JP2004320878A

JP2004320878A - Manufacturing method of laminated core and laminated core

Info

Publication number: JP2004320878A
Application number: JP2003110490A
Authority: JP
Inventors: Katsufusa Fujita; 勝房藤田
Original assignee: Mitsui High Tec Inc
Current assignee: Mitsui High Tec Inc
Priority date: 2003-04-15
Filing date: 2003-04-15
Publication date: 2004-11-11
Anticipated expiration: 2023-04-15
Also published as: JP4366103B2

Abstract

【課題】回転軸となる回動連結部を特に形成することなく分割積層鉄心ブロック同士を容易に連結でき、かつ、連結し合う分割ヨーク部に傷がつかない積層鉄心の製造方法及び積層鉄心を提供する。
【解決手段】磁極片部１６を平面視してその対称軸に対し対称軸の両側に伸びた分割ヨーク片部１８の長さが非対称に形成される第１分割鉄心片１１、及び第１分割鉄心片１１とは逆非対称に形成される第２分割鉄心片１２をそれぞれ打ち抜きかしめ積層して形成される分割積層鉄心ブロック１３の分割ヨーク部１４の一方側で第１分割鉄心片１１及び第２分割鉄心片１２から構成される凹部２４及び凸部２３に対して、隣り合う分割積層鉄心ブロック１３の分割ヨーク部１４の他方側で第１分割鉄心片１１及び第２分割鉄心片１２から構成される凸部２３及び凹部２４を相互に入り込ませて連結して積層鉄心１０を形成する。
【選択図】図１A method of manufacturing a laminated core and a laminated core in which divided laminated core blocks can be easily connected to each other without particularly forming a rotary connecting portion serving as a rotation axis, and the coupled divided yoke portions are not damaged. provide.
A first split core piece (11) in which the length of a split yoke piece (18) extending on both sides of a symmetric axis with respect to the axis of symmetry when viewed in a plan view of a pole piece (16) is asymmetric. The first split core piece 11 and the second split core piece 12 are formed on one side of the split yoke portion 14 of the split laminated core block 13 formed by punching and laminating a second split core piece 12 formed in an asymmetrical manner with respect to the core piece 11. In contrast to the concave portion 24 and the convex portion 23 formed by the divided core pieces 12, the other side of the divided yoke portion 14 of the adjacent divided laminated core block 13 is constituted by the first divided core piece 11 and the second divided core piece 12. The protrusions 23 and the recesses 24 are inserted into each other and connected to form the laminated iron core 10.
[Selection diagram] Fig. 1

Description

【０００１】
【発明の属する技術分野】
本発明は、電動機の固定子に使用する積層鉄心の製造方法及び積層鉄心に関する。
【０００２】
【従来の技術】
図６に示すように、電動機の固定子に使用する積層鉄心９０は、磁極部９１への巻線を、作業性及び生産性よく行うために、積層鉄心９０を構成する鉄心片９２は磁極片部９３毎にヨーク片部９４が分割された分割鉄心片９５として打ち抜きされ、この分割鉄心片９５をかしめ部９６を介してかしめ積層して分割積層鉄心９７を形成し、この分割積層鉄心９７に巻線している。そして、巻線後に、各分割積層鉄心９７を環状に配置して積層鉄心９０を形成している（例えば、特許文献１参照）。
ここで、積層鉄心の形成方法として、分割積層鉄心の分割ヨーク部の一端に形成した連結用の貫通孔と、隣り合う分割積層鉄心の分割ヨーク部の他端に形成した貫通孔の各軸心を一致させ、この貫通孔にピンを挿入することで複数個の分割積層鉄心を回転自在に連結し、これらの分割積層鉄心を環状に配置することが行われている。
【０００３】
また、分割鉄心片９５のヨーク片部９４の一端に回動連結用の半抜き凹凸部９８を形成し、隣り合う分割鉄心片９５で上下に積層されるヨーク片部９４の他端にも同様の回動連結用の半抜き凹凸部９８を形成して、各半抜き凹凸部９８の凹部に対して積層する分割鉄心片９５に形成した半抜き凹凸部９８の凸部を嵌入して回動連結部を構成しながらかしめ部９６を介してかしめ積層して、回動自在に連結した分割積層鉄心９７を形成していた。
この製造方法では、分割鉄心片９５を打ち抜き形成しながら、分割鉄心片９５同士の回動自在な連結とかしめ積層を分割鉄心片９５を打抜き形成する金型装置内で行うことができ、金型装置外でのピン挿入作業等が不要になって、有用な製造手段となっている。
【０００４】
【特許文献１】
特開２０００−２０１４５８号公報
【０００５】
【発明が解決しようとする課題】
しかしながら、貫通孔にピンを挿入して複数個の分割積層鉄心を回転自在に連結して積層鉄心を形成する方法では、巻線の作業は容易となるが、分割積層鉄心を連結して環状に組み立ててピンを挿入する工程は分割鉄心片を打抜き形成する金型装置外で行わねばならず、時間を要するという問題がある。
一方、電動機の積層鉄心９０では、省エネルギー及び高効率化をより一層図るべく、例えば０．２ｍｍ未満の厚みを有する薄い電磁鋼板等の金属薄板から分割鉄心片９５を打ち抜き、積層鉄心９０を形成することが必要になっている。
しかしながら、薄い電磁鋼板や金属板から回動連結部を構成する半抜き凹凸部９８を有する分割鉄心片９５を安定して形成することは難しく、また、半抜き凹凸部９８から構成される回動連結部に不良が発生し易いという問題がある。このため、製造には高度の技術が要求され、高度な技術を有する熟練要員を養成しなければならないという問題が生じていた。
【０００６】
更に、分割鉄心片９５に半抜き凹凸部９８を形成するための金型装置が必要になると共に、製造工程が長くなるという問題が生じていた。
なお、このように金属薄板から打ち抜いた分割鉄心片をかしめ積層して積層鉄心を形成することは、電動機の積層鉄心に限らず一般の積層鉄心においても適用されることである。
本発明はかかる事情に鑑みてなされたもので、分割積層鉄心ブロックに回転軸となる回動連結部を特に形成することなく、分割積層鉄心ブロック同士を容易に連結でき、また極薄の金属薄板からでも製造可能で、かつ連結し合う分割ヨーク部に傷がつかない積層鉄心の製造方法及び積層鉄心を提供することを目的とする。
【０００７】
【課題を解決するための手段】
