JP2007124788A - Manufacturing method of laminated iron core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a laminated core in which a predetermined number of core pieces each having a plurality of crimped portions are laminated and the laminated core pieces are bonded to each other via the crimped portions. An object of the present invention is to provide a method for manufacturing a laminated core capable of producing a laminated core excellent in shape accuracy such as degree and plane parallelism.
A method of manufacturing a laminated core according to the present invention includes a step of caulking and laminating a predetermined number of iron core pieces to form a laminated core, and a plurality of caulking portions in the laminated core or a laminating thickness in the vicinity of the caulking portion. The step of measuring and calculating the deviation of the laminated thickness in the vicinity of the plurality of caulking parts or the caulking parts, and the plural caulking parts in the laminated iron core or the vicinity of the caulking parts in the manner of eliminating the deviation of the laminating thickness from the laminating direction And a pressing step.
[Selection] Figure 6

Description

    The present invention relates to a method for manufacturing a laminated core in which a predetermined number of core pieces each having a plurality of crimped portions are laminated, and the laminated core pieces are coupled to each other via the crimped portions.

    For example, a laminated core constituting a motor core (stator / rotor), which is a main component of an electric motor, is formed by punching a core piece formed in a predetermined shape from a metal plate in order to increase the output and efficiency of the electric motor. It is manufactured by laminating and integrating the laminated iron core pieces with each other via a caulking portion (caulking laminating).

  The laminated iron core A shown in FIGS. 9 and 10 is formed by laminating a predetermined number of iron core pieces B and connecting the individual iron core pieces B to each other by a plurality of caulking portions C. The caulking portion C is The lower core piece B has a protrusion Ct protruding from the lower surface Bl of the core piece B and a back-side recess Cr recessed in the upper surface Bu of the core piece B, and the protrusion Ct of the caulking portion C in the upper core piece B. The upper and lower iron core pieces B are coupled to each other (crimped) by being fitted in the back side concave portion Cr of the crimped portion C.

  Here, in the laminated core A manufactured by caulking and laminating a predetermined number of core pieces B as described above, the laminated core pieces are formed by a competition between the projection Ct of the caulking portion C and the back-side recess Cr. Along with the fact that minute gaps are likely to occur between B, and due to the plate thickness deviation of the metal plate from which the core piece B is formed by punching, the degree of uprightness and surface parallelism in the formed laminated core A is reduced. As a result, the laminated core A has a disadvantage in that it deteriorates the shape accuracy.

  In addition, since the deterioration of the shape accuracy as described above appears more noticeably in larger laminated cores, for example, in a large electric motor, the air gap between the stator (stator laminated core) and the rotor (rotor laminated core) is not satisfactory. There has been a problem that the performance becomes uniform and the performance of the electric motor is significantly reduced.

  As a technique for solving the above problems, there is provided a method in which a predetermined number of iron core pieces are caulked and laminated to form a laminated iron core, and then the laminated iron core is re-pressurized (see, for example, Patent Document 1).

In other words, in the core piece outer shape punching station of the progressive die apparatus, the outer core piece is drawn into the die, and is caulked with the lower core piece that has been drawn first, and a predetermined number of iron cores are placed in the die. After the pieces are caulked and laminated to form a laminated iron core, the laminated iron core is supported from below by a pressure pad, and is pressed from above with an outer punch to temporarily apply a re-caulking force to the laminated iron core. In addition, the lamination thickness is made uniform as the caulking bonding force increases.
JP-B-2-27047

    By the way, in the method of repressurizing the laminated iron core as described above, the pressing force from the outer punch and the pressure pad is applied over the entire top surface and bottom surface of the laminated iron core, and thus is formed at a plurality of locations on the iron core piece. It was difficult to individually deal with local deformation due to the competition of the caulking portions, and it was difficult to eliminate the defective shape of the laminated core due to the accumulation of thickness deviations in each core piece.

  An object of the present invention is to provide a method for manufacturing a laminated core capable of producing a laminated core excellent in shape accuracy such as uprightness and plane parallelism in view of the above-described actual situation.

