CA1077688A - Method for producing a pole piece for a generator - Google Patents
Method for producing a pole piece for a generatorInfo
- Publication number
- CA1077688A CA1077688A CA301,009A CA301009A CA1077688A CA 1077688 A CA1077688 A CA 1077688A CA 301009 A CA301009 A CA 301009A CA 1077688 A CA1077688 A CA 1077688A
- Authority
- CA
- Canada
- Prior art keywords
- workpiece
- annular projection
- disc portion
- pole piece
- generator
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K1/00—Making machine elements
- B21K1/28—Making machine elements wheels; discs
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacture Of Motors, Generators (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
Abstract
METHOD FOR PRODUCING A POLE PIECE FOR A GENERATOR
Abstract of the Disclosure The specification discloses a method for producing a pole piece for a generator from a round steel bar material in which a slug or workpiece of a length suitable for said pole piece is cut off the bar material, the workpiece is extruded to form an annular projection at one end of the workpiece, the workpiece is upset to form a radially outwardly extending bulge on the main portion of the workpiece, the workpiece is pressed to deform the bulge into a circular disc portion and spiders integral with and extending radially outwardly from the outer periphery of the disc portion, the spiders are shaped or trimmed, a center hole is punched through the disc portion, the spiders are bent on the side of the annular projection of the workpiece in a direction parallel to the common axis of the annular pro-jection and the center hole and the workpiece is finally trimmed.
By this method, the use of conventional high capacity presses can be avoided with a consequent reduction in production costs.
Abstract of the Disclosure The specification discloses a method for producing a pole piece for a generator from a round steel bar material in which a slug or workpiece of a length suitable for said pole piece is cut off the bar material, the workpiece is extruded to form an annular projection at one end of the workpiece, the workpiece is upset to form a radially outwardly extending bulge on the main portion of the workpiece, the workpiece is pressed to deform the bulge into a circular disc portion and spiders integral with and extending radially outwardly from the outer periphery of the disc portion, the spiders are shaped or trimmed, a center hole is punched through the disc portion, the spiders are bent on the side of the annular projection of the workpiece in a direction parallel to the common axis of the annular pro-jection and the center hole and the workpiece is finally trimmed.
By this method, the use of conventional high capacity presses can be avoided with a consequent reduction in production costs.
Description
lQ77688 This invention relates to a method for producing a pole piece for use as a component of a rotor of a generator of the type referred to as an alternator in the automobile industry, i.e. a pole piece for a generator which is adapted to produce alternating current and to supply the current as direct current.
In generators of the above type, two pole pieces are mounted on a generator rotor shaft in a spaced relationship to each other. In the prior art, such pole piece have been produced by mechanically cutting a slug or workpiece of a predetermined length off a round steel bar mate-rial and mechanically processing the workpiece. This has required a relatively high capacity press line including various mechanical cutting means, resulting in high production costs.
Therefore, the purpose of the present invention is to provide a method for producing a pole piece of the above type which can perform all the processing steps without requiring any mechanical cutting means, except in the initial step in which the workpiece is cut off a round steel bar material, which can employ a relatively low capacity press line for performing the processing steps preferably at room temperature, which can attain a high yield rate.
According to the invention there is provided a method for producing a pole piece for a generator comprising the steps of (a) extruding one end of a cylindrical steel workpiece to form an annular projection of reduced diameter at one end of said workpiece; (b) upsetting said workpiece so as to cause the main portion adjacent said annular projection to bulge radially outwardly, (c) deforming said bulged main portion into a central disc portion with said annular projection integrally formed on one face thereof and said ~ .
disc portion having at the periphery thereof a plurality of - radial projections integrally formed therewith, said projections being of substantial length relative to the radius of the original workpiece, (d) punching a hole through the center of said disc portion and coincident with said annular projection, and (e) bending the outer portions of said radial projections in the direction of said annular projection to form teeth members having peripheral portions parallel to the axis of the central hole and radially spaced from said annular projection.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings show a workpiece in various stages of formation according to a preferred method of the present invention as described in detail in the following.
