14C, the thin connecting portion 11 can be easily cut and the attitude holding portion 12 can be detached. .

Embodiment 3 FIG. FIG. 15 is a perspective view showing a state immediately after a magnetic member having a predetermined shape is formed by press-punching a large number of magnetic materials and stacked in a mold.
6 is a plan view showing a step of positioning the core portions of the respective magnetic members and fixing the respective core portions in FIG. 15, and FIG. 17 shows a state immediately after the respective core portions of the respective magnetic members are fixed in FIG. FIG. 18 is a perspective view, and FIG.
1 is a perspective view showing a configuration of a laminated core of a small transformer obtained by the manufacturing method in FIG.
FIG. 9 is a perspective view showing a step of performing laser welding on the side surface of the core portion in FIG.

In the figure, reference numeral 23 denotes a number of magnetic members formed into a predetermined shape by press punching in a mold (not shown), and a core portion 24 having the shape of an iron core of a small transformer; On one side of the portion 24, for example, when the thickness of the magnetic member 1 is 0.5 mm, a posture holding portion 26 connected via a thin connecting portion 25 having a width of 1 mm is formed. These magnetic members 23 are sequentially stacked in a mold, and at the same time, the posture holding portion 26 is crimped 26a in the same manner as in the first embodiment, and each magnetic member 23 is shown in FIG. Thus, the laminated core 30 of the iron core is constituted.

Next, the laminated core 30 is taken out of the mold and inserted into the resin integral molding mold 27. At this time, the laminated core 3
At 0, inclination and undulation have occurred, so as shown in FIG. 16, the side surface of the core portion 24 is pressed from the directions of arrows A ₁ and A _{2 in the} figure by the width adjusting guide 28 immediately before insertion to correct the shape. .
Next, the laminated core 30 is inserted into the resin-integrated molding die 27 with the pressing jig 29, and the molten resin is injected into the die to fix the core portion 24. In this case, it is cost effective if the resin bobbins 31 necessary for winding a coil (not shown) around the outer periphery of the core portion 24 are integrally formed at the same time as shown in FIG. Finally, using the means described in the second embodiment, the thin connecting portion 25 is cut as shown in FIG. 18 to release the posture holding portion 26, and the core portion is removed as shown in FIG. 24 is subjected to laser welding 32 on the side surface.

As described above, according to the third embodiment, a large number of magnetic members 23 each composed of the core portion 24 and the posture holding portion 26 connected via the thin connecting portion 25 are stacked,
Since the respective magnetic members 23 are integrated by applying the crimping 26a to the posture holding portion 26, the process from taking out the press die to positioning the core portion 24 can be handled as one component. Therefore, the productivity can be improved without being restricted by the shape. Further, after positioning the core portion 24, the core portion 24 is inserted into the resin integral molding die 27, and the core portion 24 is formed by resin integral molding.
Is fixed, the distortion between the core portion 24 and the posture holding portion 26 generated at the time of positioning is absorbed by the deformation of the thin connecting portion 25 having relatively low strength, so that a high-precision lamination is performed. Core 30 can be obtained,
Further, since the laser welding 32 is applied to the side surface of the core portion 24 integrally molded with the resin, the laminated core 30 itself is mechanically mounted, such as when a magnet having a large wire diameter is wound during coil formation. This is effective when strength is required or when it is necessary to prevent beats and vibrations, such as when forming a transformer.

Embodiment 4 FIG. FIG. 20 is a perspective view showing a configuration of a laminated core of a stator of a rotating electric machine obtained by a manufacturing method according to a fourth embodiment of the present invention, together with a detached posture holding unit, and FIG. 21 combines the laminated cores of FIG. Front view showing the configuration of the stator core of the rotating electric machine formed by
FIG. 22 is a perspective view showing a state immediately after forming a magnetic member having a predetermined shape by press-punching a large number of magnetic materials and stacking them in a mold, and FIG. 23 is a line XXI in FIG.
FIGS. 24 and 25 are a plan view and a side view showing a step of positioning the core portions of the respective magnetic members in FIG. 22 and fixing the respective core portions to each other, and FIGS. 23 is a cross-sectional view showing a modification example different from the unevenness in FIG. 23, FIG. 27 is a cross-sectional view showing another modification example different from the unevenness in FIG. 23, and FIG.
FIG. 4 is a cross-sectional view for explaining a method of forming irregularities in FIG.

