JP4472417B2 - Method for manufacturing laminated iron core and mold apparatus - Google Patents

Description

The present invention comprises a predetermined number of divided laminated iron cores each having a divided yoke portion and a tooth portion, and is provided with an annular yoke portion and a predetermined number of teeth portions protruding inward of the yoke portion. The present invention relates to a method for manufacturing a laminated core and a mold apparatus for manufacturing a stator core.

FIG. 10 shows a conventional laminated iron core (stator iron core) A constituting a stator of an electric motor. This laminated iron core A is manufactured by laminating a predetermined number of iron core pieces Aa and caulking and joining them. And a plurality of teeth portions At, At... Projecting inwardly from the yoke portion Ay.

In such a circumferentially integrated laminated core A, as shown in FIG. 11, the core piece Aa constituting the laminated core (stator) A is the same as the core piece Ra constituting the rotor core (not shown). It is usual that the material is taken on the strip steel plate W and manufactured together with the rotor core in the same progressive die apparatus (not shown).

On the other hand, in the above-described laminated iron core A, since the yoke portion Ay has an annular shape and the interval between the adjacent tooth portions At is narrow, winding work on each tooth portion At becomes difficult. In order to solve such problems, a laminated core (stator core) B as shown in FIG. 12 is provided.

This laminated iron core B is manufactured by manufacturing a predetermined number of divided laminated iron cores C having divided yoke portions Cy and teeth portions Ct, and assembling and connecting the plurality of divided laminated iron cores C to each other. A laminated iron core B including By and a plurality of tooth portions Bt (Ct) is configured.

According to such a laminated iron core B, after winding the teeth Ct in each divided laminated iron core C, each divided laminated iron core C, C... The winding work on the tooth portion Ct is extremely easy.

Here, the above-mentioned prior art known to the applicant is a publicly known / public technique and does not relate to a known literature invention, and therefore there is no prior art document information to be described.

By the way, in the laminated iron core B having the above-described configuration, that is, the circumferentially divided laminated iron core B formed by assembling a plurality of divided laminated iron cores C, due to molding restrictions due to its unique form, FIG. As shown in a), since the core pieces Ca constituting the divided laminated core C are arranged on the strip steel plate WS, and the material is taken and manufactured using a dedicated progressive die apparatus (not shown), the laminated core B There was a problem that the yield of the materials related to the production of the steel was poor, and the productivity was lowered and the production cost was increased.

Further, as described above, since the core pieces Ca are arranged on the strip steel plate WS and the material is taken, the core piece Ra constituting the rotor core (not shown) is a separate strip steel plate as shown in FIG. Since the material is taken up on the WR and the rotor core must be manufactured using a separate progressive die device (not shown), the stator core and the rotor core constituting the motor are manufactured. There was a disadvantage that the cost increased significantly.

SUMMARY OF THE INVENTION In view of the above circumstances, the present invention provides a method for manufacturing a laminated core and a mold apparatus that can improve the productivity associated with the production of the laminated core and can also achieve a reduction in production cost. .

In order to achieve the above object, a method for manufacturing a laminated core according to the present invention comprises a predetermined number of divided core pieces being caulked and laminated, and a divided yoke portion and one tooth portion integrated with the divided yoke portion. And a predetermined number of split laminated iron cores having connecting portions at both ends of the split yoke portion connected endlessly to each other, and a predetermined number of ring-shaped yoke portions and a predetermined number of protrusions projecting inwardly from the yoke portions. A method of manufacturing a laminated core for manufacturing a stator core comprising a teeth portion,
A cutting and bending process in which, after the rotor core pieces are formed by punching from a thin plate material, the connecting portions of the adjacent divided core pieces are sheared and separated from each other in the yoke portion forming region in which the divided core pieces are connected to each other. ,
A pushback step of forming the same material as the thin plate material by pushing back the bent portion of the thin plate material;
A slotting step for forming a predetermined number of teeth by punching a predetermined number of slots in a thin plate material;
An inner diameter punching step for punching and forming tooth tips in a predetermined number of teeth parts
A step of punching the outer shape of the split core pieces to separate and form the individual split core pieces, and laminating the split core pieces on the lower split core pieces formed by punching first, and caulking and laminating steps,
In the caulking and laminating process, the divided core pieces are transposed for the purpose of offsetting the thickness deviation.