前記目的に沿う本発明に係る積層鉄心の製造方法は、磁極片部を平面視してその対称軸に対し該対称軸の両側に伸びた分割ヨーク片部の長さが非対称に形成される第１分割鉄心片、及び磁極片部を平面視してその対称軸に対し該対称軸の両側に伸びた分割ヨーク片部の長さが前記第１分割鉄心片とは逆非対称に形成される第２分割鉄心片をそれぞれ打ち抜く工程と、
前記第１分割鉄心片及び前記第２分割鉄心片をかしめ積層して分割積層鉄心ブロックを形成する工程と、
前記各分割積層鉄心ブロックの分割ヨーク部の一方側で前記第１分割鉄心片及び前記第２分割鉄心片から形成される凹部並びに凸部に対して、隣り合う前記分割積層鉄心ブロックの分割ヨーク部の他方側で前記第１分割鉄心片及び前記第２分割鉄心片から形成される凸部並びに凹部を相互に入り込ませて、前記各分割積層鉄心ブロック同士を相互に連結して積層鉄心を形成する工程とを有する。
【０００８】
分割ヨーク片部の長さが非対称とは、磁極片部を平面視してその対称軸に対して一方側に伸びる分割ヨーク片部の長さが、他方側に伸びる分割ヨーク片部の長さと異なっていることを指す。
また、第２分割鉄心片を第１分割鉄心片とは逆非対称に形成するとは、第２分割鉄心片で一方側に伸びる分割ヨーク片部の長さを第１分割鉄心片で他方側に伸びる分割ヨーク片部の長さと実質的に同一とし、第２分割鉄心片で他方側に伸びる分割ヨーク片部の長さを第１分割鉄心片で一方側に伸びる分割ヨーク片部の長さと実質的に同一にすることを指す。
【０００９】
このように形成された第１分割鉄心片と第２分割鉄心片を交互に、あるいは複数枚毎交互にかしめ積層して分割積層鉄心ブロックを形成すると、例えば、形成された分割積層鉄心ブロックの分割ヨーク部の一方側では、第１分割鉄心片の一方側は突出し、第２分割鉄心片の一方側は後退して、凸部と凹部が交互に形成されている状態になる。また、分割ヨーク部の他方側では、第１分割鉄心片の他方側は後退し、第２分割鉄心片の他方側は突出して、凹部と凸部が交互に形成されている状態になる。
従って、各分割積層鉄心ブロックを環状に並べて配置した際に、分割積層鉄心ブロックの分割ヨーク部の一方側の凸部並びに凹部に対して、隣り合う分割積層鉄心ブロックの分割ヨーク部の他方側の凹部並びに凸部をそれぞれ対応させることができる。
このため、各分割積層鉄心ブロックを環状に並べて分割積層鉄心ブロックの分割ヨーク部の一方側の凸部並びに凹部に対して、隣り合う分割積層鉄心ブロックの分割ヨーク部の他方側の凹部並びに凸部を入り込ませることができる。
その結果、各分割積層鉄心ブロック同士を相互に連結して一体化することができ、環状の積層鉄心を形成することができる。
【００１０】
本発明に係る積層鉄心の製造方法において、前記第１分割鉄心片及び前記第２分割鉄心片は、それぞれ複数枚連続して交互に積層され、しかも、前記第１分割鉄心片及び前記第２分割鉄心片を複数枚連続して積層する中で最初に積層する前記第１分割鉄心片及び前記第２分割鉄心片はその分割ヨーク片部を下方から打ち抜き形成した後に外形抜きして形成され、前記第１分割鉄心片及び前記第２分割鉄心片を複数枚連続して積層する中で最後に積層する前記第１分割鉄心片及び前記第２分割鉄心片はその分割ヨーク片部を上方から打ち抜き形成した後に外形抜きして形成されることが好ましい。
【００１１】
第１分割鉄心片及び第２分割鉄心片をダイとパンチを備えた金型装置で金属薄板から打ち抜いて形成する場合、打ち抜きパンチが切断を始める側の面には抜きだれ部（角が丸められた領域）が形成され、打ち抜きパンチが抜き出る側の面にはバリ部（微小切れ残り）が形成される。
ここで、第１分割鉄心片及び第２分割鉄心片をそれぞれ複数枚連続して積層する中で、最初に積層する第１分割鉄心片及び第２分割鉄心片では、その分割ヨーク片部の両端を打ち抜きパンチで下方から打ち抜いて形成し、その後に外形抜きする。これによって、最初に積層する第１分割鉄心片及び第２分割鉄心片では、分割ヨーク片部の上面側にバリ部が、下面側に抜きだれ部がそれぞれ形成される。また、第１分割鉄心片及び第２分割鉄心片をそれぞれ複数枚連続して積層する中で、最後に積層する第１分割鉄心片及び第２分割鉄心片では、その分割ヨーク片部の両端を打ち抜きパンチで上方から打ち抜いて形成し、その後に外形抜きする。これによって、最後に積層する第１分割鉄心片及び第２分割鉄心片では、分割ヨーク片部の下面側にバリ部が、上面側に抜きだれ部がそれぞれ形成される。
【００１２】
従って、上記のようにして形成した第１分割鉄心片及び第２分割鉄心片をそれぞれ複数枚ずつ連続して交互にかしめ積層して形成される分割積層鉄心ブロックでは、分割ヨーク部の両側に形成される凸部の先端角部には抜きだれ部が配置される。
このため、隣の分割積層鉄心ブロックと接合連結する際、ヨーク面に傷をつけずに滑らかに連結を行うことができる。
【００１３】
前記目的に沿う本発明に係る積層鉄心は、磁極片部を平面視してその対称軸に対し該対称軸の両側に伸びた分割ヨーク片部の長さが非対称に形成される第１分割鉄心片、及び磁極片部を平面視してその対称軸に対し該対称軸の両側に伸びた分割ヨーク片部の長さが前記第１分割鉄心片とは逆非対称に形成される第２分割鉄心片をそれぞれ複数枚ずつ連続して交互にかしめ積層して形成される分割積層鉄心ブロック同士を、該各分割積層鉄心ブロックの分割ヨーク部の両側に形成された凹部及び凸部を介して連結して形成される積層鉄心において、
前記分割ヨーク部の両側に形成される前記凸部の先端角部及び前記凹部の底角部（先端角部）には、打ち抜き時に形成された抜きだれ部が配置されている。
【００１４】
このように、凸部の先端角部に抜きだれ部を配置することにより、先端角部が丸みを帯びた形状になる。また、凹部の底角部に抜きだれ部を配置することにより、底角部に逃がし空間を備えた凹部が形成される。
その結果、分割積層鉄心ブロックに巻線した後、分割積層鉄心ブロックの分割ヨーク部の一方側の凸部並びに凹部に対して、隣り合う分割積層鉄心ブロックの分割ヨーク部の他方側の凹部並びに凸部を入り込ませて連結する際、連結始めから連結終わりまでの抵抗を小さくすることができ、かつ、凸部と凹部の先端同士が密接した状態に連結する。また、容易に連結でき、入り込み合う分割ヨーク部の各面に傷がつかず、絶縁被膜が損傷されない。
【００１５】
【発明の実施の形態】
続いて、添付した図面を参照しつつ、本発明を具体化した実施の形態につき説明し、本発明の理解に供する。
ここに、図１は本発明の一実施の形態に係る積層鉄心の製造方法で製造された積層鉄心の斜視図、図２は同積層鉄心を構成する第１分割鉄心片を打ち抜き形成した際の平面図、図３は同積層鉄心を構成する第２分割鉄心片を打ち抜き形成した際の平面図、図４は同積層鉄心の分割積層鉄心ブロックの斜視図、図５は金型装置内の各ステーションで金属薄板に順次形成されていく第１分割鉄心片及び第２分割鉄心片をそれぞれ形成する形成過程を示す説明図である。
図１に示すように、本発明の一実施の形態に係る積層鉄心の製造方法を適用して製造された積層鉄心１０は、分割積層鉄心ブロック１３を、環状に複数個組み合わせて構成されている。そして、各分割積層鉄心ブロック１３は、第１分割鉄心片１１及び第２分割鉄心片１２をかしめ積層して形成されている。以下、これらについて詳細に説明する。
【００１６】
図２に示す第１分割鉄心片１１は、２枚毎連続して打ち抜きされて、かしめ積層される。
ここで、第１分割鉄心片１１は、分割切断線１５により分割ヨーク片部１８が相互に切り離されて形成され、磁極片部１６と、磁極片部１６の軸部１７を介して連結している分割ヨーク片部１８を備えている。
また、分割ヨーク片部１８は、磁極片部１６を平面視してその対称軸に対し対称軸の両側に伸びた長さが非対称、すなわち、磁極片部１６を平面視してその対称軸に対して一方側に伸びる長さが、他方側に伸びる長さと異なるように形成されている。
【００１７】
図３に示す第２分割鉄心片１２は、２枚毎連続して打ち抜きされて、かしめ積層される。
ここで、第２分割鉄心片１２は、分割切断線１５ａにより分割ヨーク片部１９が相互に切り離されて形成され、磁極片部１６と、磁極片部１６の軸部１７を介して連結している分割ヨーク片部１９を備えている。