In the drawing, reference numeral 33 denotes a number of magnetic members formed into a predetermined shape by press punching in a mold (not shown), and a core portion having a shape of one pole of a stator of a rotating electric machine. And a position holding portion 3 connected to the inner diameter side of the core portion 34 via a thin connecting portion 35 having a width of 1 mm when the thickness of the magnetic member 33 is 0.5 mm, for example.
6 are formed. As shown in FIG. 23, a concave portion 34a and a convex portion 34b are formed at predetermined positions of the core portion 34 at the time of press punching, and a predetermined portion is formed between adjacent concave portions 34a and convex portions 34b at the time of stacking described later. Are formed in such a size that a gap is formed.

The magnetic members 33 are sequentially stacked in the mold while the concave portions 34a and the convex portions 34b are fitted, and at the same time, are crimped to the posture holding portion 36.
a, and the respective magnetic members 33 are integrated as shown in FIG. 22 to form the laminated core 40 of the stator. Next, after taking out the laminated core 40 from the mold, the core portion 34 is positioned by a jig 37 to correct the overall shape as shown in FIGS. 24 and 25, and then the side surface of the core portion 34 is laser-welded. 3
8, the core portions 34 are firmly fixed to each other to perform the final fixing, and the laminated core 40 is completed. Next, the laminated core 40 thus completed is cut at the root portion of the thin-walled connecting portion 35 on the core portion 34 side by performing thermal processing such as laser irradiation or mechanical processing such as bending or shearing. After the posture holding unit 36 is detached from the core unit 34 as shown in FIG. 20, a predetermined number of combinations are stored in a bracket (not shown) and fixed at a predetermined position as shown in FIG. Thus, the stator core 39 of the rotating electric machine is configured.

As described above, according to the fourth embodiment, a large number of magnetic members 33 composed of the core portion 34 and the posture holding portion 36 connected via the thin connecting portion 35 are stacked,
Since the respective magnetic members 33 are integrated by applying the crimping 36a to the posture holding portion 36, the process of taking out from the press die and positioning the core portion 34 can be handled as one component. Therefore, it is possible to improve the productivity without being restricted by the shape, and since the core portion 34 is fixed by the laser welding 38 after the positioning, the posture is maintained with the core portion 34 generated at the time of positioning. Since the distortion with the portion 36 is absorbed by the deformation of the thin connecting portion 35 having relatively low strength, the laminated core 40 with high accuracy can be obtained.

Further, at the time of press punching, each core portion 34
Forming a concave portion 34a and a convex portion 34b at predetermined positions of
Since the concave portions 34a and the convex portions 34b are sequentially stacked while being fitted, the core portions 34 are separated by the gap formed by the concave portions 34a and the convex portions 34b of the adjacent core portions 34. Since the displacement can be allowed below, and the displacement can be prevented more than the gap, the lamination fixing by the laser welding 38 can be performed accurately without applying an excessive force.
Due to the presence of the convex portions 4a and the convex portions 34b, the displacement of the core portion 34 due to the deformation of the thin connecting portion 35 is restricted, and even if the thin connecting portion 35 is removed before the laser welding 38 is performed, the core portion 3 is not removed.
For example, the production equipment can be simplified or stabilized, for example, the deviation of the production equipment 4 can be regulated.

A concave portion 34a formed in the core portion 34
The shape of the projections 34b is not limited to the shape shown in FIG. 23, but may be, for example, a shape with little roundness as shown in FIG. 26, and further, as shown in FIG.
28, the gap in the radial direction between the first mold 41 and the lower mold 4 may be increased as shown in FIG.
3. A small hole 44 corresponding to the volume of the gap between the concave portion 34a and the convex portion 34b was punched out by the concave portion 43a formed in 3, and then formed in the upper die 46 of the mold 45 in the same shape as the convex portion 34b. The concave portion 46a and the concave portion 34
It can be easily obtained by abutting the protruding portions 47a formed in the same shape as a.

Embodiment 5 FIG. FIG. 29 is a perspective view showing a state immediately after forming a magnetic member having a predetermined shape by stamping out a large number of magnetic materials and stacking them in a mold.
0 is a perspective view showing a state in which the magnetic members stacked as shown in FIG.
FIG. 31 is a perspective view showing a step of detaching the attitude holding unit, and FIG.
2 is a perspective view showing a step of performing laser welding on the side surface of the core portion, and FIG. 33 is a front view showing a configuration of a laminated core of the stator of the universal electric motor obtained by the manufacturing method according to the fifth embodiment of the present invention. .