In order to achieve the above object, a mold apparatus according to the present invention is formed by caulking and laminating a predetermined number of divided core pieces, and includes a divided yoke portion and one tooth portion integrated with the divided yoke portion. And a predetermined number of split laminated iron cores having connecting portions at both ends of the split yoke portion connected endlessly to each other, and a predetermined number of ring-shaped yoke portions and a predetermined number protruding inward of the yoke portions. A mold apparatus for manufacturing a stator core comprising a teeth portion,
After punching and forming the rotor core pieces from a thin plate material, in the yoke part forming region in which the divided core pieces are connected to each other, a cutting and bending process of shearing and bending the connecting portions of the adjacent divided core pieces together. A bending station to perform,
A pushback station for performing a pushback process of forming the same material as the thin plate material by pushing back the bent portion of the thin plate material;
A slotting station for performing a slotting step of forming a predetermined number of teeth by punching and forming a predetermined number of slots in a thin plate material;
An inner diameter punching station for performing an inner diameter punching process for punching and forming tooth tips in a predetermined number of teeth portions;
An outer shape for punching the outer shape of the split core pieces to separate and form the individual split core pieces and laminating the split core pieces on the lower split core pieces formed by punching first and then caulking and bonding With a crimping coupling station
At the outer shape caulking / combining station, the divided core pieces are transposed for the purpose of offsetting the thickness deviation.

In the method for manufacturing a laminated core and the mold apparatus according to the present invention, the connecting portions of the adjacent split core pieces are subjected to shearing and bending to each other, and then the bent portions are pushed back to be formed flush with the thin plate material. By doing so, it is possible to manufacture a circumferentially divided laminated core in the same manner as when manufacturing a circumferentially integrated laminated core even though adjacent divided cores are separated from each other. It becomes.

Thus, since it can be manufactured in the same manner as the circumferentially integrated laminated core, the core pieces constituting the laminated core (stator core) are placed on the same strip steel plate W together with the core pieces constituting the rotor core. It is possible to manufacture materials and manufacture a laminated core (stator core) together with the rotor core in the same progressive mold apparatus.

Thus, according to the method for manufacturing a laminated core and the mold apparatus according to the present invention, it is possible to improve the productivity associated with the production of the circumferentially divided type laminated core, and to achieve a reduction in production costs. It becomes possible.

Hereinafter, the present invention will be described in detail with reference to the drawings illustrating embodiments.
1 and 2 show an embodiment of a laminated core (stator core) constituting an electric motor manufactured by a mold apparatus according to the present invention based on a method for manufacturing a laminated core according to the present invention. The laminated core 1 includes a ring-shaped yoke portion 2 and a predetermined number of teeth portions 3, 3... Protruding inward of the yoke portion 2.

The laminated core 1 is configured by connecting a predetermined number of divided laminated cores 10, 10 to each other endlessly, and each divided laminated core 10 is a part of the yoke portion 2 in the laminated core 1. Are divided yoke portions 10Y and teeth portions 10T constituting one of the plurality of teeth portions 3, 3...

The divided laminated core 10 is configured by caulking and laminating a predetermined number of divided core pieces 11, and the divided laminated core 10 of the laminated core 1 in this embodiment has a predetermined skew with respect to the individual divided core pieces 11. It is configured by caulking and stacking with corners.

Further, the divided core piece 11 constituting the divided laminated core 10 has a divided yoke portion 11Y and a tooth portion 11T, and connecting portions 11A and 11B are formed at both ends of the divided yoke portion 11Y, respectively. Has been.

Specifically, a connecting portion 11A that protrudes in the circumferential direction in the radially outer region is formed at one end portion (end portion on the counterclockwise direction) of the divided yoke portion 11Y, and the other end portion (clockwise direction). A connecting portion 11B that protrudes in the circumferential direction in the radially inner region is formed on the end portion on the direction side.

As a result, in the divided laminated core 10 formed by caulking and laminating the divided core pieces 11 having the above-described form, convex portions extending in the height direction of the divided laminated core 10 are formed at one end and the other end of the divided yoke portion 10Y. Each of the strip-shaped connecting portions 10A and 10B is defined.

A predetermined number of the divided laminated cores 10, 10... Constituting the laminated core 1 are formed by assembling the connecting portion 10 </ b> A in one of the divided laminated cores 10 adjacent to each other and the connecting portion 10 </ b> B in the other divided laminated core 10. The ring-shaped yoke portion 2 is formed by the divided yoke portions 10Y, 10Y,.

Below, the method to manufacture the laminated core 1 of the structure mentioned above is demonstrated.
FIG. 3 shows an example of material removal for the strip steel plate (thin plate material) W when the laminated iron core manufacturing method according to the present invention is carried out. On the strip steel plate W, a predetermined number of divided core pieces are shown. 11, 11... Are formed into a ring by assembling the connecting portions 11 </ b> A and 11 </ b> B, in other words, the material is taken in the same form as the planar shape of the laminated core 1.