In the drawings:-Fig. 1 is an isometric view of a slug formed by cutting a section of a suitable length off a round steel bar material in a first method step;
Fig. 2A is an end elevational view of one half portion of said workpiece processed in a second method step and cut across the longitudinal axis of the workpiece;
Fig. 2B is a vertically sectional view of said workpiece shown in Fig. 2A taken along the longitudinal axis of said workpiece;
Fig. 3A is a plan view of one half portion of said workpiece processed in a third method step and cut across the longitudinal axis of the workpiece;
Fig. 3B is a vertically sectional view of said workpiece of Fig. 3A taken along the longitudinal axis of the workpiece. ~
1C~77688 Fig. 4A is a plan view of one half portion of said workpiece processed in a fourth method step and cut across the longitudinal axis of the workpiece;
Fig. 4B is a vertically sectional view of said workpiece of Fig. 4A taken along the longitudinal axis of the workpiece;
Fig. 5A is a plan view of one half portion of said workpiece processed in a fifth method step and cut across the longitudinal axis of the workpiece;
Fig. 5B is a vertically sectional view of said workpiece - 3a -~,, of Fig. 5A taken along the longitudinal axis of the workpiece;
Fig. 6A is a plan view of one half portion of said workpiece processed in a sixth method step and cut across the longitudinal axis of the workpiece;
Fig, 6B is a vertically sectional view of said workpiece of Fig. 6A taken along the longitudinal axis of the workpiece;
Fig. 7A is a plan view of one half portion of said workpiece processed in a seventh method step and cut across the longitudinal axis of the workpiece;
Fig. 7B is a vertically sectional view of said workpiece of Fig. 7A taken along the longitudinal axis of the workpiece, Fig. 8A is a plan view of one half portion of said workpiece processed in an eighth method step and cut across the longitudinal axis of the workpiece;
Fig. 8B is a vertically sectional view of said workpiece of Fig. 8A taken along the longitudinal axis of the workpiece;
and Fig. 9 is a cross-sectional view which shows a pair of pole pieces assembled on the rotor of a generator with the 20 annular projections of the pole pieces abutting against each other.
One preferred embodiment of the method of the present invention will be now described with reference to the accompanying drawings.
First of all, a round steel bar material is provided and a section is cut off having a length suitable for forming the desired pole piece by means of a suitable cutter to obtain a slug or workpiece 1 as shown in Fig. 1.
The slug or workpiece 1 is extruded in a press so as 30 to form a reduced diameter annular projection 2 at one end of `-the workpiece 1 a~ shown in Figs. 2A and 2B.
., ~' ,.
1~:)7768l5 After the extruding step, the workpiece i8 upset 80 as to cause the main portion of the workpiece to bulge radially outwardly so as to form a bulge 1' as shown in Figs. 3A and 3B.
The workpiece is then subjected to a fourth step in which it is processed so as to deform the bulge 1' into a disc portion 3, coaxial with the annular projection 2 and having a diameter greater than and a thickness smaller than that of the bulge l', and spiders 3' integral with and extending radially outwardly from the outer periphery of the disc portion as shown in Figs. 4A and 4B.
The thus processed workpiece is then subjected to a fifth step in the method in which the spiders 3' are shaped or trimmed as shown in Figs. 5A and 5B.
After the fifth step, the thus processed workpiece is turned upside down to locate the disc portion 3 at the bottom and an axial hole 4 is punched through the disc portion 3 in communication with the opening defined by the annular projection
In generators of the above type, two pole pieces are mounted on a generator rotor shaft in a spaced relationship to each other. In the prior art, such pole piece have been produced by mechanically cutting a slug or workpiece of a predetermined length off a round steel bar mate-rial and mechanically processing the workpiece. This has required a relatively high capacity press line including various mechanical cutting means, resulting in high production costs.
Therefore, the purpose of the present invention is to provide a method for producing a pole piece of the above type which can perform all the processing steps without requiring any mechanical cutting means, except in the initial step in which the workpiece is cut off a round steel bar material, which can employ a relatively low capacity press line for performing the processing steps preferably at room temperature, which can attain a high yield rate.
According to the invention there is provided a method for producing a pole piece for a generator comprising the steps of (a) extruding one end of a cylindrical steel workpiece to form an annular projection of reduced diameter at one end of said workpiece; (b) upsetting said workpiece so as to cause the main portion adjacent said annular projection to bulge radially outwardly, (c) deforming said bulged main portion into a central disc portion with said annular projection integrally formed on one face thereof and said ~ .
disc portion having at the periphery thereof a plurality of - radial projections integrally formed therewith, said projections being of substantial length relative to the radius of the original workpiece, (d) punching a hole through the center of said disc portion and coincident with said annular projection, and (e) bending the outer portions of said radial projections in the direction of said annular projection to form teeth members having peripheral portions parallel to the axis of the central hole and radially spaced from said annular projection.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings show a workpiece in various stages of formation according to a preferred method of the present invention as described in detail in the following.
