阅读说明：本技术 层叠铁心的制造方法 (Method for manufacturing laminated iron core ) 是由 荒川广一 加藤刚 山口翔 佐野新也 于 2017-05-18 设计创作，主要内容包括：本发明涉及层叠铁心的制造方法。定子层叠铁心的制造方法包括：在电磁钢板W的宽度方向排成一列的第1～第N(N为2以上的自然数)的位置,冲落电磁钢板W并形成冲压部件(10<Sub>1</Sub>～10<Sub>N</Sub>)的第1工序；层叠冲压部件(10<Sub>1</Sub>～10<Sub>N</Sub>)来形成定子层叠铁心的第2工序。冲压部件(10<Sub>k</Sub>)(k为1～N的自然数)的多个异形部中至少1个异形部的形状或者配置,与冲压部件(10<Sub>m</Sub>)(m为1～N且满足m≠k的自然数)的多个异形部中至少1个异形部的形状或者配置不同,从而任意的2个冲压部件(10)的形状彼此相互不一致。(The present invention relates to a method for manufacturing a laminated core. The method for manufacturing the laminated stator core includes: punching the electromagnetic steel sheet W at the 1 st to N th (N is a natural number of 2 or more) positions aligned in a row in the width direction of the electromagnetic steel sheet W to form a punched member (10) 1 ～10 N ) The 1 st step; laminated stamped component (10) 1 ～10 N ) And a2 nd step of forming a laminated stator core. Punching part (10) k ) At least 1 of the plurality of profiles (k is a natural number of 1 to N) is shaped or arranged together with the press member (10) m ) At least 1 of the plurality of deformed portions (m is 1 to N and satisfies a natural number of m ≠ k) has a different shape or arrangement, and the shapes of arbitrary 2 punched members (10) do not coincide with each other.)

1. A method of manufacturing a laminated core, comprising:

a1 st step of punching out a strip-shaped metal plate along a predetermined 1 st to nth punched shape at 1 st to nth positions arranged in a width direction of the metal plate, where N is a natural number of 2 or more, to form 1 st to nth punched members corresponding to the 1 st to nth punched shapes, respectively; and

a2 nd step of laminating a plurality of the press members to form a laminate,

a plurality of irregularly shaped portions having a concave shape or a convex shape are formed at positions where the 1 st to nth press members overlap each other at the time of lamination in the 2 nd step,

a shape or an arrangement of at least 1 of the plurality of irregularly shaped portions of the kth press member of the 1 st to nth press members is different from a shape or an arrangement of at least 1 of the plurality of irregularly shaped portions of the mth press member of the 1 st to nth press members, so that the shape of the kth press member and the shape of the mth press member do not coincide with each other, where k is a natural number of 1 to N, m is 1 to N, and m ≠ k is satisfied.

2. The method of claim 1, wherein the first and second light sources are selected from the group consisting of a red light source, a green light source, and a blue light source,

the irregular parts are formed on the peripheries of the 1 st to nth press members, and are 1 of welding parts for welding the press members to each other, fitting parts for fitting with a die when the press members are punched out of the metal plate, or rotation lamination identification parts for identifying rotation lamination.

3. The method of claim 1, wherein the first and second light sources are selected from the group consisting of a red light source, a green light source, and a blue light source,

the punching component is annular.

4. The method of claim 2, wherein the first and second light sources are selected from the group consisting of a red light source, a green light source, and a blue light source,

the punching component is annular.

5. The method of claim 1, wherein the first and second light sources are selected from the group consisting of a red light source, a green light source, and a blue light source,

in the 2 nd step, the laminated body is formed by rotationally laminating the punching member or the block body in which a predetermined number of punching members are laminated.

6. The method of claim 2, wherein the first and second light sources are selected from the group consisting of a red light source, a green light source, and a blue light source,

in the 2 nd step, the laminated body is formed by rotationally laminating the punching member or the block body in which a predetermined number of punching members are laminated.

7. The method of claim 3, wherein the first and second light sources are selected from the group consisting of a red light source, a green light source, and a blue light source,

in the 2 nd step, the laminated body is formed by rotationally laminating the punching member or the block body in which a predetermined number of punching members are laminated.

8. The method of claim 4, wherein the first and second light sources are selected from the group consisting of a red light source, a green light source, and a blue light source,

in the 2 nd step, the laminated body is formed by rotationally laminating the punching member or the block body in which a predetermined number of punching members are laminated.

9. The method according to any one of claims 1 to 8,

in the step 1, an identification mark for identifying the front and back sides of the press member is formed.

Technical Field

The present invention relates to a method for manufacturing a laminated core.

Background

A method for manufacturing a laminated core disclosed in japanese patent application laid-open No. 2013-013189 includes: a first step of punching a metal plate (a plate to be processed), which is a strip-shaped metal plate wound in a coil shape, while intermittently and sequentially feeding a coil material, which is a coil, from an uncoiler at a predetermined pitch, by a punch, to form a plurality of punching members in a width direction of the metal plate; a2 nd step of laminating the respective press-formed members to form a divided core piece; and a3 rd step of assembling the divided core pieces to obtain an annular laminated core. In step 1, in order to identify a position in the width direction of the metal plate from which the punched member was punched out, identification marks are formed at different positions of the punched member according to the position (width position) in the width direction of the metal plate. Thus, even when a failure of the press member is found after the divided core pieces are formed or after the laminated core is formed, it is possible to specify from which position in the width direction of the metal plate the press member is punched out.

Disclosure of Invention

However, in the method described in patent document 1, a punch and a die for forming the identification mark are required. Therefore, the number of punches and dies increases, and the configuration of the apparatus for manufacturing the laminated core may be complicated.

Here, in the method for manufacturing a laminated core according to the present invention, when a plurality of punching members are punched from a metal plate in the width direction of the metal plate, it is possible to determine from which position in the width direction of the metal plate the punching member is punched, while suppressing the complexity of the apparatus.