    In order to achieve the above object, a method of manufacturing a laminated core according to the present invention includes a laminated core in which a plurality of core pieces each having a plurality of crimped portions are laminated, and the laminated core pieces are coupled to each other via the crimped portions. In the manufacturing method, a step of caulking and laminating a predetermined number of iron core pieces to form a laminated iron core, a step of measuring a plurality of caulking portions in the laminated core or a laminating thickness in the vicinity of the caulking portion, a plurality of caulking portions or the Calculating a deviation of the lamination thickness in the vicinity of the caulking portion, and pressing a plurality of caulking portions in the laminated iron core or the vicinity of the caulking portion from the lamination direction in such a manner that the deviation of the lamination thickness is eliminated. It is said.

    According to the method for manufacturing a laminated core according to the present invention, a caulking portion or a vicinity of the caulking portion where a gap is easily generated between the laminated core pieces is pressed from the laminating direction in a manner that locally eliminates a deviation in the laminated thickness. By doing so, it is possible to improve the uprightness and the plane parallelism of the laminated core without being affected by the thickness deviation in the individual core pieces, and thus it is possible to produce a laminated core excellent in shape accuracy. It becomes possible.

Hereinafter, the present invention will be described in detail with reference to the drawings illustrating embodiments.
1 and 2 show an example of a laminated core manufactured in accordance with the present invention. The laminated core 1 is a stator (stator laminated core) of an electric motor, and includes an annular yoke 1Y, Radial magnetic poles 1T, 1T... Projecting inward from the yoke 1Y.

  Further, the laminated core 1 is formed by laminating a predetermined number of core pieces 10, 10... And the laminated core pieces 10 are coupled to each other via caulking portions 10C formed in the respective yoke portions 10y. It is formed by (caulking).

  The iron core piece 10 constituting the laminated iron core 1 is formed with a plurality of (eight in the embodiment) caulking portions 10C, 10C... At a predetermined location of the annular yoke portion 10y. A protrusion 10 </ b> Ct that protrudes from the lower surface 10 l of the core piece 10 and a back-side recess 10 </ b> Cr that is depressed in the upper surface 10 u of the iron core piece 10 are provided.

  Further, the core pieces 10, 10... Constituting the laminated core 1 are coupled by fitting the protrusions 10 </ b> Ct of the caulking portion 10 </ b> C in the upper iron core piece 10 into the back side recess 10 </ b> Cr of the caulking portion 10 </ b> C in the lower iron core piece 10. As a result, the laminated core pieces 10, 10... Are fastened to each other via the caulking portion 10C, whereby the whole laminated iron core 1 is integrated.

  2B, in the lowermost (lowermost layer) iron core piece 10 constituting the laminated iron core 1, a portion corresponding to the protrusion 10Ct of the caulking portion 10C in the upper iron core piece 10 is formed to penetrate therethrough. ing.

  In order to manufacture the laminated iron core 1 as described above, first, in a progressive mold apparatus (not shown), a core piece 10 having a predetermined shape is punched and formed from a strip-shaped metal plate, and a predetermined number of core pieces 10, 10,. At the same time, the laminated iron core pieces 10 are fastened and integrated with each other by a caulking portion 10C. In addition, since the structure of the progressive metal mold apparatus mentioned above and the manufacturing process of the laminated iron core by this progressive metal mold apparatus are already well-known techniques, detailed description is abbreviate | omitted.

  As described above, after the laminated iron core 1 is formed in the progressive die apparatus, the laminated iron core 1 is taken out from the progressive metal mold apparatus and carried into the repressurizing apparatus 100 shown in FIGS. In the pressure device 100, the laminated core 1 is re-pressurized to correct the shape.

  The repressurization apparatus 100 includes a measurement station St1 and a pressurization station St2, as shown in FIG. 3, and the measurement station St1 has a base B1 on which the loaded laminated core 1 is placed (set); The measuring head 101 is fixed to the apparatus frame 100F in the upper region of the base B1.

  The pressurizing station St2 is fixed to the apparatus frame 100F on the base B2 on which the laminated core 1 transferred from the base B1 of the measuring station St1 as indicated by an arrow is placed (set), and in the upper area of the base B2. And a pressure head 102 provided.

  Further, the repressurizing device 100 is a controller (control device) for controlling the operation of the pressurizing head 102 of the pressurizing station St2 based on the measurement result of the measuring head 101 of the measuring station St1, as will be described in detail later. 103.