In the drawing, reference numeral 48 denotes a number of magnetic members formed into a predetermined shape by press punching in a mold (not shown), and a core formed by being connected in a belt shape through a bent portion 49a. A portion 49 and a plurality of posture holding portions 52 connected to one side of the core portion 49 via a thin connecting portion 51. A concave portion 49b and a convex portion 49c having a shape as described in the fourth embodiment are formed at predetermined positions of the core portion 49 at the time of press punching, respectively.
Each magnetic member 48 is provided in the mold with each concave portion 49b and each convex portion 49b.
c are sequentially stacked while being fitted, and at the same time, the posture holding portion 52 is crimped 52a, and integrated as shown in FIG. 29 to form the laminated core 50 of the stator.

The laminated core 50 thus configured is taken out of the mold, and although not shown, the third embodiment is not shown.
Similarly to the above, after the core portion 49 is positioned by a jig to correct the entire shape, the core portion 49 is inserted into a resin integral molding die, and the molten resin is injected into the die to form the core portion 49. Fixation is performed and a state as shown in FIG. 30 is obtained. Next, as shown in FIG. 31, by cutting the thin connecting portion 51 with a laser 53, the attitude holding portion 52 is detached from the core portion 49, and a laser welding 54 is attached to the side surface of the core portion 49 as shown in FIG. Apply. Finally, as shown in FIG. 23, the core portion 49 is formed into a rectangular shape by bending the bent portion 49a,
The universal motor stator 56 is completed by being housed and fixed in the bracket 55.

As described above, according to the fifth embodiment, as in the above-described embodiments, the magnetic members 48 are integrated by applying the crimping 52a to the posture holding portion 52. Since the process until the core 49 is removed from the press die can be handled as a single part, productivity can be improved, and the core 49 is fixed by resin integral molding. Therefore, distortion between the core portion 49 and the posture holding portion 52 caused at the time of positioning is reduced by the thin connecting portion 5 having relatively low strength.
1 is absorbed by the deformation, so that the laminated core 50 with high accuracy can be obtained.

Further, a core portion 49 integrally molded with resin is provided.
The laser welding 54 is applied to the side surface of the laminated core 50, as in the case where a magnet having a large wire diameter is wound at the time of forming a coil, the laminated core 50 itself needs to have mechanical strength, or a transformer is formed. This is effective when it is necessary to prevent beats and vibrations. In addition, since the concave portions 49b and the convex portions 49c of each core portion 49 are sequentially stacked while being fitted, the core formed by the concave portions 49b and the convex portions 49c of the adjacent core portions 49 is formed. Since it is possible to allow the portions 49 to be displaced within the gap and to prevent the portions 49 from being displaced more than the gap, the lamination and fixing of the core 49 can be performed accurately without applying excessive force.

Embodiment 6 FIG. FIG. 34 is a perspective view showing a state immediately after forming a magnetic member of a predetermined shape by punching out a large number of magnetic materials and stacking them in a mold. FIGS. 35 and 36 are views of each magnetic member in FIG. FIG. 37 is a plan view and a side view showing a step of positioning the core portions and fixing the respective core portions to each other. FIG. 37 shows the configuration of the magnetic head core obtained by the manufacturing method according to the sixth embodiment of the present invention in a detached posture. It is a perspective view shown with a holding part.

In the figure, reference numeral 57 denotes a number of magnetic members formed into a predetermined shape by press punching in a mold (not shown), and a core portion 58 having a shape of a magnetic head core at a central portion; Thin connecting portions 59 are provided on both sides of the core portion 58.
The core portion 58 is formed with a concave portion 58a and a convex portion 58b at the time of press punching. These magnetic members 57 are sequentially stacked in a mold, and at the same time, the posture holding portion 61 is crimped 61a.
Are integrated as shown in FIG. 34 to form a stacked core 60 of the magnetic head. In the configuration shown in FIG. 34, a predetermined number of magnetic members 57 are provided from both end surfaces with thin connecting portions 59, and the intermediate magnetic member 57 has a core portion 58 and a posture holding portion 61 separated from each other. It is in a state.

Such a state can be easily realized by intermittently operating the punch and the die near the thin connecting portion 59 in the progressive press. In the core portion 58 laminated without the thin connecting portion 59, each concave portion 58a
And the projection 58b is held by the fitting, so that the projection 58b does not jump out greatly. Further, instead of the concave portion 58a and the convex portion 58b, the outer shape of the posture holding portion 61 may be configured to wrap the core portion 58 through a predetermined gap to prevent the protrusion.

The laminated core 60 constructed as described above
Is removed from the mold, the core 58 is positioned by a jig 62 to correct the overall shape as shown in FIGS. 35 and 36, and then the laser welding 63 is performed on the side surface of the core 58. Then, the core portions 58 are fixed to each other to perform the main fixing, and the laminated core 60 is completed. Next, in the laminated core 60 completed in this manner, the root portion of the thin connecting portion 59 on the core portion 58 side is cut by the cutter 64 as shown in FIG. The magnetic head core 65 is configured.

As described above, according to the sixth embodiment, the thin connecting portions 59 for connecting the core portion 58 of the magnetic member 57 and the attitude holding portion 61 are reduced to a predetermined number at both ends of the laminated core 60. As the number of the thin connecting portions 59 is reduced, the cutting work for detaching the posture holding portion 61 from the core portion 58 is facilitated, and the workability can be improved.

Embodiment 7 FIG. 38 is a perspective view showing a configuration of a main part of a laminated core of a stator of a rotating electric machine obtained by a manufacturing method according to Embodiment 7 of the present invention, and FIG. 39 is a plan view showing a different configuration of the laminated core in FIG. 40 is a perspective view showing a step of detaching the attitude holding portion of the laminated core in FIG. 39, and FIG. 41 is a perspective view showing another configuration of the laminated core.

In the present embodiment, as shown in FIG. 38, the magnetic member 66 is composed of a core 67, a thin connecting portion 68, and a posture holding portion 69.
Depressions 66a and 66b are formed at the root portion where is connected. Therefore, after the core portion 67 is positioned and fixed in the same manner as described in each of the above embodiments, the thin connecting portion 68 is cut and the posture holding portion 69 is detached.
The cutting position is set at a position depressed from the outer shape of the core portion 67, that is, inside the depressed portions 66a and 66b, and the laser 71 is used for cutting.

In the above configuration, the case where the present invention is applied to the laminated core of the stator of the rotating electric machine formed in an annular shape has been described. However, as shown in FIG. 39, the present invention is applied to the case where the magnetic member 72 is formed in a belt shape. In this example, the attitude holding portion 73 may be connected to the pole portions adjacent to the core portion 74 by the thin connecting portions 7.
The recesses 74a and 74b are formed at the root portion of the core 74 where the thin connection portion 75 is connected. Also in this case, as shown in FIG. 40, at the stage of cutting the thin connecting portion 75 and detaching the posture holding portion 73, the cutting position is depressed from the outer shape of the core portion 74,
That is, the laser 71 is set in the depressions 74a and 74b.
Disconnect with

As described above, according to the seventh embodiment, the cutting position of the thin connecting portion 75 is set at a position depressed from the outer shape of the core portion 74, that is, inside the depressed portions 74a and 74b. Even if burrs or protrusions occur on the surface, the laminated core 7
Since it can be prevented from jumping out of the outer shape of 0, post-processing of the cut surface can be omitted and productivity can be improved.

In each of the above embodiments, a case has been described in which each of the posture holding units is individually connected, but as shown in FIG. 41, a belt-like posture holding unit 76 is provided.
May be connected to the core 78 via a plurality of thin connecting portions 77, respectively.

[0057]

As described above, according to the first aspect of the present invention, a magnetic member having a shape having a posture holding portion connected via a core portion and a thin connecting portion is formed by press punching. A step of sequentially laminating, a step of integrating each magnetic member by sequentially caulking a posture holding part at the time of laminating, a step of positioning each core part of each integrated magnetic member, and a step of positioning each core Since the step of fixing the parts is included, it is possible to provide a method of manufacturing a laminated core that can obtain a laminated core having excellent productivity and high assembly accuracy.

According to a second aspect of the present invention, a step of forming a magnetic member having a posture holding portion connected via a core portion and a thin connecting portion by press punching and sequentially laminating the magnetic members in a mold. And a step of sequentially integrating the magnetic members by caulking the posture holding parts during lamination, a step of positioning each core part of each integrated magnetic member, and fixing the positioned core parts to each other. A method of manufacturing a laminated core capable of obtaining a laminated core having excellent productivity and high assembling accuracy because the method includes a step and a step of separating each posture holding part from each core part by cutting the thin-walled connecting part. Can be provided.