Further, on the strip-shaped steel plate W, a rotor core piece 20 constituting a rotor core (not shown) is made of a material in a central region of a predetermined number of divided core pieces 11, 11. Has been taken. That is, as with the material removal (see FIG. 11) when manufacturing the circumferentially integrated laminated core, the core piece constituting the rotor core and the core piece constituting the stator core are the same strip steel plate W. The material is taken up above.

4 to 6 are plan views of a strip steel plate (thin plate material) W processed by a progressive die device (die device) according to the present invention based on the method for manufacturing a laminated core according to the present invention. The progressive die apparatus for manufacturing the laminated core 1 includes a cutting and bending station S1, a pushback station S2, a slot removing station S3, an inner diameter removing station S4, a first crimping portion forming station S5, and a second crimping portion forming station. S6, a third caulking portion forming station S7, an idle station S8, and an outer shape caulking coupling station S9 are provided.

Here, the progressive die apparatus includes a processing station for manufacturing a rotor core (not shown) by sequentially forming the rotor core pieces 20 prior to the above-described stations S1 to S9. Therefore, the rotor core and the stator core are manufactured by a common progressive mold apparatus as in the case of manufacturing the circumferentially integrated type laminated core.

In the manufacturing process of the laminated iron core 1 by the progressive die apparatus described above, first, the rotor core piece 20 is extracted ( crimped and laminated) to form a round hole-shaped opening O in a preceding processing station (not shown). After that, in the cutting and bending station S1, the yoke portion forming region on the strip steel plate (thin plate material) W, that is , the portion where the divided yoke portions 11Y, 11Y . The connecting part 11A and the connecting part 11B between the adjacent divided core pieces 11 are sheared and separated from each other (bending process).

Here, the connecting portion 11A in one divided core piece 11 and the connecting portion 11B in the other divided core piece 11 extend along an association line between the connecting portion 11A and the connecting portion 11B, as shown in FIG. Further, shear separation is performed along a slit line L extending to an outer diameter area and an inner diameter area of the yoke portion forming area on the belt-shaped steel plate W.

8A and 8B, in the cutting and bending station S1, the strip steel plate W is sheared and separated along the slit line L by the punch P and the die D, and the punch P As a result of the lowering, the connecting portion 11A is bent downward. That is, in the cutting and bending station S1, so-called slit foam is performed in which the strip steel plate W is sheared and bent at the same time.

The die D of the cutting and bending station S1 is provided with a pushback slider Q that is biased upward by a spring V in order to support the bending of the connecting portion 11A.

In addition, the shape of the slit line L is not limited to the embodiment as long as the connecting portion 11A and the connecting portion 11B can be shear-separated and bent, and can be appropriately set. Needless to say.

As described above, in the cutting and bending station S1, the connecting portion 11A and the connecting portion 11B of the adjacent split core pieces 11 are sheared and bent, and then the connecting portion 11A that is bent in the pushback station S2 is bent. Push it back and form it flush with the strip steel plate W (pushback process).

That is, as shown in FIGS. 9A, 9B, and 9C, the strip steel plate W is sandwiched between the die D and the stripper plate SP, and the bent connecting portion 11A is faced on the lower surface of the stripper plate SP. By doing so, the connecting portion 11A is pushed back so as to be flush with the strip steel plate W.

As described above, after the bent connecting portion 11A is formed flush with the strip steel plate W in the pushback station S2, a predetermined number of slots S, S... A predetermined number of teeth portions 11T, 11T,... Are formed around the opening O (slot removal step), and then the tooth tips 11t in the respective tooth portions 11T are punched and formed at the inner diameter removal station S4 (inner diameter). Extraction process).

Next, in the first caulking part forming station S5 to the third caulking part forming station S7, the caulking parts 11C, 11C,.
That is, the first caulking portion forming station S5 is formed by punching a skew throwing hole of the caulking portion 11C, and the second lower caulking portion forming station S6 is the lowermost divided core piece 11 constituting one laminated core 1. In the third caulking portion forming station S7, the claw portion of the caulking portion 11C is bent into a predetermined shape with respect to the divided core pieces 11 other than the lowermost layer. (Bending).

Then, the outer vent caulking station S9 that passes through the idle station S8, punching the outer shape of the split yoke portion 11Y of each segment core piece 11, to form individual segment core pieces 11, 11 ... into a predetermined shape, and adjacent The split core pieces 11 can be separated from each other.