A method for manufacturing a laminated core according to an aspect of the present invention includes: a1 st step of punching out the metal plate along a predetermined 1 st to Nth punched shapes at 1 st to Nth (N is a natural number of 2 or more) positions arranged in a line in a width direction of the strip-shaped metal plate to form 1 st to Nth punched members corresponding to the 1 st to Nth punched shapes, respectively; and a2 nd step of stacking a plurality of press members to form a stacked body. A plurality of irregular parts having a concave shape or a convex shape are formed at positions where the 1 st to Nth press members overlap each other at the time of lamination in the 2 nd step. The shape or arrangement of at least 1 of the plurality of deformed portions of the kth press member among the 1 st to nth press members is different from the shape or arrangement of at least 1 of the plurality of deformed portions of the mth press member among the 1 st to nth press members, so that the shape of the kth (k being a natural number of 1 to N) press member and the shape of the mth (m being a natural number of 1 to N and satisfying m ≠ k) press member do not coincide with each other.

According to the method of manufacturing a laminated core of the present invention, when a plurality of punching members are punched from a metal plate in the width direction of the metal plate, it is possible to determine from which position in the width direction of the metal plate the punching member is punched, while suppressing the complexity of the apparatus.

Drawings

Fig. 1 is a perspective view showing an example of a laminated stator core.

Fig. 2 is a plan view showing an example of the punch member.

Fig. 3 is a schematic diagram showing an example of the shape of the irregularly shaped portion.

Fig. 4 is a diagram showing an example of the layout of the irregularly shaped portions of the stamped part.

Fig. 5 is a diagram showing an example of the layout of the irregularly shaped portions of the stamped part.

Fig. 6 is a side view showing an example of a mainly irregularly shaped portion in the stator laminated core.

Fig. 7 is a schematic diagram showing an example of an apparatus for manufacturing a laminated stator core.

Fig. 8 is a schematic diagram showing an example of the press apparatus.

Fig. 9 is a cross-sectional view schematically showing a mechanism for laminating the punch members and a mechanism for ejecting the laminated stator core from the die plate.

Fig. 10 is a diagram showing an example of a layout of press working.

Fig. 11 is a plan view showing another example of the press-molding member of the stator laminated core.

Fig. 12 is a plan view showing an example of a press-formed member of the laminated rotor core.

Detailed Description

Since the embodiments of the present invention described below are examples for describing the present invention, the present invention should not be limited to the following.

< summary of the embodiments >

[1] A method of manufacturing a laminated core according to an example of the present embodiment includes: a1 st step of punching out the metal plate along a predetermined 1 st to Nth punched shapes at 1 st to Nth (N is a natural number of 2 or more) positions arranged in a line in a width direction of the strip-shaped metal plate to form 1 st to Nth punched members corresponding to the 1 st to Nth punched shapes, respectively; and a2 nd step of stacking a plurality of press members to form a stacked body. A plurality of irregular parts having a concave shape or a convex shape are formed at positions where the 1 st to Nth press members overlap each other at the time of lamination in the 2 nd step. The shape or arrangement of at least 1 of the plurality of deformed portions of the kth press member among the 1 st to nth press members is different from the shape or arrangement of at least 1 of the plurality of deformed portions of the mth press member among the 1 st to nth press members, so that the shape of the kth (k being a natural number of 1 to N) press member and the shape of the mth (m being a natural number of 1 to N and satisfying m ≠ k) press member do not coincide with each other.

In the method of manufacturing a laminated core according to an example of the present embodiment, the 1 st to nth press members punched out from the metal plates in the 1 st step form a plurality of irregular portions having a concave shape or a convex shape at positions overlapping each other in the lamination in the 2 nd step. The shape or arrangement of at least 1 of the plurality of profiles of the kth stamped component is different from the shape or arrangement of at least 1 of the plurality of profiles of the mth stamped component, such that the shape of the kth stamped component and the shape of the mth stamped component do not coincide with each other. Therefore, since the shapes of the press-formed members to be punched out at the 1 st to nth positions in the width direction of the metal plate are different from each other, it is possible to determine at which position of the 1 st to nth positions any press-formed member is punched out. Here, the stamped component may be formed with various irregular portions for the sake of convenience in manufacturing the laminated core. In the method for manufacturing a laminated core according to one aspect of the present invention, the shape of the kth stamped member is distinguished from the shape of the mth stamped member by the shape or arrangement of the irregularly shaped portions. Therefore, since the existing punch, die, and the like for forming the irregularly shaped portion can be used to identify the punch members different from each other, it is not necessary to newly add a punch, a die, and the like for identifying the punch members. As described above, it is possible to determine from which position in the width direction of the metal plate the punching member is punched out, while suppressing the complication of the apparatus.

[2] In the method according to claim 1, the irregular parts may be formed at the peripheral edges of the 1 st to nth press members, respectively, and may be 1 of a welded part for welding the press members to each other, a fitting part for fitting the press members to a die when the press members are punched out of the metal plate, or a rotation lamination identification part for identifying the rotation lamination. In the case where the irregularly shaped portion is the welded portion, the irregularly shaped portion can have both: the identification function of the punching position of the punching part and the welding function are 2 functions. In the case where the irregularly shaped portion is a fitting portion, the irregularly shaped portion may have both: the punch press has 2 functions of identifying the punch-down position of the punch member and fitting the punch member. In the case where the irregularly shaped portion is a rotationally laminated identification portion, the irregularly shaped portion may have both: the punching position of the punching member is identified, and the rotation lamination state is identified.

[3] In the method according to claim 1 or 2, the press member may have an annular shape.

[4] In the method according to any one of items 1 to 3, in the 2 nd step, the press members or the blocks in which a predetermined number of press members are stacked may be rotationally stacked to form a stacked body.

[5] In the method according to any one of claims 1 to 4, the identification mark for identifying the front and back sides of the press member may be formed in the 1 st step. In this case, even if the shapes of the 2 different punch members match each other when the front and back are reversed, it is possible to determine at which position of the metal plate the punch members are punched out. Therefore, by using the identification mark in addition to the type of the shape of the irregularly shaped portion, the number of patterns of the shape of the punched member that are not overlapped can be increased.