According to the third aspect of the present invention, the posture holding portion connected by the press punching via the core portion and the thin connecting portion, and the unevenness at predetermined positions on the front and back surfaces of the core portion are provided. Forming a magnetic member having a shaped shape and sequentially laminating it in a mold while fitting the irregularities, a process of integrating each magnetic member by sequentially caulking a posture holding portion during lamination, and a process of integrating each magnetic member. Since the step of positioning each core part of the member, the step of fixing the positioned core parts to each other, and the step of separating each posture holding part from each core part by cutting the thin connecting part were included, It is possible to provide a method of manufacturing a laminated core that is excellent in productivity and can obtain a laminated core with high assembling accuracy and that can simplify or stabilize production equipment.

According to the fourth aspect of the present invention, the first magnetic member having the posture holding portion connected via the core portion and the thin connecting portion by press punching is formed, and is sequentially formed in the mold. A step of laminating a predetermined number of sheets, forming a second magnetic member having the same shape as the posture holding portion and a third magnetic member having the same shape as the core portion by press punching, and sequentially forming a predetermined number of sheets on the first magnetic member. Laminating, forming a first magnetic member, sequentially laminating a predetermined number of the magnetic members on the second and third magnetic members, and attaching the posture holding portion of the first magnetic member and the second magnetic member at the time of lamination. Integrating the first, second and third magnetic members by caulking sequentially;
A step of positioning the integrated core part and the third magnetic member of each first magnetic member, and a step of fixing the positioned core part and the third magnetic member of each first magnetic member to each other; Cutting the thin connecting portion of the first magnetic member to detach each position holding portion from each core portion, so that a laminated core with higher productivity and higher assembly accuracy can be obtained. A method for manufacturing a core can be provided.

According to a fifth aspect of the present invention, in any one of the first to fourth aspects, a predetermined position of each of the positioned core portions or the side surfaces of the respective core portions and the third magnetic member is laser-welded. By doing so, the respective core portions or the respective core portions and the third magnetic member are fixed to each other, so that a method for manufacturing a laminated core which can obtain a laminated core having excellent productivity and high assembling accuracy is provided. be able to.

According to a sixth aspect of the present invention, in any one of the first to fourth aspects, a resin is applied to a predetermined region of each of the positioned core portions or each of the core portions and the third magnetic member. Since the respective core portions or the respective core portions and the third magnetic member are fixed to each other by being attached, a method for manufacturing a laminated core capable of obtaining a laminated core having excellent productivity and high assembling accuracy is provided. can do.

According to a seventh aspect of the present invention, in any one of the first to fourth aspects, the thin connecting portion is connected to the core portion at a position depressed from the outer shape of the core portion, so that further production is achieved. It is possible to provide a method for manufacturing a laminated core which can obtain a laminated core having excellent assembly characteristics and high assembling accuracy.

According to the eighth aspect of the present invention, in any one of the second to fourth aspects, the notch is provided in the thin connecting portion, so that a laminated core having higher productivity and higher assembling accuracy can be obtained. A possible method of manufacturing a laminated core can be provided.

According to the ninth aspect of the present invention, in any one of the second to fourth aspects, the thin connecting portion is provided with a crack that does not break due to the half-removal.
It is possible to provide a method of manufacturing a laminated core that can obtain a laminated core having excellent productivity and high assembling accuracy.

According to the tenth aspect of the present invention, a plurality of magnetic members having a posture holding portion connected via a core portion formed by press punching and a thin connecting portion are formed by stacking. In addition, it is possible to provide a method of manufacturing a laminated core that can obtain a laminated core having excellent productivity and high assembling accuracy.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a configuration of a laminated core of a stator of a rotating electric machine obtained by a manufacturing method according to Embodiment 1 of the present invention.

FIG. 2 is a cross-sectional view showing a state where the laminated core in FIG. 1 is incorporated in a bracket of a rotating electric machine.

FIG. 3 is a cross-sectional view showing a state immediately after forming a magnetic member having a predetermined shape by stamping out a large number of magnetic materials and stacking them in a mold;

FIG. 4 is a cross-sectional view illustrating a stacked state of a posture holding unit of the magnetic member in FIG. 3;

FIG. 5 is a plan view showing a step of positioning core portions of the respective magnetic members in FIG. 3 and fixing the respective core portions to each other.