Further, in the outer shape caulking / combining station S9, each of the divided core pieces 11, 11,... Formed in a predetermined shape is connected to the previously formed divided core pieces 11, 11,. Are laminated together with caulking portions 11C, 11C..., And caulking and bonding to each other (caulking laminating step).

That is, in the outer shape caulking / combining station S9, the individual divided core pieces 11, 11,... Are punched and formed, and a predetermined number of divided products are obtained by laminating a predetermined number of the divided core pieces 11 and caulking them together. As well as the iron cores 10, 10... Are manufactured, the laminated core 1 is manufactured by connecting a predetermined number of divided product cores 10, 10,.

As described above, in the method for manufacturing a laminated core according to the present invention, the connecting portions 11A and 11B of adjacent divided core pieces 11 are subjected to shearing separation and bending, and then the bent connecting portions 11A and 11B are pushed back. In the same manner as in the case of manufacturing a circumferentially-integrated laminated iron core, although the adjacent divided iron core pieces 11 are separated from each other by being formed flush with the belt-shaped steel plate W, the circumferentially divided steel core W is formed. It becomes possible to manufacture the laminated iron core 1 of the mold.

Thus, since the circumferentially divided laminated core 1 can be manufactured in the same manner as the circumferentially integrated laminated core, a predetermined number of divided core pieces 11 constituting the divided laminated core 10 of the laminated core 1 are As shown in FIG. 3, it is possible to take the material in the form of being connected in an annular shape, and therefore, compared with the conventional manufacturing method (see FIG. 13) in which the divided core pieces are arranged on the strip steel plate and the material is taken. The yield of materials related to manufacturing can be remarkably improved, and productivity can be improved and manufacturing cost can be reduced.

Further, since the circumferentially divided laminated core 1 can be manufactured in the same manner as the circumferentially integrated laminated core 1, the predetermined number of divided core pieces 11 constituting the divided laminated core 10 of the laminated core 1 are shown in FIG. As shown in FIG. 4, it is possible to take the material on the same strip steel plate W together with the rotor core piece 20, and thus, the laminated core 1 can be manufactured together with the rotor core using the same progressive die apparatus. The costs associated with the production of the laminated core 1 and, in turn, the production cost of the entire electric motor including the stator core and the rotor core can be greatly reduced.

By the way, the laminated iron core 1 taken out from the progressive die apparatus is once separated into individual divided laminated iron cores 10, 10... As a result, the stator of the electric motor is completed.

Here, when the connecting portions 10A and the connecting portions 10B of the adjacent divided laminated cores 10 are assembled to each other to connect the divided laminated cores 10, 10, ..., the divided core pieces 11 constituting the connecting portions 10A, 10B are connected. Since the connecting portions 11A and 11B are obtained by shearing and separating the association lines, the laminated core 1 having good conformability and excellent shape accuracy can be obtained.

In the embodiment described above, the connecting portions 10A and 10B (the connecting portions 11A and 11B of the split core piece 11) of the split laminated core 10 protrude in the circumferential direction from both ends of the split yoke portion 10Y (the split yoke portion 11Y). However, it is needless to say that the shape of the connecting portion is not limited to the embodiment, and can be appropriately set based on various conditions such as specifications of the laminated core.

In the above-described embodiment, the cutting process and the pushback process are performed in the separate cutting and bending station S1 and pushback station S2, but the portion bent by the pushback slider Q of the cutting and bending station S1. Can be completely pushed back, the pushback station S2 can be omitted, and the cutting and pushing back process can be performed at the cutting and bending station S1.

Further, in the above-described embodiment, in the caulking coupling station S9 without the outer shape of the progressive die apparatus, a predetermined skew angle is given to each of the divided core pieces 11, 11. It is also possible to perform transposition of each of the divided core pieces 11, 11... For the purpose of offsetting.

Furthermore, in the above embodiment, the outer vent caulking station S9 in progressive die apparatus, although each of the segment core pieces 11, 11 ... by applying a predetermined skew angle has caulking laminated, each of the segment core It is also possible to stack the pieces 11, 11 ... in a straight manner and to perform caulking connection. In this case as well, it is of course possible to roll the divided core pieces 11, 11, ... for the purpose of offsetting the thickness deviation. is there.