< example of embodiment >

An example of an embodiment according to the present invention will be described in more detail below with reference to the drawings. In the following description, the same reference numerals are used for the same elements or elements having the same function, and redundant description is omitted.

[ laminated stator core ]

First, the structure of the stator laminated core 1 will be described with reference to fig. 1. The stator laminated core 1 (stator) has a cylindrical shape. That is, a through hole 1a extending along the central axis Ax is provided in the central portion of the stator laminated core 1. A rotor laminated core (rotor), not shown, can be disposed in the through hole 1 a. The stator laminated core 1 and the rotor laminated core together constitute an electric motor (motor).

The stator laminated core 1 is a laminated body in which a plurality of punched parts 10 are stacked. The stator laminated core 1 includes: a yoke 2; a plurality of pole teeth 3 (6 pole teeth 3 in fig. 1); a plurality of ear portions 4 (3 ear portions 4 in fig. 1).

The yoke 2 is annular and extends so as to surround the central axis Ax. The width of the yoke 2 in the radial direction, the inner diameter of the yoke 2, the outer diameter of the yoke 2, and the thickness of the yoke 2 can be set to various sizes according to the use and performance of the motor.

A plurality of the shaped portions 5 (6 shaped portions in fig. 1) are provided on the outer periphery of the yoke 2. Each irregularly shaped portion 5 is recessed toward the central axis Ax. The irregularly shaped portions 5 are arranged at substantially equal intervals in the circumferential direction of the yoke portion 2 (hereinafter simply referred to as the circumferential direction). Each of the irregularly shaped portions 5 extends linearly from one end surface to the other end surface of the stator laminated core 1 in the lamination direction of the stator laminated core 1 (hereinafter, simply referred to as the lamination direction).

The yoke 2 has a surface formed with identification marks 6. The identification mark 6 functions as a mark for identifying the surface of the yoke 2. The identification mark 6 is, for example, a character, a figure, or the like printed by laser engraving. The back surface of the yoke 2 may be formed with a mark different from the identification mark 6, instead of the mark. This allows the front surface and the back surface of the punch member 10 to be distinguished.

Each of the teeth 3 extends from the inner edge of the yoke 2 toward the central axis Ax along the radial direction of the laminated stator core 1 (hereinafter, simply referred to as the radial direction). In the laminated stator core 1 shown in fig. 1, each tooth portion 3 is formed integrally with the yoke portion 2.

The pole teeth 3 are arranged at substantially equal intervals in the circumferential direction. The width of each circumferential pole tooth portion 3, the length of each radial pole tooth portion 3, the interval between adjacent pole tooth portions 3, and the thickness of each pole tooth portion 3 can be set to various sizes according to the application and performance of the motor.

When the laminated stator core 1 is configured as a motor, a predetermined number of windings (not shown) are wound around each of the pole teeth 3. A space for arranging the winding, i.e., a slit 1b, is defined between adjacent tooth portions 3. Each tooth 3 is provided with a caulking portion 7. The caulking portions 7 join the punched pieces 10 adjacent in the stacking direction to each other.

Each ear portion 4 projects radially outward from the outer edge of the yoke portion 2 so as to be spaced apart from the center axis Ax. The ear portions 4 are arranged at substantially equal intervals in the circumferential direction. Each ear portion 4 extends linearly from one end surface to the other end surface of the stator laminated core 1 in the central axis Ax direction.

Each ear portion 4 is provided with a through hole 4a penetrating the ear portion 4 in the stacking direction. The through holes 4a function as insertion holes for bolts for fixing the laminated stator core 1 to a housing (not shown) of an electric motor.

The stamped member 10 is obtained by, for example, processing (for example, press working, cutting and bending) an electrical steel sheet W (see fig. 6 to 9). When the pre-caulking is not provided to the stamped member 10, the shape of the stamped member 10 as viewed from the central axis Ax direction is substantially the same as the shape of the stator laminated core 1 as viewed from the central axis Ax direction (see fig. 1 and 2). Therefore, the punch member 10 is also annular as viewed from the center axis Ax as shown in fig. 2. A through hole 10a is provided in the central portion of the punch member 10.

The press member 10 includes: a yoke 12; a plurality of pole teeth 13 (6 pole teeth 13 in fig. 2); a plurality of ear portions 14 (3 ear portions 14 in fig. 1). The yoke portion 12, the tooth portions 13, and the ear portions 14 correspond to the yoke portion 2, the tooth portions 3, and the ear portions 4 of the laminated stator core 1, respectively. Therefore, the yoke portion 12, the tooth portions 13, and the ear portions 14 have the same shape as the yoke portion 2, the tooth portions 3, and the ear portions 4 of the laminated stator core 1, respectively. That is, when the stamped parts 10 are laminated to form the laminated stator core 1, the yoke portion 12 of the stamped part 10 forms the yoke portion 2 of the laminated stator core 1, the tooth portion 13 of the stamped part 10 forms the tooth portion 3 of the laminated stator core 1, and the ear portion 14 of the stamped part 10 forms the ear portion 4 of the laminated stator core 1.

A plurality of the odd-shaped portions 15 (6 odd-shaped portions 15A to 15F in fig. 2) are provided on the outer periphery of the yoke 12. Each irregularly shaped portion 15 is recessed toward the central axis Ax. The irregularly shaped portions 15 are arranged at substantially equal intervals in the circumferential direction of the yoke portion 12. In fig. 2, the irregularly shaped portions 15A to 15F are arranged in this order clockwise when viewed from above. The yoke 12 has a surface on which identification marks 6 are formed.

A space for arranging the winding, i.e., a slit 10b is defined between adjacent tooth portions 13. The ear portion 14 is provided with a through hole 14a penetrating the ear portion 14 in the central axis Ax direction.