As shown in FIG. 4, when the laminated iron core 1 is placed on the base B1 of the measuring station St1, eight optical measurement units corresponding to the eight caulking portions 10C (10C _{1 to} 10C ₈ ) in the laminated iron core 1 are provided. the distance sensor _S (S 1 ~S _8), the laminated layer thickness _h (h 1 ~h ₈₎ of the caulking portion 10C of the laminated core 1 _(10C 1 ~10C _8), as details shown in FIG. 6 (a), The stacking thickness h of the back side concave portion 10Cr in the caulking portion 10C is measured.

The measured in the measurement station St1, lamination thickness h of the caulking portion _{10C (10C 1 ~10C 8) (} h 1 ~h 8) is input to the controller 103 described above, in this controller 103, the caulking portion 10C deviation lamination thickness at _{(10C 1 ~10C 8) h (} h 1 ~h 8) Δh (Δh 1 ~Δh 8) is calculated.

Here, the deviation Δh (Δh _{1 to} Δh ₈ ) of the lamination thickness h (h _{1 to} h ₈ ) is the minimum lamination thickness (in the embodiment, the lamination of the caulking portion 10C ₅ ) as shown in FIG. It is a value calculated from the difference from the thickness h ₅ ). As shown in FIG. 7B, the deviation Δh (Δh _{1 to} Δh ₈ ) of the laminated thickness h (h _{1 to} h ₈ ) is a value calculated from the difference from the desired set laminated thickness h _0. May be.

After the measurement at the measurement station St1, when the laminated core 1 is placed on the base B2 of the pressurizing station St2, as shown in FIG. 5, eight caulking portions 10C (10C _{1 to} 10C) in the laminated core 1 are placed. by eight pressure device P corresponding _(P 1 to P ₈₎ to _8), the pressing of the caulking portion 10C of the laminated core 1 _(10C 1 ~10C ₈₎ is performed.

  Here, as shown in FIG. 6B, the pressurizing device P has a hydraulic cylinder Ps and a plunger Pp driven up and down by the hydraulic cylinder Ps, and a controller 103 (FIG. 6) inputted to the hydraulic cylinder Pp. The operation (vertical movement) of the plunger Pp is controlled by a command signal from (see 5).

In the pressurizing station St2, from the controller 103 to be output based on the deviation Delta] h of the laminated layer thickness h in each caulking portion _{10C (10C 1 ~10C 8) (} h 1 ~h 8) (Δh 1 ~Δh 8) the command signal, the deviation Delta] h in (Δh ₁ ~Δh ₈₎ manner to eliminate, the caulking portion 10C plunger Pp is the laminated core 1 in each pressure device _{P (P 1 ~P 8) (} 10C 1 ~10C 8) Specifically, the bottom of the back side recess 10Cr in the caulking portion 10C is pressed from above (stacking direction).

At this time, the plunger as deviation Delta] h of the laminated layer thickness _{h (h 1 ~h 8) (} Δh 1 ~Δh 8) is larger caulking portion _10C (10C 1 ~10C _8), pressure device _P (P 1 ~P ₈₎ It will be pressed deep with Pp or with a large force.

In the after-pressure apparatus 100, by pressing the respective caulking portion 10C of the laminated core ₁ (10C 1 ~10C ₈₎ in such manner described above, the laminated core 1 without deviation lamination thickness of each caulking portion 10C is formed Then, the laminated core 1 is taken out from the repressurizing apparatus 100 as a finished product.

Here, in the after-pressure apparatus 100 described above, the caulking portion 10C at the measurement station St1 _(10C 1 ~10C _8), details measures the laminated layer thickness h of the rear-side recess 10Cr (h1~h _8), pressurized In the pressure station St2, the back side concave portion 10Cr of each caulking portion 10C (10C _{1 to} 10C ₈ ) is pressed. As shown in FIG. 8A, the caulking is performed by the optical distance measuring sensor S ′ of the measuring station St1. The stacking thickness h of the upper surface 10u of the iron core piece 10 adjacent to the caulking part 10C is measured near the caulking part 10C, and as shown in FIG. 8B, the pressurizing device P ′ (hydraulic cylinder Ps) of the pressurizing station St2 is measured. The plunger Pp ′) driven by ′ may press the vicinity of the caulking portion 10C (the upper surface 10u of the iron core piece 10 adjacent to the caulking portion 10C).

  Even in the case of the configuration as described above, the calculation of the deviation in the laminated thickness of each caulking portion 10C and the operation control of each pressurizing device P ′ based on the deviation in the laminated thickness are shown in FIGS. There is no difference from the configuration of the repressurizing apparatus 100 described.

  In the manufacturing method of the laminated core described above, the caulking portion 10C or the vicinity of the caulking portion 10C in which a gap is easily generated between the laminated core pieces 10 is locally pressed from the laminating direction in such a manner that the deviation of the laminating thickness is eliminated. By this, without being affected by the thickness deviation in the individual iron core pieces 10, it is possible to improve the uprightness and the plane parallelism in the laminated iron core 1, and according to the above-described method for producing a laminated iron core, It becomes possible to manufacture the laminated iron core 1 excellent in shape accuracy.

  In the re-pressurizing device of the above-described embodiment, the local laminated thickness of the laminated iron core is measured using an optical distance measuring sensor, but not only the optical distance measuring sensor but also, for example, a magnetic type, Needless to say, various ranging sensors such as an acoustic type and a mechanical type can be employed as the measuring means.

  In the re-pressurizing apparatus of the above-described embodiment, the laminated thickness of the laminated iron core is measured at the measuring station, and this measured value is input to the controller. However, the operator uses a measuring means such as a caliper or a micrometer to The laminated thickness may be measured manually, and the measured value may be input to the controller manually by the operator.

  In addition, the laminated core manufactured in the embodiment has a trapezoidal shape in which the protrusion of the crimping portion of the iron core piece protrudes from the lower surface of the iron core piece, but the protrusion of the crimping portion has a concave shape or a V shape, Furthermore, it goes without saying that the present invention can also be applied effectively in the manufacture of a laminated iron core in which the protrusions of the crimped portion are raised and protruded.

  In addition, the laminated iron core manufactured in the examples has caulking portions formed at eight locations of the iron core pieces, but the present invention is used to produce laminated iron cores of various specifications regardless of the number of caulking portions. It can be applied effectively.

  Furthermore, in the above-described embodiments, an example in which the present invention is applied to the manufacture of a stator (stator laminated core) in an electric motor has been shown.Of course, in the manufacture of a rotor (rotor laminated core) in an electric motor, Needless to say, the present invention can be applied very effectively.

(a) is an external appearance perspective view which shows the core piece of the laminated iron core manufactured according to this invention, (b) is an external appearance perspective view which shows the whole laminated iron core manufactured according to this invention. (a) is sectional drawing which shows notionally the iron core piece which comprises the laminated iron core of FIG. 1, (b) is sectional drawing which shows notionally the whole laminated iron core in FIG. The conceptual diagram which shows the repressurization apparatus for manufacturing the laminated iron core shown in FIG. The conceptual diagram of the measurement station in the repressurization apparatus shown in FIG. The conceptual diagram of the pressurization station in the repressurization apparatus shown in FIG. (a) And (b) is a conceptual diagram which shows the operation | work process by a repressurization apparatus. (a) And (b) is a figure which shows the concept of the deviation of lamination | stacking thickness. (a) And (b) is a conceptual diagram which shows the operation | work process by a repressurization apparatus. The external appearance perspective view which shows the conventional laminated iron core. (a) is sectional drawing which shows notionally the iron core piece which comprises the laminated iron core of FIG. 9, (b) is sectional drawing which shows notionally the whole laminated iron core in FIG.

Explanation of symbols

1 ... laminated iron core,
10 ... Iron core piece,
10C ... crimping part,
10 Ct ... protrusions,
10Cr ... concave part on the back side,
100 ... Repressurizing device,
h _{1 to} h ₈ ... lamination thickness,
Δh _{1 to} Δh ₈ ... deviation.

Claims (1)

A method of manufacturing a laminated core in which a plurality of core pieces each having a plurality of crimped portions are laminated, and the laminated core pieces are coupled to each other via the crimped portions,
A step of caulking and laminating a predetermined number of the core pieces to form a laminated core;
A step of measuring the thickness of the plurality of crimped portions in the laminated core or the thickness of the laminated portions in the vicinity of the crimped portions;
The deviation of the laminated thickness in the vicinity of the plurality of crimped portions or the crimped portion is calculated, and the plurality of crimped portions in the laminated core or the vicinity of the crimped portion is pressed from the lamination direction in such a manner that the deviation of the laminated thickness is eliminated. And a process of
A method for producing a laminated iron core, comprising:

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