6 is a front view showing a step different from that in FIG. 5 in which the core portions of the respective magnetic members in FIG. 3 are positioned and the respective core portions are fixed to each other.

FIG. 7 is a perspective view showing a state immediately after forming a magnetic member having a predetermined shape by punching out a large number of magnetic materials and stacking them in a mold;

FIG. 8 is a plan view showing a step of positioning a core portion of each magnetic member in FIG. 7 and fixing the core portions to each other.

FIG. 9 is a perspective view showing a configuration of a laminated core according to Embodiment 2 of the present invention, together with a detached attitude holding unit.

FIG. 10 is a cross-sectional view for explaining a method of forming a crack in a thin connecting portion.

FIG. 11 is a diagram schematically showing a crack in FIG. 10;

FIG. 12 is a characteristic diagram showing a relationship between a half-removed amount determined by a protrusion dimension of a protrusion and a strength of a magnetic member when a half-removed portion is formed.

FIG. 13 is a front view showing a step of an example of a method of cutting the thin communication portion.

FIG. 14 is a front view showing a step of an example different from that shown in FIG. 13 of the method of cutting the thin connection portion.

FIG. 15 is a perspective view showing a state immediately after forming a magnetic member having a predetermined shape by press-punching a large number of magnetic materials and stacking them in a mold.

FIG. 16 is a plan view showing a step of positioning the core portions of the magnetic members in FIG. 15 and fixing the core portions to each other.

FIG. 17 is a perspective view showing a state immediately after the core portions of the magnetic members are fixed to each other in FIG.

FIG. 18 is a perspective view showing a configuration of a laminated core of a small transformer obtained by a manufacturing method according to Embodiment 3 of the present invention, together with a detached attitude holding unit.

FIG. 19 is a perspective view showing a step of performing laser welding on the side surface of the core portion in FIG. 18;

FIG. 20 is a perspective view showing a configuration of a laminated core of a stator of a rotating electrical machine obtained by a manufacturing method according to Embodiment 4 of the present invention, together with a detached attitude holding unit.

21 is a front view showing a configuration of a stator core of a rotating electric machine formed by combining the laminated cores in FIG. 20;

FIG. 22 is a perspective view showing a state immediately after forming a magnetic member having a predetermined shape by punching out a large number of magnetic materials and stacking them in a mold.

FIG. 23 is a line XXIII-XXIII in FIG. 22;
FIG. 4 is a cross-sectional view showing a cross section taken along a line.

24 is a plan view showing a step of positioning core portions of the respective magnetic members in FIG. 22 and fixing the respective core portions to each other.

FIG. 25 is a side view showing a step in FIG. 24.

FIG. 26 is a cross-sectional view showing a modified example different from the unevenness in FIG.

FIG. 27 is a cross-sectional view showing a modification example further different from the unevenness in FIG.

FIG. 28 is a diagram for explaining a method of forming unevenness in FIG. 27;

FIG. 29 is a perspective view showing a state immediately after forming a magnetic member having a predetermined shape by punching out a large number of magnetic materials and stacking them in a mold;

30 is a perspective view showing a state in which the magnetic members stacked as shown in FIG. 29 are integrally molded with resin and the core portions are fixed to each other.

FIG. 31 is a perspective view showing a step of detaching the posture holding unit.

FIG. 32 is a perspective view showing a step of performing laser welding on the side surface of the core portion.

FIG. 33 is a front view showing a configuration of a laminated core of a stator of a universal motor obtained by a manufacturing method according to a fifth embodiment of the present invention.

FIG. 34 is a perspective view showing a state immediately after a magnetic member having a predetermined shape is formed by punching out a large number of magnetic materials and stacked in a mold.

FIG. 35 is a plan view showing a step of positioning the core portions of the respective magnetic members in FIG. 34 and fixing the respective core portions to each other.

FIG. 36 is a side view showing the step in FIG. 35.

FIG. 37 is a perspective view showing a configuration of a magnetic head core obtained by a manufacturing method according to a sixth embodiment of the present invention, together with a separated attitude holding unit.

FIG. 38 is a perspective view showing a configuration of a main part of a laminated core of a stator of a rotating electric machine obtained by a manufacturing method according to Embodiment 7 of the present invention.

FIG. 39 is a plan view showing a different configuration of the laminated core in FIG. 38.

40 is a perspective view showing a step of detaching the attitude holding portion of the laminated core in FIG. 39.

FIG. 41 is a perspective view showing the configuration of another laminated core.

[Explanation of symbols]

1,8,23,33,48,57,66,72 Magnetic member, 2,9,24,34,49,58,67,74,7
8 core parts, 3, 11, 25, 35, 51, 59, 6
8,75,77 Thin connection part, 4,12,26,36,
52, 61, 69, 73, 76 Posture holder, 6, 3
2,38,54,63 Laser welding, 10,20,3
0, 40, 50, 60, 70 laminated core, 4a, 12
a, 26a, 36a, 52a, 61a
5, 13, 37, 62 jig, 13 crack, 22 notch, 34a, 49b, 58a recess, 34b, 49c,
58b convex portion, 67a, 67b, 74a, 74b depression.

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-4-105536 (JP, A) JP-A-1-273628 (JP, A) JP-A-62-171436 (JP, A) JP-A-6-171436 165447 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) H02K 15/00-15/16 H02K 1/00-1/34

Claims (10)

(57) [Claims] 1. A step of forming a magnetic member having a posture holding portion connected via a core portion and a thin-walled connection portion by press punching and sequentially laminating the magnetic members in a mold; A step of integrating the magnetic members by caulking, a step of positioning the core portions of the integrated magnetic members, and a step of fixing the positioned core portions to each other. A method for producing a laminated core. 2. A step of forming a magnetic member having a posture holding portion connected via a core portion and a thin-walled connection portion by press punching, and sequentially stacking the magnetic members in a mold; A step of integrating the magnetic members by caulking, a step of positioning the cores of the integrated magnetic members, a step of fixing the positioned cores to each other, A step of disconnecting each of the posture holding sections from each of the core sections by cutting the connecting section. 3. A magnetic member having a posture holding portion connected via a core portion and a thin connecting portion by press punching, and a magnetic member having irregularities at predetermined positions on the front and back surfaces of the core portion. A step of sequentially laminating the magnetic members in the mold while fitting the concaves and convexes, a step of sequentially caulking the posture holding parts during lamination, and a step of integrating the respective magnetic members, and the respective cores of the integrated magnetic members Positioning the parts, fixing the positioned core parts to each other, and cutting the thin connecting parts to release the posture holding parts from the core parts. A method for manufacturing a laminated core, which is characterized in that: 4. A step of forming a first magnetic member having a posture holding portion connected via a core portion and a thin connecting portion by press punching and sequentially laminating a predetermined number of the first magnetic members in a mold, and press punching. Forming a second magnetic member having the same shape as the posture holding portion and a third magnetic member having the same shape as the core portion, and sequentially laminating a predetermined number of the second magnetic member on the first magnetic member; Forming one magnetic member and sequentially laminating a predetermined number of the magnetic members on the second and third magnetic members, and caulking the posture holding portion of the first magnetic member and the second magnetic member sequentially during lamination A step of integrating the first, second and third magnetic members, a step of positioning the integrated core portion and the third magnetic member of each of the first magnetic members, and Each of the first magnetic members Fixing the core portion and the third magnetic member to each other, and disconnecting each of the posture holding portions from each of the core portions by cutting the thin connecting portion of the first magnetic member. The manufacturing method of the laminated core characterized by the above-mentioned. 5. The respective core portions or the respective core portions and the third magnetic member are mutually welded by laser welding a predetermined position of each positioned core portion or the respective core portions and the side surface of the third magnetic member. The method for manufacturing a laminated core according to any one of claims 1 to 4, wherein the laminated core is fixed. 6. The cores or the cores and the third magnetic member are adhered to each other by adhering a resin to predetermined regions of the core portions or the core portions and the side surfaces of the third magnetic member that are positioned. 5. The method for manufacturing a laminated core according to claim 1, wherein the core is fixed. 7. The method according to claim 2, wherein the thin connecting portion is connected to the core at a position depressed from the outer shape of the core. 8. The method for producing a laminated core according to claim 2, wherein a notch is provided in the thin connecting portion. 9. The thin connecting portion is provided with a crack which does not lead to breakage due to half-retraction.
The method for producing a laminated core according to any one of the above. 10. A laminated core comprising a plurality of magnetic members each having a core portion formed by press punching and a posture holding portion connected via a thin connecting portion, and stacked.