Here, the irregularly shaped portion 15 has a shape selected from a plurality of kinds different from each other. For example, the irregularly shaped portion 15 may have any 1 of 3 shapes a to c shown in fig. 3(a) to (c). Therefore, in the stamped part 10 shown in fig. 2, the irregularly shaped portions 15A to 15F can take 3 shapes a to c, respectively.

As shown in fig. 3(a), the shape "a" is a cut-away portion formed of a convex portion "a 1 and a pair of concave portions" a 2. The convex portion a1 has an arc shape protruding toward the side away from the central axis Ax (radially outward of the punch member 10). The pair of concave portions a2 are each in the shape of an arc recessed toward the central axis Ax and are located on both sides of the convex portion a 1. The inner ends of the pair of concave portions a2 are connected to the ends of the convex portions a 1. The outer ends of the pair of concave portions a2 are connected to the outer peripheral edge of the punch 10.

As shown in fig. 3(b), the shape b is a cut-away shape composed of a convex portion b1, a pair of concave portions b2, and a linear portion b 3. The convex portion b1 has an arc shape protruding toward the side away from the central axis Ax (radially outward of the punch member 10). The pair of concave portions b2 are each in the shape of an arc recessed toward the central axis Ax and are located on both sides of the convex portion b 1. The inner ends of the pair of concave portions b2 are connected to the ends of the convex portions b1, respectively. The outer end of the one concave portion b2 is coupled to the outer peripheral edge of the punch member 10. The linear portion b3 extends linearly in the radial direction of the punch member 10. The straight portion b3 connects the outer end of the other concave portion b2 to the outer peripheral edge of the punch member 10. The opening width d2 of shape b is set smaller than the opening width d1 of shape a (d1 > d 2).

As shown in fig. 3(c), the shape c is a cut-away shape composed of a convex portion c1, a pair of concave portions c2, and a pair of linear portions c 3. The convex portion c1 has an arc shape protruding toward the side away from the central axis Ax (radially outward of the punch member 10). The pair of concave portions c2 are each in the shape of an arc recessed toward the central axis Ax and are located on both sides of the convex portion c 1. The inner ends of the pair of concave portions c2 are connected to the ends of the convex portion c 1. The pair of linear portions c3 each linearly extend in the radial direction of the punch member 10. The one linear portion c3 connects the outer end of the one concave portion c2 with the outer peripheral edge of the punch member 10. The other linear portion c3 connects the outer end of the other concave portion c2 to the outer peripheral edge of the punch member 10. The opening width d3 of shape c is set smaller than the opening width d2 of shape b (d2 > d 3).

In the stamped-out part 10 shown in fig. 2, the position and shape of the irregularly shaped portion 15 can be expressed by a combination of a symbol showing the positions 15A to 15F of the irregularly shaped portion 15 and symbols showing the shapes a to c of the irregularly shaped portion 15. For example, in the stamped part 10A illustrated in fig. 4(a), the irregularly shaped portions 15A, 15B are shaped as C, the irregularly shaped portions 15C, 15D are shaped as B, and the irregularly shaped portions 15E, 15F are shaped as a. Therefore, the stamped member 10A of fig. 4(a) has the irregularly shaped portions 15Ac, 15Bc, 15Cb, 15Db, 15Ea, 15 Fa.

Similarly, the punched member 10B illustrated in fig. 4(B) has the irregularly shaped portions 15Aa, 15Bc, 15Cc, 15Db, 15Eb, and 15 Fa. The punched member 10C exemplified in FIG. 4(C) has the deformed portions 15Ab, 15Bc, 15Ca, 15Db, 15Ec, 15 Fa. The punched member 10D exemplified in fig. 4(D) has the irregularly shaped portions 15Ac, 15Bb, 15Ca, 15Dc, 15Eb, 15 Fa.

The punched member 10E exemplified in fig. 5(a) has the irregularly shaped portions 15Aa, 15Bc, 15Cb, 15Dc, 15Eb, 15 Fa. The punched member 10F illustrated in fig. 5(b) has the irregularly shaped portions 15Ab, 15Bb, 15Cc, 15Da, 15Ea, and 15 Fa. The punched member 10G illustrated in fig. 5(c) has the irregularly shaped portions 15Ab, 15Bb, 15Cb, 15Da, 15Ea, and 15 Fa. The punched member 10H exemplified in fig. 5(d) has the irregularly shaped portions 15Aa, 15Ba, 15Ca, 15Db, 15Ea, 15 Fa.

The number of combinations of the positions and shapes of the irregularly shaped portions 15 can be determined by a cyclic arrangement (cyclic periodicity) or a necklace arrangement (necklacerepetition) depending on the presence or absence of the ear-shaped portions 14 and the presence or absence of the identification marks 6.

The stator laminated core 1 may be formed by so-called rotary lamination. "rotationally laminating" means that when the stator laminated core 1 is obtained by laminating a plurality of the punch members 10, the punch members 10 are relatively angularly displaced from each other, and includes rotating and laminating the punch members 10. The rotational lamination is mainly performed for the purpose of canceling the thickness deviation of the punched member 10. In order to obtain the laminated stator core 1, the stamped parts 10 may be stacked in a rotatable manner for each 1 piece, or a predetermined number of stamped parts 10 may be stacked in a rotatable manner for each unit block 20 (see fig. 6). The angle of the rotational lamination may be set to any value as long as the ear portions 14 of the punch 10 overlap each other. For example, in the present embodiment, since the punch member 10 has 3 ear portions 14, the angle of the rotational lamination may be set to 120 °. In the case where the unit blocks 20 are stacked by rotation, the number of the stacked unit blocks 20 may be a times (a is a natural number of 1 or more) the number of the ear portions 14 of the punch member 10. In this case, the flatness, parallelism, and squareness of the obtained laminated stator core 1 can be improved.