また、分割ヨーク片部１９は、第１分割鉄心片１１の分割ヨーク片部１８とは逆非対称、すなわち、第２分割鉄心片１２の磁極片部１６を平面視してその対称軸に対して一方側に伸びる長さを、第１分割鉄心片１１で他方側に伸びる長さと実質的に同一とし、第２分割鉄心片１２で対称軸に対して他方側に伸びる長さを第１分割鉄心片１１で一方側に伸びる長さと実質的に同一になるように形成されている。
【００１８】
更に、第１分割鉄心片１１の分割ヨーク片部１８と磁極片部１６、及び第２分割鉄心片１２の分割ヨーク片部１９と磁極片部１６には、それぞれかしめ部２０が形成されている。そして、第１分割鉄心片１１と第２分割鉄心片１２を積層させた際に、第１分割鉄心片１１に現れるかしめ部２０の位置と第２分割鉄心片１２に現れるかしめ部２０の位置とは実質的に重なり合うように形成されている。
ここで、かしめ部２０は、周知の構造であって、一方が突起で他方が窪みであってもよいし、それぞれのかしめ部２０が表面側と裏面側で窪みと突起を組み合わせたような構造であってもよい。
以上のような構成とすることにより、第１分割鉄心片１１と第２分割鉄心片１２を、例えば、２枚毎交互にかしめ積層することにより、図４に示すように、外周側に配置される分割ヨーク部１４と、分割ヨーク部１４から内側に突出する磁極部２１を備えた分割積層鉄心ブロック１３を形成することができる。
【００１９】
ここで、第１分割鉄心片１１を２枚連続してかしめ積層する場合、最初の第１分割鉄心片１１では、分割ヨーク片部１８に抜きだれ部２２が形成された側を下面側になるように載置する。そして、２枚目の（すなわち、最後に積層する）第１分割鉄心片１１では、分割ヨーク片部１８に抜きだれ部２２が形成された側を上面側になるように載置して、かしめ積層を行う。
かしめ積層された第１分割鉄心片１１の上に第２分割鉄心片１２を２枚連続してかしめ積層する場合、最初の第２分割鉄心片１２では、分割ヨーク片部１９に抜きだれ部２２が形成された側を下面側になるように載置する。そして、２枚目の（すなわち、最後に積層する）第２分割鉄心片１２では、分割ヨーク片部１９に抜きだれ部２２が形成された側を上面側になるように載置して、かしめ積層を行う。
【００２０】
このようにして得られた分割積層鉄心ブロック１３では、分割ヨーク部１４の一方側においては第１分割鉄心片１１の一方側を突出させ、第２分割鉄心片１２の一方側を後退させて、凸部２３と凹部２４が交互に形成されている。
また、分割ヨーク部１４の他方側では第１分割鉄心片１１の他方側を後退させ、第２分割鉄心片１２の他方側を突出させて、凹部２４と凸部２３が交互に形成されている。
そして、各凸部２３の先端角部、及び各凹部２４の底角部には、いずれも抜きだれ部２２が配置されている状態になっている。
従って、各凸部２３の先端角部に抜きだれ部２２を配置することにより、先端角部に丸みが形成された凸部２３を形成することができ、凹部２４の底角部に抜きだれ部２２を配置することにより、底角部に逃がし空間を備えた凹部２４を形成することができる。
【００２１】
このため、分割積層鉄心ブロック１３の磁極部２１に別途巻線した後、分割積層鉄心ブロック１３同士を並べて、分割積層鉄心ブロック１３の分割ヨーク部１４の一方側の凸部２３並びに凹部２４に対して、隣り合う分割積層鉄心ブロック１３の分割ヨーク部１４の他方側の凹部２４並びに凸部２３を入り込ませる際に、入り込ませるときの抵抗を小さくすることができ、分割積層鉄心ブロック１３同士の連結が容易になり、また、分割ヨーク部１４の面に傷を付けることがない。従って、分割積層鉄心ブロック１３を環状に複数個並べて配置し、分割積層鉄心ブロック１３の分割ヨーク部１４の一方側の凸部２３並びに凹部２４に対して、隣り合う分割積層鉄心ブロック１３の分割ヨーク部１４の他方側の凹部２４並びに凸部２３を入り込ませることにより、各分割積層鉄心ブロック１３同士を相互に連結して一体化し環状の積層鉄心１０を容易に形成することができる。
【００２２】
次に、本発明の一実施の形態に係る積層鉄心の製造方法について説明する。
図５に示すように、電磁鋼板等の磁気特性に優れた帯状の金属薄板２５の幅方向の両側に所定間隔でガイド孔２６を設け、このガイド孔２６に図示しないガイド部材を挿入して金属薄板２５を打ち抜き用の図示しない金型装置内に装入する。ここで、金型装置内には、上流側から順に回転子片２８の外形抜きを行うステーションＡ、磁極片部１６の形成を行うステーションＢ、第１分割鉄心片１１の各分割ヨーク片部１８の分割切断線１５を形成するステーションＣ、第２分割鉄心片１２の各分割ヨーク片部１９の分割切断線１５ａを形成するステーションＤ、第１分割鉄心片１１及び第２分割鉄心片１２にそれぞれかしめ部２０を形成するステーションＥ、並びに第１分割鉄心片１１及び第２分割鉄心片１２をそれぞれ外形抜きするステーションＦが設けられている。なお、図中、ステーションＥ２はアイドル工程を示す。
【００２３】
金型装置内のステーションＡにおいては、金属薄板２５を図示しないダイ上でストリッパーにより挟持しながら回転子片外形抜きパンチで回転子片２８を順次外形抜きする。そして、回転子片２８が外形抜きされた金属薄板２５は、順次ステーションＢに通板する。
ステーションＢにおいては、図示しないダイ上でストリッパーにより挟持しながら回転子片２８が外形抜きされて形成された孔２９の外側に磁極片形成パンチで磁極片部１６を順次形成する。
そして、磁極片部１６が形成された金属薄板２５は、次いでステーションＣに通板する。
【００２４】
ステーションＣにおいては、磁極片部１６が形成された金属薄板２５に対して、図示しないダイ上でストリッパーにより挟持しながら、分割切断線形成パンチを下方から移動させて磁極片部１６の外側に第１分割鉄心片１１の各分割ヨーク片部１８の分割切断線１５を形成し、次に通板されてくる金属薄板２５に対しては分割切断線形成パンチを上方から移動させて磁極片部１６の外側に第１分割鉄心片１１の各分割ヨーク片部１８の分割切断線１５を形成する。その際、ステーションＤの稼動は停止させる。
そして、ステーションＣにおいて第１分割鉄心片１１の各分割ヨーク片部１８の分割切断線１５の形成が連続して２回行われた後では、ステーションＣの稼動を停止させて、ステーションＢにおいて磁極片部１６が形成された金属薄板２５をステーションＤまで通板させて、分割切断線形成パンチを下方から移動させて第２分割鉄心片１２の磁極片部１６の外側に各分割ヨーク片部１９の分割切断線１５ａを形成し、次に通板されてくる金属薄板２５に対しては分割切断線形成パンチを上方から移動させて磁極片部１６の外側に第２分割鉄心片１２の各分割ヨーク片部１９の分割切断線１５ａを形成する。
ステーションＤにおいて第２分割鉄心片１２の各分割ヨーク片部１９の分割切断線１５ａの形成が連続して２回行われた後では、ステーションＤの稼動を停止させて、ステーションＣの稼動を再開する。
このように、この実施の形態においては、ステーションＣ、Ｄでは、一方のステーションを２回連続して稼動させながら他方のステーションの稼動を停止し、このような稼動と停止を各ステーションで交互に行う。
【００２５】
第１分割鉄心片１１及び第２分割鉄心片１２の各分割ヨーク片部１８、１９用の各分割切断線１５、１５ａがそれぞれ形成された金属薄板２５がステーションＥに通板してくると、図示しないダイ上でストリッパーにより挟持しながらかしめ部形成パンチでかしめ部２０を順次形成する。そして、かしめ部２０が形成された金属薄板２５は、ステーションＦに通板する。
従って、ステーションＥを通過した金属薄板２５には、第１分割鉄心片１１用の磁極片部１６、分割ヨーク片部１８の分割切断線１５、及びかしめ部２０の形成されている領域と、第２分割鉄心片１２用の磁極片部１６、分割ヨーク片部１９の分割切断線１５ａ、及びかしめ部２０が形成されている領域が２組ずつ交互に形成された状態になっている。
ステーションＦにおいては、図示しないダイ上でストリッパーにより挟持しながら、第１分割鉄心片１１及び第２分割鉄心片１２を外形抜きする分割鉄心片パンチで外形抜きし図示しないダイホール内に順次抜き込み、ダイホール内に設けられた受け台上にてかしめ積層していく。
【００２６】
このとき、受け台上には、第１分割鉄心片１１及び第２分割鉄心片１２が２枚連続して交互に順次載置されるが、連続の中の始めに載置される第１分割鉄心片１１及び第２分割鉄心片１２では、それぞれ分割ヨーク片部１８、１９に抜きだれ部２２が形成されている面を下側にして載置され、２枚目の第１分割鉄心片１１及び第２分割鉄心片１２では、分割ヨーク片部１８、１９に抜きだれ部２２が形成されている面を上側にして載置される。