BRIEF DESCRIPTION OF THE DRAWINGS The whole top view which shows one Example of the laminated iron core manufactured with the manufacturing method concerning this invention, and a metal mold apparatus. (a) And (b) is the top view and side view of the division | segmentation laminated | stacked iron core which comprise the laminated iron core shown in FIG. The principal part top view of the strip | belt-shaped steel plate which shows the material removal of the rotor core piece and stator core piece at the time of manufacturing the laminated iron core shown in FIG. The top view of the strip | belt-shaped steel plate which showed the manufacturing process in each station of the progressive die apparatus in the manufacturing method of the laminated core concerning this invention. The top view of the strip | belt-shaped steel plate which showed the manufacturing process in each station of the progressive die apparatus in the manufacturing method of the laminated core concerning this invention. The top view of the strip | belt-shaped steel plate which showed the manufacturing process in each station of the progressive die apparatus in the manufacturing method of the laminated core concerning this invention. (a) is a principal part top view of the strip | belt-shaped steel plate in 1 process in the middle of manufacture, (b) is the bb sectional view taken on the line in (a). (a) And (b) is a conceptual diagram which shows the processing aspect of the strip | belt-shaped steel plate in 1 process in the middle of manufacture. (a), (b) and (c) are the conceptual diagrams which show the processing aspect of the strip | belt-shaped steel plate in 1 process in the middle of manufacture. The external view which shows the conventional laminated iron core. The top view of the strip | belt-shaped steel plate at the time of manufacturing the laminated iron core shown in FIG. The external view which shows the other conventional laminated iron core. The top view of the strip | belt-shaped steel plate at the time of manufacturing the laminated iron core shown in FIG.

Explanation of symbols

1 ... laminated iron core,
2 ... Yoke part,
3 ... Teeth club,
10: Divided laminated iron core,
10Y: Divided yoke part,
10T ... Teeth club,
10A, 10B ... connecting part,
11 ... split core pieces,
11Y: Divided yoke part,
11T ... Teeth club,
11A, 11B ... connection part,
20 ... Rotor core piece,
S1 ... Cutting and bending station,
S2 ... Pushback station,
S3 ... Slot removal station,
S4 ... Inner diameter removal station,
S9: Extrusion caulking connection station,
W: Strip steel plate (thin plate material).

Claims (4)

A split laminated core having a split yoke portion and one tooth portion integrated with the split yoke portion, and having connecting portions at both ends of the split yoke portion, which is formed by caulking and laminating a predetermined number of split core pieces. And a laminated core for manufacturing a stator core comprising a ring-shaped yoke portion and a predetermined number of teeth portions projecting inwardly of the yoke portion. A manufacturing method of
After punching and forming the rotor core pieces from a thin plate material, in the yoke portion forming region where the divided core pieces are connected to each other, the connecting portions of the adjacent divided core pieces are sheared and separated from each other and bent. Bending process;
A pushback step of forming the same portion as the thin plate material by pushing back the bent portion in the thin plate material;
A slotting step for forming a predetermined number of teeth by punching a predetermined number of slots in the thin plate material;
An inner diameter punching process for punching and forming tooth tips in the predetermined number of teeth portions;
A caulking laminating step of punching the outer shape of the split core pieces to separate and form the individual split core pieces, and laminating the split core pieces on the lower split core pieces previously punched and joining together ,
In the caulking and laminating step, the divided core pieces are rolled for the purpose of offsetting the thickness deviation. 2. The method of manufacturing a laminated core according to claim 1, wherein the divided core pieces are caulked and laminated with a skew angle as well as the rolling. A split laminated core having a split yoke portion and one tooth portion integrated with the split yoke portion, and having a connecting portion at both ends of the split yoke portion, is formed by caulking and laminating a predetermined number of split core pieces. A mold for producing a stator core comprising a predetermined number of endlessly connected pieces, and comprising a ring-shaped yoke portion and a predetermined number of teeth portions projecting inwardly of the yoke portion. A device,
After punching and forming the rotor core pieces from a thin plate material, in the yoke portion forming region where the divided core pieces are connected to each other, the connecting portions of the adjacent divided core pieces are sheared and separated from each other and bent. A cutting and bending station for carrying out the bending process;
A pushback station for performing a pushback step of forming the same material as the thin plate material by pushing back the bent portion of the thin plate material;
A slotting station for performing a slotting step of forming a predetermined number of teeth by punching and forming a predetermined number of slots in the thin plate material;
An inner diameter punching station for performing an inner diameter punching step of punching and forming tooth tips in the predetermined number of teeth portions;
Performing a caulking laminating step of punching the outer shape of the split core pieces to separate and form the individual split core pieces, and laminating the split core pieces on the lower split core pieces that have been punched and bonded together An outer shape caulking coupling station,
And the die apparatus is characterized in that, in the caulking connection station without the outer shape, the divided core pieces are rolled for the purpose of offsetting the thickness deviation. 4. The mold apparatus according to claim 3, wherein a skew angle is given together with the rolling of the divided core pieces at the outer shape caulking joint station.

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