Fig. 6 shows an example of a laminated stator core 1 manufactured by rotationally laminating a punched member 10A as an example of fig. 4(a) as a unit block 20, with the unit block 20 being shifted by 120 °. Since the shapes (widths) of the shapes a to c are different from each other, the boundaries of the unit blocks 20 can be easily recognized as shown in fig. 6. Thus, when the unit blocks 20 are joined to each other by welding, the boundary portions of the unit blocks 20 can be welded accurately. Therefore, the size of the welded portion 21 joining the unit blocks 20 can be reduced, and therefore, the influence of the welded portion 21 on the magnetic characteristics of the laminated core 1 can be reduced.

[ manufacturing apparatus of laminated stator core ]

Next, referring to fig. 7, a manufacturing apparatus 100 of the stator laminated core 1 will be described. The manufacturing apparatus 100 is an apparatus for manufacturing the stator laminated core 1 from an electromagnetic steel sheet W (processed sheet) which is a strip-shaped metal sheet. The manufacturing apparatus 100 includes an uncoiler 110, a feeder 120 (feeder), a press apparatus 130, and a controller 150 (controller).

The uncoiler 110 holds a coil 111 in a rotatable manner in a state where the coil 111, which is a strip-shaped electromagnetic steel sheet W wound in a coil shape, is loaded. The feeding device 120 includes a pair of rollers 121 and 122 sandwiching the magnetic steel sheet W from above and below. The pair of rollers 121 and 122 rotate and stop based on an instruction signal from the controller 150, and intermittently and sequentially send the electromagnetic steel sheets W to the press apparatus 130.

The length of the electromagnetic steel sheet W constituting the coil 111 may be, for example, about 500m to 10000 m. The thickness of the electrical steel sheet W may be, for example, about 0.1mm to 0.5 mm. The thickness of the electromagnetic steel sheet W may be, for example, about 0.1mm to 0.3mm from the viewpoint of obtaining a laminated stator core 1 having more excellent magnetic properties. The width of the electrical steel sheet W may be, for example, about 50mm to 500 mm.

The controller 150 generates instruction signals for operating the feeding device 120 and the pressing device 130, respectively, based on a program recorded in a recording medium (not shown), an operation input from an operator, or the like, and sends the instruction signals to the feeding device 120 and the pressing device 130.

[ Press apparatus ]

Next, the press apparatus 130 will be described with reference to fig. 7 to 9. The press device 130 includes: a function of sequentially press-working the electromagnetic steel sheets W intermittently fed out by the feeding device 120 to form the press member 10; the function of manufacturing the laminated stator core 1 is to sequentially stack the stamped members 10 obtained by the stamping process and to combine them.

As shown in fig. 7 and 8, the press machine 130 includes a base 131, a lower die 132, a die plate 133, a stripper 134, an upper die 135, a top plate 136, a press machine 137 (driving unit), a spreader 138, punches a1 to a6, and press pins B1 to B6. The base 131 supports a lower mold 132 placed on the base 131.

The lower die 132 holds a die platen 133 placed on the lower die 132. In the lower die 132, discharge holes C1 to C6 through which a material (for example, a punched member 10, scrap, or the like) punched out of the electromagnetic steel sheet W is discharged are provided at positions corresponding to the punches a1 to a6, respectively. In the discharge hole C6, as shown in fig. 9, a cylinder 132a, a table 132b, and a pusher 132C are disposed.

The cylinder 132a supports the punch member 10 in order to prevent the punch member 10 punched out of the magnetic steel sheet W by the punch a6 from falling downward. The cylinder 132a is configured to be movable in the vertical direction based on an instruction signal from the controller 150. Specifically, the cylinder 132a intermittently moves downward each time the pressing member 10 is deposited on the cylinder 132 a. When the punching member 10 is laminated to a predetermined number of sheets in the cylinder 132a and the stator laminated core 1 is formed, the cylinder 132a is moved to a position where the surface of the cylinder 132a and the surface of the table 132b are at the same height.

The table 132b is provided with a hole through which the cylinder 132a can pass. The pusher 132c is configured to be movable in the horizontal direction on the surface of the table 132b based on an instruction signal from the controller 150. The pusher 132c pushes the stator laminated core 1 from the cylinder 132a toward the table 132b in a state where the cylinder 132a moves to a position where the surface of the cylinder 132a and the surface of the table 132b are at the same height. The stator laminated core 1 pushed out to the table 132b is conveyed to the outside of the manufacturing apparatus 100.

Returning to fig. 8, the die plate 133 has a function of molding the press member 10 together with the punches a1 to a 6. Dies D1 to D6 are provided on the die plate 133 at positions corresponding to the punches a1 to a6, respectively. Through holes D1a to D6a (punch holes) extending in the vertical direction and communicating with the corresponding discharge holes C1 to C6 are provided in the dies D1 to D6. The diameters of the through holes D1a to D6a are set to be slightly smaller than the diameters of the distal end portions of the punches a1 to a6 that can be inserted therethrough. The die plate 133 is provided with insertion holes E1 to E6 at positions corresponding to the pressing pins B1 to B6, respectively.

The stripper plate 134 has a stripper plate 134a, a retainer plate 134 b. The stripper plate 134a has a function of removing the electromagnetic steel sheet W biting into the punches a1 to a6 from the punches a1 to a6 when the electromagnetic steel sheet W is punched by the punches a1 to a 6. The stripper plate 134a is located above the die plate 133. The holding plate 134b holds the discharge plate 134a from above.

The stripper 134 has through holes F1 to F6 at positions corresponding to the punches a1 to a6, respectively. The through holes F1 to F6 extend in the vertical direction and communicate with the through holes D1a to D6a of the corresponding dies D1 to D6 when the stripper plate 134a contacts the die plate 133. The lower portions of the punches a1 to a6 are inserted into the through holes F1 to F6, respectively. The lower portions of the punches a1 to a6 are slidable in the through holes F1 to F6, respectively.

The stripper 134 has through holes F7 to F12 at positions corresponding to the pressing pins B1 to B6, respectively. The through holes F7 to F12 extend in the vertical direction and communicate with the corresponding insertion holes E1 to E6 when the stripper plate 134a contacts the die plate 133. The lower portions of the pressing pins B1 to B6 are inserted into the through holes F7 to F12, respectively. The lower portions of the pressing pins B1 to B6 are slidable in the through holes F7 to F12, respectively.

Upper die 135 is positioned above stripper 134. The upper die 135 is fixed with bases (upper portions) of punches a1 to a6 and pressing pins B1 to B6. Therefore, the upper die 135 holds the punches a1 to a6 and the pressing pins B1 to B6. An accommodating space 135a located on the top plate 136 side and extending in the vertical direction is provided at each of the upstream and downstream ends of the press device 130 in the upper die 135; a through hole 135b penetrating downward from the accommodating space 135 a.

The top plate 136 is located above the upper die 135. The top plate 136 holds the upper die 135. The press 137 is located above the top plate 136. The piston of the pressurizing machine 137 is connected to the top plate 136 and operates based on an instruction signal from the controller 150. When the press 137 is operated, the piston extends and contracts, and the punch press 134, the upper die 135, the top plate 136, the hanger 138, the punches a1 to a6, and the press pins B1 to B6 (hereinafter, these are referred to as the movable part 160) move up and down as a whole.

A spreader 138 suspends and holds stripper 134 to upper die 135. Spreader 138 has an elongated stem 138 a; a head portion 138b disposed at the upper end of the stem portion 138 a. The lower end of the stem 138a is secured to the stripper plate 134. The upper end of the rod 138a is inserted into the through hole 135b of the upper die 135. The head portion 138b has a larger diameter than the lower end portion and is accommodated in the accommodation space 135a of the upper die 135. Therefore, the head portion 138b can move up and down with respect to the upper die 135 within the accommodation space 135 a.

The punches a1 to a6 have a function of punching the electromagnetic steel sheet W into a predetermined shape together with the die plate 133 (dies D1 to D6). The punches a1 to a6 are arranged in this order from the upstream side (the feeder 120 side) of the press apparatus 130 to the downstream side. The plurality of punches a1 are arranged in a row in the width direction of the electromagnetic steel sheet W (hereinafter simply referred to as the width direction). The plurality of punches a2 are arranged in a row in the width direction. The plurality of punches a3 are arranged in a row in the width direction. The plurality of punches a4 are arranged in a row in the width direction. The plurality of punches a5 are arranged in a row in the width direction. The plurality of punches a6 are arranged in a row in the width direction.

The end shapes of the punches a1 are all substantially the same. That is, the electromagnetic steel sheet W is punched by the punches a1 in substantially the same shape. The end shapes of the punches a2 are all substantially the same. That is, the electromagnetic steel sheet W is punched by the punches a2 in substantially the same shape. The shapes of the ends of the punches a3 are different from each other. That is, the punching shapes of the magnetic steel sheets W by the punches a3 do not match each other.

The end shapes of the punches a4 are all substantially the same. That is, the electromagnetic steel sheet W is punched by the punches a4 in substantially the same shape. The end shapes of the punches a5 are all substantially the same. That is, the electromagnetic steel sheet W is punched by the punches a5 in substantially the same shape. The end shapes of the punches a6 are all substantially the same. That is, the electromagnetic steel sheet W is punched by the punches a6 in substantially the same shape.

The pressing pins B1 to B6 have a function of pressing the electromagnetic steel sheet W against the die plate 133 when the electromagnetic steel sheet W is punched out by the punches a1 to a 6. The pressing pins B1 to B6 are arranged in this order from the upstream side (the feeder 120 side) of the press apparatus 130 to the downstream side.

[ method for manufacturing laminated stator core ]

Next, a method of manufacturing the stator laminated core 1 will be described with reference to fig. 7 to 10. First, when the magnetic steel sheet W is sent out to the press apparatus 130 by the sending-out apparatus 120 and the portion to be processed of the magnetic steel sheet W reaches the punch a1, the controller 150 instructs the press machine 137 to push the movable portion 160 downward toward the die plate 133 by the press machine 137. After the stripper 134 reaches the die plate 133 and clamps the electromagnetic steel sheet W by these, the controller 150 instructs the pressing machine 137 to press the movable portion 160 downward by the pressing machine 137.

At this time, the punches a1 to a6 and the tip ends of the pressing pins B1 to B6 move in the through holes F1 to F12 of the stripper plate 104 and reach the corresponding through holes D1a to D6a and the insertion holes E1 to E6 in the die plate 133 without moving the stripper plate 134. Therefore, the magnetic steel sheet W is punched by the punch a1 along a predetermined punching shape, and a pair of through holes W1 are formed near both side edges of the magnetic steel sheet W (refer to position S1 in fig. 8 and 10). That is, the pair of through holes W1 are arranged in a row in the width direction. The punched waste material is discharged from the discharge hole C1 of the lower die 132. Thereafter, the press 137 operates to raise the movable portion 160.

Next, when the electromagnetic steel sheet W is sent out by the sending-out device 120 and the portion to be processed of the electromagnetic steel sheet W reaches the punch a2, the controller 150 instructs the press 137 to move the movable portion 160 up and down. Thus, in the width direction, the magnetic steel sheet W is punched along a predetermined punching shape by a plurality of punches a2 arranged in a row, and a plurality of punched portions W2 are formed in the magnetic steel sheet W (refer to position S3 in fig. 8 and 10). That is, the plurality of punched portions W2 are arranged in a row in the width direction.

Each punch portion W2 is formed of 6 through holes arranged in a circular shape in fig. 10. Each through hole corresponds to the slit 10b of the punch member 10. The punched waste material is discharged from the discharge hole C2 of the lower die 132. When the electromagnetic steel sheet W is punched by the punch a2, the press pins B1 and B2 are inserted into the through hole W1 and the insertion holes E1 and E2 (see positions S2 and S4 in fig. 8 and 10).

Next, when the electromagnetic steel sheet W is sent out by the sending-out device 120 and the portion to be processed of the electromagnetic steel sheet W reaches the punch a3, the controller 150 instructs the press 137 to move the movable portion 160 up and down. Thus, in the width direction, the electromagnetic steel sheet W is punched along a predetermined punching shape by a plurality of punches a3 arranged in a row, and a plurality of punched portions W3₁～W3_N(N is a natural number of 2 or more) is formed in the magnetic steel sheet W (see position S5 in fig. 8 and 10). Namely, a plurality of pressed parts W3₁～W_3NArranged in a row in the width direction.

Each punching part W3₁～W3_NIn fig. 10, the through holes are 6 through holes arranged in a circular shape. The inner peripheral edge of each through hole corresponds to the deformed portion 15 of the stamped-out member 10. Here, since the end shapes of the plurality of punches a3 arranged in a row in the width direction are different from each other, each punch portion W3₁～W3_NThe pressed shapes (shapes of the inner peripheral edges of the through holes) of the pressing portions do not coincide with each other. The punched waste material is discharged from the discharge hole C3 of the lower die 132. When the electromagnetic steel sheet W is punched by the punch a3, the press pins B2 and B3 are inserted into the through hole W1 and the insertion holes E2 and E3 (see positions S4 and S6 in fig. 8 and 10).

Next, when the electromagnetic steel sheet W is sent out by the sending-out device 120 and the portion to be processed of the electromagnetic steel sheet W reaches the punch a4, the controller 150 instructs the press 137 to move the movable portion 160 up and down. Thus, the electromagnetic steel sheet W is punched or half-punched along a predetermined punching shape by the plurality of punches a4 arranged in the width direction, and the plurality of processed portions W4 are formed in the electromagnetic steel sheet W (see position S7 in fig. 8 and 10). That is, the plurality of processed portions W4 are arranged in a row in the width direction.

Each processing portion W4 is formed of 6 through holes or concave-convex portions arranged in a circular shape in fig. 10. Each through hole corresponds to a through hole of the caulking portion 7. Each of the uneven portions corresponds to caulking of the caulking portion 7. When each processing portion W4 is a through hole, the punched scrap is discharged from the discharge hole C4 of the lower die 132. When the electromagnetic steel sheet W is punched by the punch a4, the press pins B3 and B4 are inserted into the through hole W1 and the insertion holes E3 and E4 (see positions S6 and S8 in fig. 8 and 10).

Next, when the electromagnetic steel sheet W is sent out by the sending-out device 120 and the portion to be processed of the electromagnetic steel sheet W reaches the punch a5, the controller 150 instructs the press 137 to move the movable portion 160 up and down. Thus, the magnetic steel sheet W is punched by the plurality of punches a5 arranged in a row in the width direction, and the plurality of punched portions W5 are formed in the magnetic steel sheet W (see position S9 in fig. 8 and 10). That is, the plurality of punched portions W5 are arranged in a row in the width direction.

Each stamped portion W5 includes in fig. 10: one through hole in the center surrounded by the pressed portion W2; and 3 through holes arranged in a circular shape outside the pressed portion W2. One through hole at the center corresponds to the through hole 10a of the punch member 10. The 3 through holes on the outer periphery correspond to the through holes 14a of the punch member 10. The punched waste material is discharged from the discharge hole C5 of the lower die 132. When the electromagnetic steel sheet W is punched by the punch a5, the press pins B4 and B5 are inserted into the through hole W1 and the insertion holes E4 and E5 (see positions S8 and S10 in fig. 8 and 10).

Next, when the electromagnetic steel sheet W is sent out by the sending-out device 120 and the portion to be processed of the electromagnetic steel sheet W reaches the punch a6, the controller 150 instructs the press 137 to move the movable portion 160 up and down. Thus, in the width direction, the magnetic steel sheet W is punched along a predetermined punching shape by a plurality of punches a6 arranged in a row, and a plurality of punched portions W6 are formed in the magnetic steel sheet W (refer to position S11 in fig. 8 and 10). That is, the plurality of punched portions W6 are arranged in a row in the width direction. In other words, the punched portions W6 are located at the 1 st to nth positions arranged in a row in the width direction.

In fig. 10, each stamped part W6 has a ring shape corresponding to the shape of the outer peripheral edge of the stamped part 10 except for the deformed part 15. Thereby, a plurality of the punch members 10 are formed in the width direction₁～10_N(refer to position S11 of fig. 8 and 10). When the electromagnetic steel sheet W is punched by the punch A6, the press pin B5 is inserted into the through hole W1 and the insertion holes E5 and E6,B6 (refer to positions S10 and S12 in fig. 8 and 10). Thus, each of the punched parts 10₁～10_NThe punching members 10 are respectively placed on the cylinder 132a in the discharge hole C6 and punched and dropped₁～10_NAnd bonding and laminating. The above steps are repeated to form the stator laminated core 1. The identification mark 6 may be formed by laser marking or the like after the punch member 10 is ejected from the die (the lower die 132 and the upper die 135) and reaches the ejection hole C6.

Here, since the pressed shapes of the pressed portions W31 to W3N do not match each other, the pressed member 10₁～10_NAre also mutually inconsistent. For example, when N is 2, the punch member 10 is formed₁The punched member 10A exemplified in FIG. 4(a) can be formed as the punched member 10₂The stamped component 10B illustrated in fig. 4(B) can also be formed. At this time, the press member 10 is pressed₁And a press member 10₂The shape of the odd-shaped portion 15A is different from a at C, the shape of the odd-shaped portion 15C is different from C at b, and the shape of the odd-shaped portion 15E is different from b at a. Thus, the stamped component 10₁At least 1 of the plurality of profiles 15 has a shape or configuration corresponding to the shape or configuration of the stamped part 10₂At least 1 of the plurality of profiles 15 differs in shape or configuration.

Function of

In the present embodiment as described above, the stamped member 10 stamped and dropped from the electrical steel sheet W₁～10_NA plurality of the irregularly shaped portions 15 are formed at positions overlapping each other when stacked. In the present embodiment, the press member 10₁～10_NOf (2) a press part 10_kAt least 1 of the plurality of profiles 15 is shaped or arranged in relation to the stamped part 10₁～10_NOf (2) a press part 10_mAt least 1 of the plurality of profiles 15 differ in shape or configuration, so that the component 10 is stamped_k(k is a natural number of 1 to N) shape and press member 10_m(m is 1 to N and m.noteq.k) are not consistent with each other. Therefore, the electromagnetic steel sheet W is provided with the punch members 10 punched at the 1 st to N th positions in the width direction thereof₁～10_NSince the shapes of the punch members 10 are different from each other, it is possible to determine which position among the 1 st to nth positions the arbitrary punch member 10 is punched out.

In the present embodiment, the pressed member 10 is formed with the plurality of irregularly shaped portions 15 for the sake of convenience in manufacturing the laminated stator core 1. According to the shape or configuration of the profile 15, the component 10 is punched_kShape and punch component 10_mThe shapes are distinguished. Therefore, since the existing punch, die, and the like for forming the irregularly shaped portion 15 can be used to identify the different punching members 10 from each other, it is not necessary to newly add a punch, a die, and the like for identifying the punching members 10. As described above, it is possible to determine from which position in the width direction of the metal plate W the punching member 10 is punched out, while suppressing the complexity of the apparatus.

In the present embodiment, the irregularly shaped portion 15 has both: a function for identifying a punching position of the punch member 10; a function as a welded portion 21 that joins the stamped parts 10 to each other by welding; 3 functions as a rotation lamination recognition unit for recognizing the boundary of the rotation lamination. Therefore, it is not necessary to separately provide the pressing member 10 with members and shapes for performing these functions.

In the present embodiment, the identification mark 6 for identifying the front and back sides of the punch member 10 is formed on the punch member 10. Therefore, even if the shapes of the 2 punch members 10 different from each other are matched when the front and back sides are reversed, it is possible to determine at which position of the electromagnetic steel sheet W the punch members 10 are punched out. Therefore, by using the identification mark 6 in addition to the type of the shape of the irregularly shaped portion 15, the number of patterns of the shape of the punch member 10 that do not overlap can be increased.

[ other embodiments ]

While the embodiments according to the present invention have been described in detail, various modifications may be made to the embodiments within the scope of the gist of the present invention. For example, the identifying mark 6 may not be provided on the punch member 10.

The punch member 10 may have a ring shape other than a circular ring. The punch member 10 may not be annular. That is, the punch member 10 may be 1 metal piece which is formed in a ring shape when a plurality of punch members 10 are combined and which constitutes the split die laminated core.

In order to join the plurality of stamped parts 10, various known methods may be employed in addition to the rivet 7, or instead of the rivet 7. For example, the plurality of press members 10 may be joined by joining using an adhesive or a resin material, welding, or the like. Among them, from the viewpoint of low cost and work efficiency, the plurality of press members 10 may be joined by caulking or welding. On the other hand, from the viewpoint of finding high torque of the motor and reducing iron loss, the plurality of press members 10 may be joined by joining using an adhesive or a resin material. Further, a pre-caulking plate (not shown) formed with a pre-caulking may be provided to the stamped members 10, the plurality of stamped members 10 may be joined by the pre-caulking of the pre-caulking plate to obtain an intermediate body, and then the pre-caulking block laminated with the pre-caulking plate may be removed from the intermediate body to obtain the stator laminated core 1. The preliminary caulking is caulking used to temporarily integrate the plurality of press members 10.

The irregularly shaped portions 15 may have other functions for the convenience of manufacturing the laminated stator core 1 in addition to the function of identifying the punching position of the punched member 10. For example, as shown in fig. 11, the shaped portion 15 may be a notch configured to allow the stamped component 10 to engage a protrusion of the die D6. In this case, when the punch a6 punches the stamped member 10 from the electromagnetic steel sheet W, the deformed portion 15 formed on the outer peripheral edge of the stamped member 10 (yoke 12) is fitted to the protrusion of the die D6, and therefore, when the punch a6 is pulled out from the die D6, the stamped member 10 can be prevented from being carried by the punch a6 and flying out of the die D6. That is, in the embodiment of fig. 11, the irregularly shaped portion 15 has both: a function for identifying a punching position of the punch member 10; the function of the fitting portion for fitting the punch member 10 to the die D6 is provided.

The shape of the irregularly shaped portion 15 is not particularly limited, and may be a concave shape, a convex shape, or a concave-convex shape.

The modified portions 15 may also be formed in the ear portions 14 of the stamped-out part 10. That is, the odd-shaped portions 5 may be formed in the ear-shaped portions 4 of the stator laminated core 1. In this case, the ear portion 14 (ear portion 4) is provided with a protrusion, a notch, or a concave-convex portion. In this case, the irregularly shaped portion 15 also has: a function for identifying a punching position of the punch member 10; a function as a welded portion 21 that joins the stamped parts 10 to each other by welding; 3 functions as a rotation lamination recognition unit for recognizing the boundary of the rotation lamination.

Riveting can also be used as the profiled section 15. For example, the stamped component 10_kCan be formed or arranged with the punch member 10_mThe shape or configuration of the rivets of (1) is different.

As shown in fig. 12, the present invention may be applied to a stamped component 30 of a laminated rotor core. In the form shown in fig. 12, a plurality of irregularly shaped portions 15 (2 irregularly shaped portions 15 in fig. 12) are formed on the inner peripheral edge of the pressed member 30. One irregularly shaped portion 15 is 1 convex portion protruding toward the center side of the stamped-out member 30. The other irregularly shaped portions 15 are 2 concave portions recessed toward the outer peripheral edge side of the stamped-out member 30. These 2 irregularly shaped portions 15 having different shapes can identify the boundary portion of the rotationally laminated sheet. That is, in the embodiment of fig. 12, the irregularly shaped portion 15 includes both: a function for identifying a punching position of the punch member 10; the function as a rotation layer identification unit for identifying the boundary of the rotation layer.