In the drawings:-Fig. 1 is an isometric view of a slug formed by cutting a section of a suitable length off a round steel bar material in a first method step;
Fig. 2A is an end elevational view of one half portion of said workpiece processed in a second method step and cut across the longitudinal axis of the workpiece;
Fig. 2B is a vertically sectional view of said workpiece shown in Fig. 2A taken along the longitudinal axis of said workpiece;
Fig. 3A is a plan view of one half portion of said workpiece processed in a third method step and cut across the longitudinal axis of the workpiece;
Fig. 3B is a vertically sectional view of said workpiece of Fig. 3A taken along the longitudinal axis of the workpiece. ~
1C~77688 Fig. 4A is a plan view of one half portion of said workpiece processed in a fourth method step and cut across the longitudinal axis of the workpiece;
Fig. 4B is a vertically sectional view of said workpiece of Fig. 4A taken along the longitudinal axis of the workpiece;
Fig. 5A is a plan view of one half portion of said workpiece processed in a fifth method step and cut across the longitudinal axis of the workpiece;
Fig. 5B is a vertically sectional view of said workpiece - 3a -~,, of Fig. 5A taken along the longitudinal axis of the workpiece;
Fig. 6A is a plan view of one half portion of said workpiece processed in a sixth method step and cut across the longitudinal axis of the workpiece;
Fig, 6B is a vertically sectional view of said workpiece of Fig. 6A taken along the longitudinal axis of the workpiece;
Fig. 7A is a plan view of one half portion of said workpiece processed in a seventh method step and cut across the longitudinal axis of the workpiece;
Fig. 7B is a vertically sectional view of said workpiece of Fig. 7A taken along the longitudinal axis of the workpiece, Fig. 8A is a plan view of one half portion of said workpiece processed in an eighth method step and cut across the longitudinal axis of the workpiece;
Fig. 8B is a vertically sectional view of said workpiece of Fig. 8A taken along the longitudinal axis of the workpiece;
and Fig. 9 is a cross-sectional view which shows a pair of pole pieces assembled on the rotor of a generator with the 20 annular projections of the pole pieces abutting against each other.
One preferred embodiment of the method of the present invention will be now described with reference to the accompanying drawings.
First of all, a round steel bar material is provided and a section is cut off having a length suitable for forming the desired pole piece by means of a suitable cutter to obtain a slug or workpiece 1 as shown in Fig. 1.
The slug or workpiece 1 is extruded in a press so as 30 to form a reduced diameter annular projection 2 at one end of `-the workpiece 1 a~ shown in Figs. 2A and 2B.
., ~' ,.
1~:)7768l5 After the extruding step, the workpiece i8 upset 80 as to cause the main portion of the workpiece to bulge radially outwardly so as to form a bulge 1' as shown in Figs. 3A and 3B.
The workpiece is then subjected to a fourth step in which it is processed so as to deform the bulge 1' into a disc portion 3, coaxial with the annular projection 2 and having a diameter greater than and a thickness smaller than that of the bulge l', and spiders 3' integral with and extending radially outwardly from the outer periphery of the disc portion as shown in Figs. 4A and 4B.
The thus processed workpiece is then subjected to a fifth step in the method in which the spiders 3' are shaped or trimmed as shown in Figs. 5A and 5B.
After the fifth step, the thus processed workpiece is turned upside down to locate the disc portion 3 at the bottom and an axial hole 4 is punched through the disc portion 3 in communication with the opening defined by the annular projection
2, as shown in Figs. 6A and 6B. In forming the hole 4 in the workpiece, it is necessary only to punch through the disc portion 3 which is of reduced thickness as a result of the second step. Thus~ it will be understood that the service life ,, of the punch die employed in the punching step may therefore be quite long.
After the sixth step, the workpiece is subjected to a bending step in a press to bend the spiders 3' on the sides of ' the annular projections 2 of the workpiece in a direction parallel to the common axis of the center or axial hole 4 and the annular projection 2 as shown in Figs. 7A and 7B.
Finally, the workpiece is subjected to a sizing step to obtain a complete product or pole piece 5 as shown in Figs.
8A and 8B.
1077~;88 As shown in Fig. 9, in practice, a pair of pole pieces 5, 5 produced by the method as mentioned hereinabove are mounted on a rotary shaft 6 of a generator by means of the axial holes 4, 4 with the annular projections 2, 2 of the pole pieces 5, 5 abutting against each other to thereby form the rotor assembly of the generator.
All the steps in the method from the first step to the last step can be performed at room temperature. Since the annular projection 2 is formed by extrusion in the second step, the centering of the workpiece in the succeeding steps can be easily achieved. In the sixth step of the method for forming the axial hole 4, since it is necessary to punch through only the reduced thickness disc portion 3, the service life of the punch die is increased and the hole 4 can be precisely formed with a smooth hole surface. If the entire thickness of the workpiece including the annular pro~ection 2 had to be punched, the service life of the die employed in the punching of the center hole 4 would be reduced. Moreover, if the center hole forming operation were performed by means of a lathe or other turning means~ there would be the problem that, when the pole piece is fitted on the rotary shaft, so-called "biting" would occur because of the presence of traces of metal on the hole surface scored by the cutting tool. This can be effectively avoided by the present invention. The method of the present invention can also be made automatic by a press line directly connected to an assembly line.