従って、受け台上に２枚ずつ連続して載置された第１分割鉄心片１１及び第２分割鉄心片１２では、打ち抜き時に分割ヨーク片部１８、１９に形成された抜きだれ部２２が外側に面し、打ち抜き時に形成されたバリ部同士が互いに当接した状態になって、かしめ積層されている。
【００２７】
そして、第１分割鉄心片１１及び第２分割鉄心片１２のかしめ積層を所望の積厚さまで繰り返すことにより分割積層鉄心ブロック１３を形成する。
なお、形成された各分割積層鉄心ブロック１３の分割ヨーク部１４の一方側においては、第１分割鉄心片１１の一方側が突出し、第２分割鉄心片１２の一方側が後退して、凸部２３と凹部２４が交互に形成されている。また、分割ヨーク部１４の他方側においては、第１分割鉄心片１１の他方側が後退し、第２分割鉄心片１２の他方側が突出して、凹部２４と凸部２３が交互に形成されている。
従って、この実施の形態で製造された分割積層鉄心ブロック１３は環状に連結した積層鉄心１０の状態になっている。
【００２８】
巻線に際しては、形成された各分割積層鉄心ブロック１３を個々に離して、あるいは、分割ヨーク部１４同士が連結した状態で各磁極部２１の間隔を広げるように各分割積層鉄心ブロック１３を離した状態にする。そして、各磁極部２１に巻線した後、各分割積層鉄心ブロック１３を環状に配置しなおし、分割積層鉄心ブロック１３の分割ヨーク部１４の一方側の凸部２３並びに凹部２４に対して、隣り合う分割積層鉄心ブロック１３の分割ヨーク部１４の他方側の凹部２４並びに凸部２３を入り込ませ、各分割積層鉄心ブロック１３同士を相互に連結して一体化し、環状の積層鉄心１０を形成する。
ここで、各凸部２３の先端角部、及び各凹部２４の底角部には、いずれも抜きだれ部２２が配置されているので、各凸部２３の先端角部は丸みを帯びており、各凹部２４の底角部には逃がし空間が形成されている。
このため、分割積層鉄心ブロック１３の分割ヨーク部１４の一方側の凸部２３並びに凹部２４に対して、隣り合う分割積層鉄心ブロック１３の分割ヨーク部１４の他方側の凹部２４並びに凸部２３を入り込ませる際の抵抗を小さくすることができ、回動連結部を特に設けずとも分割積層鉄心ブロック１３同士の連結が容易にできる。
【００２９】
以上、本発明の実施の形態を説明したが、本発明は、この実施の形態に限定されるものではなく、発明の要旨を変更しない範囲での変更は可能であり、前記したそれぞれの実施の形態や変形例の一部又は全部を組み合わせて本発明の積層鉄心の製造方法及び積層鉄心を構成する場合も本発明の権利範囲に含まれる。例えば、本実施の形態では第１分割鉄心片と第２分割鉄心片をそれぞれ２枚連続して交互にかしめ積層して分割積層鉄心ブロックを形成したが、３枚以上毎連続してかしめ積層してもよい。また、積層の途中から第１分割鉄心片と第２分割鉄心片の枚数を変化させてもよい。
更に、本実施の形態では第１分割鉄心片及び第２分割鉄心片をそれぞれ環状に形成したが、第１分割鉄心片及び第２分割鉄心片をそれぞれ直線列状に形成してもよい。
【００３０】
【発明の効果】
請求項１及び２記載の積層鉄心の製造方法においては、磁極片部を平面視してその対称軸に対し対称軸の両側に伸びた分割ヨーク片部の長さが非対称に形成される第１分割鉄心片、及び磁極片部を平面視してその対称軸に対し対称軸の両側に伸びた分割ヨーク片部の長さが第１分割鉄心片とは逆非対称に形成される第２分割鉄心片をそれぞれ打ち抜く工程と、第１分割鉄心片及び第２分割鉄心片をかしめ積層して分割積層鉄心ブロックを形成する工程と、各分割積層鉄心ブロックの分割ヨーク部の一方側で第１分割鉄心片及び第２分割鉄心片から形成される凹部並びに凸部に対して、隣り合う分割積層鉄心ブロックの分割ヨーク部の他方側で第１分割鉄心片及び第２分割鉄心片から形成される凸部並びに凹部を相互に入り込ませて、各分割積層鉄心ブロック同士を相互に連結して積層鉄心を形成する工程とを有するので、製造不良が発生し易い半抜き凹凸部から構成される回動連結部を特に設けずに分割積層鉄心ブロックを連結してなる積層鉄心を容易に製造することが可能になる。そして、高度な技術を有する熟練要員を必要とせずに、しかも、任意の厚さの金属薄板を用いて安定して積層鉄心を製造することが可能になる。
また、回動連結部を形成するための金型装置が不要になると共に、積層鉄心の製造工程を短縮化することが可能になり、積層鉄心の製造コストの上昇を抑制することができる。
【００３１】
特に、請求項２記載の積層鉄心の製造方法においては、第１分割鉄心片及び第２分割鉄心片は、それぞれ複数枚連続して交互に積層され、しかも、第１分割鉄心片及び第２分割鉄心片を複数枚連続して積層する中で最初に積層する第１分割鉄心片及び第２分割鉄心片は分割ヨーク片部を下方から打ち抜き形成した後に外形抜きして形成され、第１分割鉄心片及び第２分割鉄心片を複数枚連続して積層する中で最後に積層する第１分割鉄心片及び第２分割鉄心片は分割ヨーク片部を上方から打ち抜き形成した後に外形抜きして形成されるので、得られた分割積層鉄心ブロックでは、その分割ヨーク部の両側にそれぞれ形成される凸部の先端角部及び凹部の底角部には、いずれも抜きだれ部が配置される状態にすることができ、分割積層鉄心ブロックの分割ヨーク部の一方側の凸部並びに凹部に対して、隣り合う分割積層鉄心ブロックの分割ヨーク部の他方側の凹部並びに凸部をそれぞれ入り込ませて連結する際の抵抗を小さくすることができ、また、分割ヨーク部の面に傷を付けることがない。その結果、連結作業を容易に行うことが可能になって、積層鉄心の生産性を向上させることが可能になる。
更に、極薄い金属薄板、例えば、０．２ｍｍ未満のものから積層鉄心を安定して製造することができる。その結果、省エネルギー及び高効率化が一層進展した積層鉄心を得ることができる。
【００３２】
請求項３記載の積層鉄心においては、磁極片部を平面視してその対称軸に対し対称軸の両側に伸びた分割ヨーク片部の長さが非対称に形成される第１分割鉄心片、及び磁極片部を平面視してその対称軸に対し対称軸の両側に伸びた分割ヨーク片部の長さが第１分割鉄心片とは逆非対称に形成される第２分割鉄心片をそれぞれ複数枚ずつ連続して交互にかしめ積層して形成される分割積層鉄心ブロック同士を、各分割積層鉄心ブロックの分割ヨーク部の両側に形成された凹部及び凸部を介して連結して形成される積層鉄心において、分割ヨーク部の両側に形成される凸部の先端角部及び凹部の底角部には、打ち抜き時に形成された抜きだれ部が配置されているので、分割積層鉄心ブロックの分割ヨーク部の一方側の凸部並びに凹部に対して、隣り合う分割積層鉄心ブロックの分割ヨーク部の他方側の凹部並びに凸部をそれぞれ入り込ませて連結した積層鉄心は、連結が無理なく行われて入り込み合った分割ヨーク部に連結加工残留応力がなく、また、分割ヨーク部の表面に傷がつかず、別途分割ヨーク部の表面に形成された絶縁被膜は損傷されず、高品質の積層鉄心が得られる。
【図面の簡単な説明】
【図１】本発明の一実施の形態に係る積層鉄心の製造方法で製造された積層鉄心の斜視図である。
【図２】同積層鉄心を構成する第１分割鉄心片を打ち抜き形成した際の平面図である。
【図３】同積層鉄心を構成する第２分割鉄心片を打ち抜き形成した際の平面図である。
【図４】同積層鉄心の分割積層鉄心ブロックの斜視図である。
【図５】金型装置内の各ステーションで金属薄板に順次形成されていく第１分割鉄心片及び第２分割鉄心片をそれぞれ形成する形成過程を示す説明図である。
【図６】従来例の積層鉄心の説明図である。
【符号の説明】
１０：積層鉄心、１１：第１分割鉄心片、１２：第２分割鉄心片、１３：分割積層鉄心ブロック、１４：分割ヨーク部、１５、１５ａ：分割切断線、１６：磁極片部、１７：軸部、１８、１９：分割ヨーク片部、２０：かしめ部、２１：磁極部、２２：抜きだれ部、２３：凸部、２４：凹部、２５：金属薄板、２６：ガイド孔、２８：回転子片、２９：孔[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a laminated core used for a stator of an electric motor and a laminated core.
[0002]
[Prior art]
As shown in FIG. 6, a laminated core 90 used for a stator of an electric motor has a core piece 92 constituting a laminated core 90 in order to perform winding to a magnetic pole part 91 with good workability and productivity. The yoke piece portion 94 is punched out as a divided core piece 95 for each part 93, and the divided core pieces 95 are caulked and laminated via the caulking portion 96 to form a divided laminated core 97. Winding. Then, after the winding, the divided laminated cores 97 are annularly arranged to form a laminated core 90 (for example, see Patent Document 1).
Here, as a method of forming the laminated core, each through-hole for connection formed at one end of the divided yoke portion of the divided laminated core and each axial center of the through-hole formed at the other end of the divided yoke portion of the adjacent divided laminated core. And a plurality of divided laminated cores are rotatably connected by inserting a pin into the through hole, and these divided laminated cores are arranged in an annular shape.
[0003]
Further, a half-punched concave / convex portion 98 for rotational connection is formed at one end of the yoke piece portion 94 of the divided core piece 95, and the same is applied to the other end of the yoke piece portion 94 vertically stacked by the adjacent divided core pieces 95. The half-recessed concave / convex portions 98 for rotation connection are formed, and the convex portions of the half-removed concave / convex portions 98 formed on the divided iron core pieces 95 stacked on the concave portions of the half-recessed concave / convex portions 98 are fitted and rotated. The divided laminated cores 97 rotatably connected to each other are formed by caulking and laminating via the caulking portion 96 while forming the connecting portion.
According to this manufacturing method, while the divided core pieces 95 are punched and formed, the rotatable connection and the swaging of the divided core pieces 95 can be performed in a mold apparatus that punches and forms the divided core pieces 95. This eliminates the need for pin insertion work and the like outside the apparatus, and is a useful manufacturing means.
[0004]
[Patent Document 1]
JP-A-2000-201458
[0005]
[Problems to be solved by the invention]
However, in the method of forming a laminated core by rotatably connecting a plurality of divided laminated cores by inserting pins into the through holes, the work of winding is easy, but the divided laminated cores are connected to form an annular shape. The process of assembling and inserting the pins has to be performed outside the die apparatus for punching and forming the divided core pieces, and there is a problem that time is required.
On the other hand, in the laminated core 90 of the electric motor, the laminated core 90 is formed by punching out the divided core pieces 95 from a thin metal plate such as a thin electromagnetic steel plate having a thickness of less than 0.2 mm in order to further save energy and improve efficiency. It is necessary.
However, it is difficult to stably form the split core piece 95 having the half-punched uneven portion 98 that constitutes the rotary connection portion from a thin electromagnetic steel plate or a metal plate. There is a problem that a failure easily occurs in the connecting portion. For this reason, high technology is required for manufacturing, and there has been a problem that skilled personnel having high technology must be trained.
[0006]
Further, there is a need for a mold device for forming the half-punched concave and convex portions 98 on the divided core pieces 95, and there has been a problem that the manufacturing process becomes long.
The formation of the laminated core by caulking and laminating the split core pieces punched out of the metal sheet in this way is not limited to the laminated core of the electric motor, but is applied to a general laminated core.
The present invention has been made in view of such circumstances, and it is possible to easily connect divided laminated core blocks to each other without particularly forming a rotation connecting portion serving as a rotation axis in the divided laminated core blocks, and to form an extremely thin metal sheet. It is an object of the present invention to provide a method for manufacturing a laminated core and a laminated core that can be manufactured even from the same and does not damage the divided yoke portions to be connected.
[0007]
[Means for Solving the Problems]
A method of manufacturing a laminated iron core according to the present invention, which meets the above object, is characterized in that, when the magnetic pole piece is viewed in plan, the length of the divided yoke piece extending to both sides of the symmetric axis with respect to the axis of symmetry is formed asymmetrically. When the one-piece core piece and the magnetic pole piece part are viewed in plan, the length of the split yoke piece part extending on both sides of the symmetric axis with respect to the symmetry axis is formed in a reverse asymmetric shape with respect to the first split core piece. A process of punching the two-piece core pieces,
Caulking and laminating the first split core piece and the second split core piece to form a split laminated core block;
On one side of the divided yoke portion of each of the divided laminated core blocks, a divided yoke portion of the divided laminated core block adjacent to a concave portion and a convex portion formed from the first divided core piece and the second divided core piece. On the other side, the convex portions and concave portions formed from the first divided core pieces and the second divided core pieces are inserted into each other, and the divided laminated core blocks are connected to each other to form a laminated core. And a process.
[0008]
When the length of the divided yoke piece is asymmetric, the length of the divided yoke piece that extends to one side with respect to the axis of symmetry when the pole piece is viewed in plan is the length of the divided yoke piece that extends to the other side. Refers to being different.
Further, to form the second split core piece asymmetrically opposite to the first split core piece means that the length of the split yoke piece that extends to one side in the second split core piece extends to the other side in the first split core piece. The length of the divided yoke piece extending substantially to the other side of the second divided core piece is substantially equal to the length of the divided yoke piece extending to the one side of the first divided core piece. To be the same.
[0009]
When the divided laminated core block is formed by alternately crimping the first divided core pieces and the second divided core pieces formed as described above or alternately by laminating a plurality of divided pieces, for example, the divided divided laminated core block may be divided. On one side of the yoke portion, one side of the first split core piece protrudes, and one side of the second split core piece retreats, so that convex portions and concave portions are alternately formed. On the other side of the split yoke portion, the other side of the first split core piece retreats, and the other side of the second split core piece protrudes, so that concave portions and convex portions are formed alternately.
Therefore, when each of the divided laminated core blocks is arranged in a ring shape, with respect to the convex part and the concave part on one side of the divided yoke part of the divided laminated core block, on the other side of the divided yoke part of the adjacent divided laminated core block. The concave portion and the convex portion can correspond to each other.
For this reason, the divided laminated core blocks are arranged in a ring shape, and the convex part and the concave part on one side of the divided yoke part of the divided laminated core block are different from the concave part and the convex part on the other side of the divided yoke part of the adjacent divided laminated core block. Can enter.
As a result, the divided laminated core blocks can be interconnected and integrated, and an annular laminated core can be formed.
[0010]
In the method for manufacturing a laminated core according to the present invention, a plurality of the first divided core pieces and the second divided core pieces are alternately laminated in succession, and the first divided core piece and the second divided core piece are further laminated. The first split iron core piece and the second split iron core piece, which are first stacked in a plurality of successively stacked iron core pieces, are formed by punching and forming the split yoke pieces from below, and then forming the outer shape. The first split core piece and the second split core piece that are finally stacked in a plurality of the first split core pieces and the second split core pieces that are successively stacked are formed by punching the split yoke pieces from above. It is preferable that the outer shape be formed after the formation.
[0011]
When the first split core piece and the second split core piece are formed by punching out a thin metal plate by using a die apparatus having a die and a punch, a punch-out portion (rounded corner) is formed on the surface on which the punching punch starts cutting. Area) is formed, and a burr portion (remaining minute cut) is formed on the surface on the side from which the punching punch is pulled out.
Here, when a plurality of the first divided core pieces and the second divided core pieces are successively laminated, respectively, the first divided core piece and the second divided core piece to be laminated first have both ends of the divided yoke piece portion. Is punched out from below by a punching punch, and then the outer shape is punched out. As a result, in the first split core piece and the second split core piece that are stacked first, a burr portion is formed on the upper surface side of the split yoke piece portion, and a cutout portion is formed on the lower surface side. In addition, in the case where a plurality of the first divided core pieces and the second divided core pieces are continuously laminated, respectively, in the last divided first and second divided core pieces, both ends of the divided yoke pieces are connected. It is formed by punching out from above with a punching punch, and then the outer shape is punched out. As a result, in the first and second divided core pieces to be laminated last, a burr portion is formed on the lower surface side of the divided yoke piece portion, and a cutout portion is formed on the upper surface side.
[0012]
Therefore, in the divided laminated core block formed by successively and alternately laminating a plurality of the first divided core pieces and the second divided core pieces formed as described above, the divided laminated core blocks are formed on both sides of the divided yoke portion. A pull-out portion is disposed at the corner of the tip of the projected portion.
For this reason, when joining and connecting with the adjacent divided laminated core block, the connection can be performed smoothly without damaging the yoke surface.
[0013]
A laminated iron core according to the present invention, which meets the above object, has a first split iron core in which the length of a split yoke piece part extending on both sides of the symmetric axis is asymmetric with respect to the axis of symmetry when the pole piece part is viewed in plan. The second split core, in which the length of the split yoke pieces extending on both sides of the symmetric axis with respect to the axis of symmetry when the piece and the pole piece are viewed in a plan view is asymmetrical to the first split core piece. The divided laminated core blocks formed by successively alternately caulking and laminating a plurality of pieces are connected to each other via concave and convex portions formed on both sides of the divided yoke portion of each divided laminated core block. In the laminated core formed by
At the tip corners of the projections formed on both sides of the split yoke part and at the bottom corners (tip corners) of the recesses, cut-out portions formed at the time of punching are arranged.
[0014]
Thus, by arranging the cut-out portion at the tip corner of the projection, the tip corner has a rounded shape. In addition, by arranging the cut-out portion at the bottom corner of the recess, a recess having an escape space at the bottom corner is formed.
As a result, after being wound on the divided laminated core block, the convex and concave portions on one side of the divided yoke portion of the divided laminated core block are opposed to the concave portions and convex portions on the other side of the divided yoke portion of the adjacent divided laminated core block. When the parts are inserted and connected, the resistance from the connection start to the connection end can be reduced, and the protrusions and the recesses are connected in a state in which the tips are closely contacted. In addition, they can be easily connected, and the surfaces of the divided yoke portions that do not enter are not damaged, and the insulating coating is not damaged.
[0015]
BEST MODE FOR CARRYING OUT THE INVENTION
Next, embodiments of the present invention will be described with reference to the accompanying drawings to provide an understanding of the present invention.
Here, FIG. 1 is a perspective view of a laminated core manufactured by the method for manufacturing a laminated core according to one embodiment of the present invention, and FIG. 2 is a diagram illustrating a case where a first divided core piece constituting the laminated core is stamped and formed. FIG. 3 is a plan view of a second laminated core piece constituting the laminated core formed by punching, FIG. 4 is a perspective view of a divided laminated core block of the laminated core, and FIG. It is explanatory drawing which shows the formation process which forms the 1st division | segmentation core piece and the 2nd division | segmentation core piece which are sequentially formed in a metal thin plate in a station.
As shown in FIG. 1, a laminated core 10 manufactured by applying the method for manufacturing a laminated core according to one embodiment of the present invention is configured by combining a plurality of divided laminated core blocks 13 in a ring shape. . Each divided laminated core block 13 is formed by caulking and laminating the first divided core pieces 11 and the second divided core pieces 12. Hereinafter, these will be described in detail.
[0016]
The first split core pieces 11 shown in FIG. 2 are continuously punched out every two pieces and are caulked and laminated.
Here, the first split iron core piece 11 is formed by separating the split yoke pieces 18 from each other by the split cutting line 15, and is connected to the magnetic pole piece 16 via the shaft 17 of the magnetic pole piece 16. Divided yoke piece 18 is provided.
Further, the split yoke piece 18 has an asymmetric length extending on both sides of the axis of symmetry with respect to the axis of symmetry when the pole piece 16 is viewed in plan. On the other hand, the length extending to one side is different from the length extending to the other side.
[0017]
The second split core pieces 12 shown in FIG. 3 are continuously punched out of every two pieces and are caulked and laminated.
Here, the second split iron core piece 12 is formed by separating the split yoke pieces 19 from each other by the split cutting line 15a, and is connected to the magnetic pole piece 16 via the shaft 17 of the magnetic pole piece 16. Divided yoke pieces 19 are provided.
The split yoke piece 19 is reversely asymmetric with respect to the split yoke piece 18 of the first split core piece 11, that is, with respect to the axis of symmetry of the magnetic pole piece 16 of the second split core piece 12 in plan view. The length extending to one side is substantially the same as the length extending to the other side in the first split core piece 11, and the length extending to the other side with respect to the axis of symmetry in the second split core piece 12 is set to the first split core. The piece 11 is formed so as to have substantially the same length as the one extending to one side.
[0018]
Further, caulking portions 20 are formed on the divided yoke piece portion 18 and the magnetic pole piece portion 16 of the first divided core piece 11 and the divided yoke piece portion 19 and the magnetic pole piece portion 16 of the second divided core piece 12, respectively. . Then, when the first split core piece 11 and the second split core piece 12 are stacked, the position of the swaging portion 20 that appears on the first split core piece 11 and the position of the swaging portion 20 that appears on the second split core piece 12 Are formed so as to substantially overlap each other.
Here, the caulking portion 20 is a known structure, and one of the caulking portions 20 may be a projection and the other may be a depression, or a structure in which each of the caulking portions 20 combines a depression and a projection on the front surface side and the back surface side. It may be.
With the above-described configuration, the first divided core pieces 11 and the second divided core pieces 12 are alternately swaged and stacked, for example, every two pieces, so as to be arranged on the outer peripheral side as shown in FIG. The divided laminated core block 13 including the divided yoke part 14 and the magnetic pole part 21 protruding inward from the divided yoke part 14 can be formed.
[0019]
Here, when the two first split core pieces 11 are successively swaged and laminated, the side of the first split core piece 11 where the cutout portion 22 is formed in the split yoke piece portion 18 is the lower surface side. As shown. In the second (that is, lastly laminated) first split core piece 11, the split yoke piece portion 18 is placed on the upper surface with the side on which the drawn-out portion 22 is formed, and swaged. Lamination is performed.
When two second split core pieces 12 are successively swaged and stacked on the swaged first split core pieces 11, in the first second split core piece 12, the cutout portion 22 is inserted into the split yoke piece portion 19. Is placed such that the side on which is formed is the lower surface side. In the second (that is, lastly laminated) second split core piece 12, the second yoke piece 19 is placed on the split yoke piece portion 19 such that the side on which the drawn-out portion 22 is formed faces the upper surface, and swaged. Lamination is performed.
[0020]
In the divided laminated core block 13 thus obtained, one side of the first divided core piece 11 protrudes on one side of the divided yoke portion 14 and one side of the second divided core piece 12 is retracted, The convex portions 23 and the concave portions 24 are formed alternately.
On the other side of the split yoke portion 14, the other side of the first split core piece 11 is retracted, and the other side of the second split core piece 12 is projected, so that the concave portions 24 and the convex portions 23 are formed alternately. .
Then, at the tip corner of each convex portion 23 and the bottom corner of each concave portion 24, the cut-out portions 22 are arranged.
Therefore, by arranging the cut-out portion 22 at the tip corner of each protrusion 23, the protrusion 23 having a rounded tip corner can be formed, and the pull-out portion is formed at the bottom corner of the recess 24. By arranging 22, it is possible to form a concave portion 24 having a relief space at the bottom corner.
[0021]
For this reason, after separately winding on the magnetic pole part 21 of the divided laminated core block 13, the divided laminated core blocks 13 are arranged side by side, and the projections 23 and the concave parts 24 on one side of the divided yoke part 14 of the divided laminated core block 13 are Therefore, when the concave portion 24 and the convex portion 23 on the other side of the divided yoke portion 14 of the adjacent divided laminated core block 13 are penetrated, the resistance at the time of entering can be reduced, and the divided laminated core blocks 13 are connected to each other. And the surface of the divided yoke portion 14 is not damaged. Accordingly, a plurality of divided laminated core blocks 13 are arranged side by side in a ring shape, and the divided yokes of the divided laminated core blocks 13 adjacent to the convex portions 23 and the concave portions 24 on one side of the divided yoke portion 14 of the divided laminated core blocks 13 are arranged. By inserting the concave portion 24 and the convex portion 23 on the other side of the portion 14, the divided laminated core blocks 13 are connected to each other and integrated, and the annular laminated core 10 can be easily formed.
[0022]
Next, a method for manufacturing a laminated core according to one embodiment of the present invention will be described.
As shown in FIG. 5, guide holes 26 are provided at predetermined intervals on both sides in the width direction of a strip-shaped thin metal plate 25 having excellent magnetic properties, such as an electromagnetic steel plate, and a guide member (not shown) is inserted into the guide holes 26 to form a metal. The thin plate 25 is loaded into a not-shown die apparatus for punching. Here, in the mold apparatus, a station A for sequentially removing the outer shape of the rotor piece 28, a station B for forming the pole piece 16 and the divided yoke pieces 18 of the first divided core piece 11 are arranged in this order from the upstream side. Station D forming the cutting line 15a, the station D forming the cutting line 15a of each split yoke piece 19 of the second split core piece 12, the first split core piece 11 and the second split core piece 12, respectively. A station E for forming the caulking portion 20 and a station F for removing the outer shapes of the first split core piece 11 and the second split core piece 12 are provided. In the drawing, a station E2 indicates an idle process.
[0023]
At station A in the mold apparatus, the rotor piece 28 is sequentially punched out by a rotor piece punching punch while holding the metal thin plate 25 on a die (not shown) by a stripper. Then, the thin metal plate 25 from which the rotor piece 28 has been cut out is sequentially passed to the station B.
In the station B, the pole piece portion 16 is sequentially formed by a pole piece forming punch outside the hole 29 formed by cutting out the outer shape of the rotor piece 28 while being pinched by a stripper on a die (not shown).
Then, the metal sheet 25 on which the pole piece 16 is formed passes through the station C.
[0024]
In the station C, the cutting line forming punch is moved from below on the metal sheet 25 on which the pole piece 16 is formed by a stripper on a die (not shown) so that A split cutting line 15 of each split yoke piece 18 of the one-piece iron core piece 11 is formed, and a split cutting line forming punch is moved from above to the metal sheet 25 to be passed next, so that the magnetic pole piece 16 Is formed on the outside of each of the first and second split core pieces 11 of the first split core piece 11. At this time, the operation of the station D is stopped.
Then, after the division cutting line 15 of each division yoke piece 18 of the first divisional iron core piece 11 is formed twice consecutively at the station C, the operation of the station C is stopped, and the magnetic poles are stopped at the station B. The metal sheet 25 on which the piece 16 is formed is passed through to the station D, and the split cutting line forming punch is moved from below so that each of the split yoke pieces 19 is located outside the pole piece 16 of the second split iron core piece 12. The cutting line 15a of the second core piece 12 is moved to the outer side of the pole piece 16 by moving the cutting line forming punch from above to the metal sheet 25 to be passed next. The division cutting line 15a of the yoke piece 19 is formed.
After the division cutting line 15a of each divided yoke piece 19 of the second divided core piece 12 is formed twice consecutively at the station D, the operation of the station D is stopped and the operation of the station C is resumed. I do.
As described above, in this embodiment, in the stations C and D, the operation of the other station is stopped while the other station is continuously operated twice, and the operation and the stop are alternately performed in each station. Do.
[0025]
When the metal sheet 25 on which the divided cutting lines 15 and 15a for the respective divided yoke pieces 18 and 19 of the first divided core piece 11 and the second divided core piece 12 are formed passes through the station E, The caulking portion 20 is sequentially formed by a caulking portion forming punch while being pinched by a stripper on a die (not shown). Then, the metal sheet 25 on which the caulking portion 20 is formed passes through the station F.
Therefore, on the metal sheet 25 that has passed through the station E, the area where the magnetic pole piece 16 for the first split iron core piece 11, the split cutting line 15 of the split yoke piece 18, and the swaged portion 20 are formed, A region in which the magnetic pole piece 16 for the two-piece iron core piece 12, the division cutting line 15 a of the division yoke piece 19, and the caulking part 20 are formed alternately in two sets.
In the station F, the outer shape of the first split core piece 11 and the second split core piece 12 is punched by a split core piece punch for punching the outer shape while being pinched by a stripper on a die (not shown), and the core pieces are sequentially extracted into a die hole (not shown). It is swaged and stacked on the receiving stand provided in the die hole.
[0026]
At this time, the first divided core pieces 11 and the second divided core pieces 12 are successively and alternately placed on the cradle in a continuous manner. The core piece 11 and the second split core piece 12 are placed on the split yoke pieces 18 and 19, respectively, with the surface on which the pull-out portion 22 is formed facing down, and the second first split core piece 11 is placed. In the second split core piece 12, the split yoke pieces 18 and 19 are placed with the surface on which the pull-out portion 22 is formed facing upward.
Therefore, in the first divided core piece 11 and the second divided core piece 12 that are successively placed two by two on the cradle, the punch-out portions 22 formed on the divided yoke pieces 18 and 19 at the time of punching are formed on the outer side. And the burrs formed at the time of punching are in contact with each other and are caulked and laminated.
[0027]
Then, the divided laminated core block 13 is formed by repeating the caulking and lamination of the first divided core pieces 11 and the second divided core pieces 12 to a desired thickness.
In addition, on one side of the divided yoke portion 14 of each of the formed divided laminated core blocks 13, one side of the first divided core piece 11 protrudes, and one side of the second divided core piece 12 retreats, and The concave portions 24 are formed alternately. On the other side of the split yoke portion 14, the other side of the first split core piece 11 retreats, the other side of the second split core piece 12 protrudes, and concave portions 24 and convex portions 23 are formed alternately.
Therefore, the divided laminated core block 13 manufactured in this embodiment is in the state of the laminated core 10 connected in a ring shape.
[0028]
At the time of winding, the formed divided laminated core blocks 13 are separated from each other, or the divided laminated core blocks 13 are separated from each other so as to widen the interval between the magnetic pole portions 21 in a state where the divided yoke portions 14 are connected to each other. State. Then, after winding on each magnetic pole portion 21, each divided laminated core block 13 is arranged in a ring shape again, and adjacent to the convex portion 23 and the concave portion 24 on one side of the divided yoke portion 14 of the divided laminated core block 13. The recessed part 24 and the convex part 23 on the other side of the divided yoke part 14 of the corresponding divided laminated core block 13 are inserted, and the divided laminated core blocks 13 are interconnected and integrated to form the annular laminated core 10.
Here, since the cut-out portion 22 is disposed at each of the tip corners of the projections 23 and the bottom corners of the recesses 24, the tip corners of the projections 23 are rounded. A relief space is formed at the bottom corner of each recess 24.
For this reason, the concave portion 24 and the convex portion 23 on the other side of the divided yoke portion 14 of the adjacent divided laminated core block 13 are arranged with respect to the convex portion 23 and the concave portion 24 of the divided yoke portion 14 of the divided laminated core block 13. The resistance at the time of entry can be reduced, and the connection between the divided laminated core blocks 13 can be easily performed without particularly providing a rotating connection portion.
[0029]
As described above, the embodiments of the present invention have been described. However, the present invention is not limited to these embodiments, and can be changed without changing the gist of the invention. The method of manufacturing the laminated core and the laminated core of the present invention by combining some or all of the forms and modifications are also included in the scope of the present invention. For example, in the present embodiment, the first divided core pieces and the second divided core pieces are successively alternately swaged and laminated alternately to form a divided laminated core block, but three or more pieces are successively swaged and laminated. You may. Also, the number of the first divided core pieces and the second divided core pieces may be changed during the lamination.
Further, in the present embodiment, the first split core piece and the second split core piece are each formed in an annular shape, but the first split core piece and the second split core piece may be formed in a straight line.
[0030]
【The invention's effect】
In the method for manufacturing a laminated iron core according to the first and second aspects, the length of the divided yoke pieces extending on both sides of the symmetry axis with respect to the axis of symmetry of the pole piece in plan view is formed asymmetrically. The split core piece and the second split core in which the length of the split yoke piece portion extending on both sides of the symmetry axis with respect to the axis of symmetry when viewed in a plan view of the magnetic pole piece portion are formed to be inversely asymmetric to the first split core piece. A step of punching each of the pieces, a step of caulking and laminating the first divided core piece and the second divided core piece to form a divided laminated core block, and a first divided core on one side of the divided yoke portion of each divided laminated core block. With respect to the concave portion and the convex portion formed from the piece and the second divided core piece, the convex portion formed from the first divided core piece and the second divided core piece on the other side of the divided yoke portion of the adjacent divided laminated core block. As well as the recesses into each other, A step of connecting the core blocks to each other to form a laminated core, so that the divided laminated core blocks are connected without particularly providing a rotating connection portion composed of a half-punched concave and convex portion, which is likely to cause manufacturing defects. Thus, it becomes possible to easily manufacture a laminated iron core. In addition, it is possible to stably manufacture a laminated iron core using a thin metal plate having an arbitrary thickness without requiring skilled personnel having advanced technology.
In addition, a mold device for forming the rotation connection portion is not required, and the manufacturing process of the laminated core can be shortened, so that an increase in the manufacturing cost of the laminated core can be suppressed.
[0031]
In particular, in the method for manufacturing a laminated core according to the second aspect, a plurality of the first divided core pieces and the second divided core pieces are alternately laminated in succession, and the first divided core piece and the second divided core piece are each alternately laminated. The first divided core piece and the second divided core piece that are first laminated in the continuous lamination of a plurality of core pieces are formed by punching and forming the divided yoke pieces from below and then punching out the outer shape. The first and second divided core pieces, which are finally laminated in the continuous lamination of a plurality of pieces and the second divided core pieces, are formed by punching the divided yoke pieces from above and then punching the outer shape. Therefore, in the obtained divided laminated core block, the cutout portions are arranged at both the corners of the projections formed on both sides of the divided yoke portion and the bottom corners of the recessed portions. Can be split laminated iron block It is possible to reduce the resistance when the concave and convex portions on the other side of the divided yoke portion of the adjacent divided laminated core block are respectively inserted into and connected to the convex and concave portions on one side of the divided yoke portion of the joint. Also, the surface of the divided yoke portion is not damaged. As a result, the connecting operation can be easily performed, and the productivity of the laminated core can be improved.
Furthermore, a laminated iron core can be stably manufactured from an extremely thin metal sheet, for example, one having a thickness of less than 0.2 mm. As a result, it is possible to obtain a laminated core in which energy saving and higher efficiency are further advanced.
[0032]
In the laminated iron core according to the third aspect, the first split core piece in which the length of the split yoke pieces extending on both sides of the symmetric axis with respect to the axis of symmetry of the pole piece in plan view is formed asymmetrically, and A plurality of second split core pieces each having a length of a split yoke piece extending in opposite directions to the symmetric axis with respect to the axis of symmetry when viewed in a plan view of the magnetic pole piece and having an inverse asymmetric shape to the first split core piece. A laminated core formed by connecting divided laminated core blocks formed by successively and alternately caulking and laminating via concave and convex portions formed on both sides of a divided yoke portion of each divided laminated core block. In the above, since the cut-out portion formed at the time of punching is arranged at the tip corner of the protrusion formed on both sides of the split yoke portion and the bottom corner of the recess, the split yoke portion of the split laminated core block is formed. Next to the convex part and concave part on one side The laminated core, which is formed by inserting the concave portion and the convex portion on the other side of the divided yoke portion of the divided laminated core block that fit into each other and connected, has no connection processing residual stress in the divided yoke portion where the connection is performed without difficulty, and In addition, the surface of the divided yoke is not damaged, and the insulating film separately formed on the surface of the divided yoke is not damaged, so that a high-quality laminated core can be obtained.
[Brief description of the drawings]
FIG. 1 is a perspective view of a laminated core manufactured by a method for manufacturing a laminated core according to an embodiment of the present invention.
FIG. 2 is a plan view when a first divided core piece constituting the laminated core is stamped and formed.
FIG. 3 is a plan view when a second divided core piece constituting the laminated core is punched and formed.
FIG. 4 is a perspective view of a divided laminated core block of the laminated core.
FIG. 5 is an explanatory view showing a forming process of forming a first divided core piece and a second divided core piece that are sequentially formed on a thin metal plate at each station in the mold apparatus.
FIG. 6 is an explanatory view of a laminated iron core of a conventional example.
[Explanation of symbols]
10: laminated core, 11: first divided core piece, 12: second divided core piece, 13: divided laminated core block, 14: divided yoke portion, 15, 15a: divided cutting line, 16: magnetic pole piece portion, 17: Shafts, 18, 19: split yoke piece, 20: caulked, 21: magnetic pole, 22: pull-out, 23: convex, 24: concave, 25: thin metal plate, 26: guide hole, 28: rotation Child piece, 29: hole

Claims

A first split core piece in which the length of a split yoke piece portion extending on both sides of the symmetry axis is formed asymmetrically with respect to the axis of symmetry of the magnetic pole piece portion in plan view, and the magnetic pole piece portion in plan view. Punching a second split core piece having a length of a split yoke piece part extending on both sides of the symmetric axis with respect to the symmetric axis, the second split core piece being formed asymmetrically opposite to the first split core piece;
Caulking and laminating the first split core piece and the second split core piece to form a split laminated core block;
On one side of the divided yoke portion of each of the divided laminated core blocks, a divided yoke portion of the divided laminated core block adjacent to a concave portion and a convex portion formed from the first divided core piece and the second divided core piece. On the other side, the convex portions and concave portions formed from the first divided core pieces and the second divided core pieces are inserted into each other, and the divided laminated core blocks are connected to each other to form a laminated core. And a method for manufacturing a laminated iron core.

The method for manufacturing a laminated core according to claim 1, wherein a plurality of the first divided core pieces and the second divided core pieces are alternately laminated in succession, and the first divided core piece and the second divided core piece are each laminated. The first split core piece and the second split core piece, which are first stacked in the stack of a plurality of split core pieces in succession, are formed by punching and forming the split yoke pieces from below, and then punching the outer shape. The first divided core piece and the second divided core piece, which are to be laminated last in the continuous lamination of the plurality of first divided core pieces and the second divided core pieces, are formed by punching the divided yoke pieces from above. A method for producing a laminated core piece, wherein the laminated core piece is formed by forming an outer shape after forming.

A first split core piece in which the length of a split yoke piece portion extending on both sides of the symmetry axis is formed asymmetrically with respect to the axis of symmetry of the magnetic pole piece portion in plan view, and the magnetic pole piece portion in plan view. A plurality of second divided core pieces each having a split yoke piece portion extending on both sides of the symmetric axis with respect to the symmetric axis and formed in a reverse asymmetric shape to the first divided core piece are successively and alternately swaged. In the laminated core formed by connecting the divided laminated core blocks formed by lamination via concave and convex portions formed on both sides of the divided yoke portion of each divided laminated core block,
A laminated iron core, wherein cut-out portions formed at the time of punching are arranged at a corner of a tip of the convex portion and a corner of a bottom of the concave portion formed on both sides of the split yoke portion.