The load applied to the presses employed is relatively small and a relatively small amount of scrap material is gener-ated, thereby increasing the yield rate. Furthermore, the pole pieces may be made o~ less expensive rimmed steel rather than expensive killed stePl as conventionally used in the prior art 1~77688 methods for producing pole pieces. Thus, the overall productlon cost can be reduced and labor expense can be saved, While one embodiment of the invention has been shown and described in detail, it will be understood that the same is for illustration purpose only and not to be taken as a definition of the invention, reference being had for this purpose to the appended clai.ms.
After the sixth step, the workpiece is subjected to a bending step in a press to bend the spiders 3' on the sides of ' the annular projections 2 of the workpiece in a direction parallel to the common axis of the center or axial hole 4 and the annular projection 2 as shown in Figs. 7A and 7B.
Finally, the workpiece is subjected to a sizing step to obtain a complete product or pole piece 5 as shown in Figs.
8A and 8B.
1077~;88 As shown in Fig. 9, in practice, a pair of pole pieces 5, 5 produced by the method as mentioned hereinabove are mounted on a rotary shaft 6 of a generator by means of the axial holes 4, 4 with the annular projections 2, 2 of the pole pieces 5, 5 abutting against each other to thereby form the rotor assembly of the generator.
All the steps in the method from the first step to the last step can be performed at room temperature. Since the annular projection 2 is formed by extrusion in the second step, the centering of the workpiece in the succeeding steps can be easily achieved. In the sixth step of the method for forming the axial hole 4, since it is necessary to punch through only the reduced thickness disc portion 3, the service life of the punch die is increased and the hole 4 can be precisely formed with a smooth hole surface. If the entire thickness of the workpiece including the annular pro~ection 2 had to be punched, the service life of the die employed in the punching of the center hole 4 would be reduced. Moreover, if the center hole forming operation were performed by means of a lathe or other turning means~ there would be the problem that, when the pole piece is fitted on the rotary shaft, so-called "biting" would occur because of the presence of traces of metal on the hole surface scored by the cutting tool. This can be effectively avoided by the present invention. The method of the present invention can also be made automatic by a press line directly connected to an assembly line.
The load applied to the presses employed is relatively small and a relatively small amount of scrap material is gener-ated, thereby increasing the yield rate. Furthermore, the pole pieces may be made o~ less expensive rimmed steel rather than expensive killed stePl as conventionally used in the prior art 1~77688 methods for producing pole pieces. Thus, the overall productlon cost can be reduced and labor expense can be saved, While one embodiment of the invention has been shown and described in detail, it will be understood that the same is for illustration purpose only and not to be taken as a definition of the invention, reference being had for this purpose to the appended clai.ms.
Claims (3)
1. A method for producing a pole piece for a generator by cold forming comprising the steps of:
(a) extruding one end of a cylindrical steel workpiece to form an annular projection of reduced diameter at one end of said workpiece;
(b) upsetting said workpiece so as to cause the main portion adjacent said annular projection to bulge radially outwardly, (c) deforming said bulged main portion into a central disc portion with said annular projection integrally formed on one face thereof and said disc portion having at the periphery thereof a plurality of radial projections integrally formed therewith, said projections being of substantial length relative to the radius of the original workpiece, (d) punching a hole through the center of said disc portion and coincident with said annular projection, and (e) bending the outer portions of said radial projections in the direction of said annular projection to form teeth members having peripheral portions parallel to the axis of the central hole and radially spaced from said annular projection.
(a) extruding one end of a cylindrical steel workpiece to form an annular projection of reduced diameter at one end of said workpiece;
(b) upsetting said workpiece so as to cause the main portion adjacent said annular projection to bulge radially outwardly, (c) deforming said bulged main portion into a central disc portion with said annular projection integrally formed on one face thereof and said disc portion having at the periphery thereof a plurality of radial projections integrally formed therewith, said projections being of substantial length relative to the radius of the original workpiece, (d) punching a hole through the center of said disc portion and coincident with said annular projection, and (e) bending the outer portions of said radial projections in the direction of said annular projection to form teeth members having peripheral portions parallel to the axis of the central hole and radially spaced from said annular projection.
2. The method as set forth in Claim 1, further including the step of trimming said radial projections between said deforming and punching steps.
3. The method as set forth in Claim 1, further including the step of finally sizing the workpiece after said bending step.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA301,009A CA1077688A (en) | 1978-04-12 | 1978-04-12 | Method for producing a pole piece for a generator |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA301,009A CA1077688A (en) | 1978-04-12 | 1978-04-12 | Method for producing a pole piece for a generator |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1077688A true CA1077688A (en) | 1980-05-20 |
Family
ID=4111219
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA301,009A Expired CA1077688A (en) | 1978-04-12 | 1978-04-12 | Method for producing a pole piece for a generator |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1077688A (en) |
-
1978
- 1978-04-12 CA CA301,009A patent/CA1077688A/en not_active Expired
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |