WO2016104686A1 - 積層鉄心用の打抜き加工方法及び積層鉄心の製造方法 - Google Patents
積層鉄心用の打抜き加工方法及び積層鉄心の製造方法 Download PDFInfo
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- WO2016104686A1 WO2016104686A1 PCT/JP2015/086190 JP2015086190W WO2016104686A1 WO 2016104686 A1 WO2016104686 A1 WO 2016104686A1 JP 2015086190 W JP2015086190 W JP 2015086190W WO 2016104686 A1 WO2016104686 A1 WO 2016104686A1
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- iron core
- punching
- steel plates
- core
- closed curve
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title claims abstract description 73
- 238000000034 method Methods 0.000 title claims description 99
- 238000004519 manufacturing process Methods 0.000 title claims description 17
- 238000003672 processing method Methods 0.000 title abstract 2
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 118
- 239000010959 steel Substances 0.000 claims abstract description 118
- 238000004080 punching Methods 0.000 claims description 86
- 238000010030 laminating Methods 0.000 claims description 4
- 238000012545 processing Methods 0.000 abstract description 7
- 230000008569 process Effects 0.000 description 35
- 230000006866 deterioration Effects 0.000 description 25
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- 239000000853 adhesive Substances 0.000 description 7
- 230000001070 adhesive effect Effects 0.000 description 7
- 238000003825 pressing Methods 0.000 description 7
- 230000007423 decrease Effects 0.000 description 6
- 229910000576 Laminated steel Inorganic materials 0.000 description 4
- 229910052761 rare earth metal Inorganic materials 0.000 description 4
- 150000002910 rare earth metals Chemical class 0.000 description 4
- 238000010008 shearing Methods 0.000 description 4
- 230000006872 improvement Effects 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 230000002093 peripheral effect Effects 0.000 description 3
- 230000000452 restraining effect Effects 0.000 description 3
- 239000004819 Drying adhesive Substances 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 238000009776 industrial production Methods 0.000 description 2
- 150000002505 iron Chemical group 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 230000002265 prevention Effects 0.000 description 2
- 230000000750 progressive effect Effects 0.000 description 2
- 238000007665 sagging Methods 0.000 description 2
- 240000001973 Ficus microcarpa Species 0.000 description 1
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- 230000002411 adverse Effects 0.000 description 1
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- 238000002788 crimping Methods 0.000 description 1
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- 229920005989 resin Polymers 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
- B21D28/14—Dies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
- B21D28/10—Incompletely punching in such a manner that the parts are still coherent with the work
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/03—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal otherwise than by folding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/03—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal otherwise than by folding
- B21D39/031—Joining superposed plates by locally deforming without slitting or piercing
- B21D39/032—Joining superposed plates by locally deforming without slitting or piercing by fitting a projecting part integral with one plate in a hole of the other plate
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0233—Manufacturing of magnetic circuits made from sheets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
- H01F41/0266—Moulding; Pressing
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/14—Stator cores with salient poles
- H02K1/145—Stator cores with salient poles having an annular coil, e.g. of the claw-pole type
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/14—Stator cores with salient poles
- H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
- H02K1/148—Sectional cores
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/022—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with salient poles or claw-shaped poles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K7/00—Disposition of motor in, or adjacent to, traction wheel
- B60K7/0007—Disposition of motor in, or adjacent to, traction wheel the motor being electric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L2220/00—Electrical machine types; Structures or applications thereof
- B60L2220/50—Structural details of electrical machines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
- B60L3/0023—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
- B60L3/0061—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to electrical machines
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/64—Electric machine technologies in electromobility
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49075—Electromagnet, transformer or inductor including permanent magnet or core
- Y10T29/49078—Laminated
Definitions
- the present invention relates to a punching method for a laminated core and a method for manufacturing the laminated core.
- the iron cores for motors and generators are manufactured by punching a magnetic steel sheet with a thin plate thickness to suppress iron loss.
- a mold for processing is installed in a press machine, and each part of the iron core is punched out while feeding a steel sheet slit to a predetermined width by a coil feeder, and then integrated by stamping in the mold or after punching After the core piece is taken out of the mold, it is integrated by welding or bolting to produce an iron core.
- an iron core manufactured by laminating and integrating thin electromagnetic steel sheets will be referred to as a “laminated iron core”.
- the steel core is formed from the steel sheet by forming the shape of the iron core while sequentially feeding the steel sheet to the next pressing process in the mold and punching the outer periphery of the iron core in the final pressing process.
- a method of detaching is generally adopted.
- the method of integrating the laminated cores by fitting the caulking projections using the lowering action of the punch is also an industrial production of iron cores using caulking. It is adopted in.
- Patent Document 1 and Patent Document 2 before the punching process at the initial stage of the press process in the mold is performed.
- a technique for fixing steel plates to each other using caulking or the like has been proposed.
- Patent Document 3 a united locking portion is formed to fix the steel plates to each other, and the convex portion is flattened using a pushback so that the convex shape of the combined locking portion does not become an obstacle in the lamination process.
- Techniques for chemical processing have been proposed. All of these conventional techniques are measures against the problem of deterioration of dimensional accuracy when a plurality of steel sheets are simultaneously punched.
- Patent Documents 4 and 5 a single press is used to punch a plurality of steel sheets while preventing an increase in sagging and burrs by using a die having a plurality of portions corresponding to punches and dies inside. Technologies that can be implemented simultaneously in the process have been proposed.
- JP-A-55-156623 JP 2003-153503 A Japanese Patent Laying-Open No. 2005-261038 JP 2012-115893 A JP 2012-115894 A JP 2005-348456 A
- Patent Document 6 when a plurality of steel plates are overlapped and punched, the longitudinal end surfaces of the steel plates are welded, or 80% or more of the steel plate plane is 3 ⁇ m or more in thickness using a semi-cured resin.
- a technique has been proposed in which punching and caulking are simultaneously performed after bonding with an adhesive layer.
- this technique has a problem in terms of productivity and manufacturing cost because it is necessary to process a wide area such as 80% or more of the longitudinal end face or flat surface of the steel sheet.
- the present invention has been made in view of the above, and an object of the present invention is to provide a punching method for a laminated core capable of manufacturing a laminated core with high productivity while minimizing deterioration of magnetic properties of the laminated core, and It is providing the manufacturing method of a laminated iron core.
- the inventors of the present invention have a closed curve corresponding to the outermost punching portion of the iron core in the outermost punching process of the iron core, which has the longest circumference and is likely to cause deterioration of magnetic properties. It was thought that the steel plates were fixed to each other by punching in a state where the steel plates were superposed after both sides of the steel plate were previously fixed, and the deterioration of the magnetic properties of the iron core due to the punching processing could be suppressed. The inventors of the present invention have arrived at the present invention by examining in detail the conditions required for the fixing portion from the viewpoint of suppressing the deterioration of the magnetic properties of the iron core due to punching.
- the punching method for a laminated iron core is a method of punching a plurality of steel sheets in a state where a plurality of steel sheets are continuously fed into a mold and overlapped in a plurality of steps provided in the mold.
- the first fixed part located outside the closed curve corresponding to the outermost periphery of the laminated core and the second fixed part finally located in the part that becomes the laminated core
- the method includes a step of punching the outermost periphery of the laminated iron core after fixing a plurality of stacked steel plates to each other.
- the length of the line segment connecting the first fixing portion and the second fixing portion is 400 times the average plate thickness of the plurality of steel plates.
- the number of sets of the first fixing portion and the second fixing portion, which are the following, is set to 0.5 or more on average per 100 mm of the length of the closed curve.
- the length of the line segment connecting the first fixing portion and the second fixing portion is 400 times the average plate thickness of the plurality of steel plates.
- the average value of the distance between the fixed portion and the closed curve is 250 times or less the average plate thickness of a plurality of steel plates.
- the punching method for a laminated core according to the present invention is the above-described invention, wherein the fixing method of the plurality of steel plates in the second fixing part is a fixing method using caulking protrusions for forming the laminated core. It is characterized by being.
- the method for producing a laminated core according to the present invention includes a step of producing a laminated core by laminating and integrating the steel plates that have been punched by the punching method for a laminated core according to the present invention. To do.
- the punching method for a laminated core and the method for producing a laminated core according to the present invention it is possible to produce a laminated core with high productivity while minimizing the deterioration of the magnetic properties of the laminated core.
- FIG. 1 is a schematic diagram showing a configuration of a punching apparatus.
- FIG. 2 is a schematic diagram showing the configuration of the stator core and the fixing portion.
- FIG. 3 is a schematic diagram showing the configuration of the stator core and the fixing portion.
- FIG. 4A is a schematic diagram illustrating a configuration of a stator core and a fixing portion.
- FIG. 4B is a schematic diagram illustrating the configuration of the stator core and the fixing portion.
- FIG. 5 is a diagram showing the relationship between the length of the line segment AB and the number of sets of fixed portions F A and F B per unit length of the closed curve L and the motor efficiency.
- FIG. 6 is a schematic diagram showing the configuration of the stator core and the fixing portion.
- FIG. 7 is a diagram illustrating the relationship between the distance between the closed curve L and the fixed portions F A and F B and the motor efficiency.
- Figure 8 is a diagram showing a relationship between the fixed portion F A, the ratio a motor efficiency of a portion having no F B in the closed curve L.
- FIG. 9 is a schematic diagram for explaining a process of fixing the steel plates to each other using caulking protrusions.
- the present invention can be applied to a punching apparatus 1 as shown in FIG.
- the punching apparatus 1 shown in FIG. 1 slits a predetermined width and then discharges a plurality of steel plates 2a to 2c wound in a coil shape by the discharging apparatuses 3a to 3c, and then uses the pinch roll 4 to A plurality of steel plates 2a to 2c are continuously inserted into the press machine 5 in an overlapped state, and the punching of the steel plates 2a to 2c is continuously performed in the press machine 5 using a mold 6 having a plurality of press processes.
- It is a device that performs automatically.
- reference numerals 7, 8, 9, and 10 denote a punch, a plate presser, a die, and a die hole, respectively.
- a symbol a indicates a gap (clearance) between the side surface of the punch 7 and the side surface of the die hole 10.
- punching of iron cores when punching out a portion with a large outer diameter, the amount of deformation near the punching end increases, and the magnetic properties tend to deteriorate.
- punching of the outermost periphery of the iron core has a long peripheral length to be processed at one time, and in the case of a stator core, the inner peripheral side (inside the tip of the teeth) is punched and the restraining force (rigidity) inside the steel sheet itself ) Is reduced, the outermost punching process is performed, so that the punching end is likely to be distorted. For this reason, when punching is performed in a state where a plurality of steel plates are overlapped, the magnetic properties of the iron core are likely to deteriorate during the outermost punching.
- the fixed portion F A placed outside across the closed curve L corresponding to the outermost periphery of the core, the part at the same time as the inner core of the closed curve L disposing the fixing portion F B.
- the fixing unit F A and the fixing portion F B is may be provided at the same time in the mold process, it may be provided in a separate step. Further, one may be formed first to the fixed portion F A and the fixing portion F B. However, in order to increase the rigidity of the entire steel sheet, because of a high effect towards the fixed portion F A, located outside the outermost may be formed ahead towards the fixed portion F A.
- the present invention when performing a punching process by stacking a plurality of steel sheets, by providing a portion for fixing the steel sheets to each other across a line (line segment or closed curve) cut by the punching process, The deformation of the edge of the steel plate is minimized and the deterioration of the magnetic properties of the iron core is suppressed.
- closed curve L corresponds to the outermost periphery of the stator core, placing the fixing portion F A to the portion to be discarded as the remainder of the stamped iron core disposing the fixing portion F B in the portion to be a.
- the fixed portion F A and the fixed portion F B are sufficiently close to each other. Furthermore, for the reasons mentioned above, the intersection of all the closed curve L line segment AB and punching is carried out connecting the fixed portion F A and the fixing portion F B is preferably set to 1 point.
- the deformation amount of the steel plate in the punching process depends on the plate thickness of the steel plate, and the rigidity decreases as the plate thickness decreases. Therefore, the deformation amount at the punching end (here, the case of punching with one steel plate) Degree of deterioration) increases.
- the magnetic properties of the iron core are suppressed by setting the length of the line segment AB connecting the fixed portion F A and the fixed portion F B to a certain value or less according to the average thickness of the steel plates to be superimposed. be able to. Specifically, as shown in FIG. 5, deterioration of motor efficiency is suppressed by setting the length of the line segment AB to 400 times or less (preferably 250 times or less) of the average thickness of the steel plates to be superimposed.
- the arrangement of the fixing portions F A and F B may be such that the line segment AB and the closed curve L do not necessarily intersect at a right angle as shown in FIG. 4-2 (e).
- a set of fixed portions F A and F B satisfying the above condition at a certain ratio or more (the average thickness of the steel plates on which the lengths of the line segments AB are superimposed) A set of fixed portions F A and F B ) that is 400 times or less.
- the set of the fixed portions F A and F B whose length of the line segment AB is 400 times or less of the average thickness of the steel plates to be superimposed is 0.5 per 100 mm of the length of the closed curve L. This is suggested as a preferred range, which limits the scope of the present invention.
- one fixed portion F A forms a set of two or more fixed portions F A and F B. To do. Even in such a case, as a set of two or more fixed portions F A and F B at the same time contributes to prevention of deformation during punching, it can be considered as a set of fixed portions F A and F B in the closed curve L. . Further, when the set of fixed portions F A and F B satisfying the condition regarding the line segment AB is distributed in an unbalanced manner with respect to the closed curve L, it is difficult to obtain a desired effect. As shown in FIG.
- the distance between the fixed portions F A and F B which are both ends of the line segment AB and the closed curve L is the length of the perpendicular line (closest distance between the fixed portion and the closed curve) drawn from the respective fixed portions to the closed curve L. To do. If the distance between the fixed portions F A and F B and the closed curve L varies, the distance between the fixed portion F A and F B closer to the closed curve L and the closed curve L is measured. These average values may be adopted.
- a method such as spot welding or partial application of an adhesive can be applied as a method of fixing the steel plates to each other.
- methods such as spot welding and partial application of adhesives it is expected that the effect of suppressing the deterioration of magnetic properties will be obtained by performing it over a wide range of steel sheets. However, if these areas become large, productivity will decrease. Invite. For this reason, it is desirable that the above-described method has as few points as possible, and the conditions specified in the present invention are suitable.
- the union locking part provided in the portion used as the iron core in the technique described in Patent Document 3 has a certain amount of area and is crushed by pushback, it is subjected to strong processing including its surroundings. Even in the locking part, the magnetic properties of the iron core are significantly deteriorated. On the other hand, the magnetic properties of the iron core do not deteriorate with the method of partial application of the adhesive, and the portion where the magnetic properties are deteriorated with the spot welding method is a very limited region. The adverse effect on the characteristics is small.
- a fixing method by caulking is suitable from the viewpoint of productivity as a method of fixing the iron cores to each other.
- the fixing method by caulking it is possible to fix the steel plates before punching by forming protrusions for caulking in the final pressing step in a state where a plurality of steel plates are overlapped.
- the core pieces can be integrated to manufacture a highly efficient iron core.
- FIG. 9 shows a schematic diagram of such a process.
- the steel plates 2a and 2b conveyed immediately above the holes 10a and 10b formed in the lower mold 21 are punched by the punches 7a and 7b lowered from the upper mold 23, thereby forming the holes 10a and 10b.
- the punch 7c lowered from the upper die 23 is used to punch the outermost periphery of the iron core, and then the upper surface of the steel plate conveyed first.
- the caulking projections 25 are stacked so as to overlap each other, and the caulking projections 25 are pushed into the caulking projections 25 of the lower steel plate by the caulking fastening punches 7d, and the steel plates are fixed to each other by fitting.
- the united locking portion is formed by being crushed by pushback, so it does not have a caulking function, and caulking for joining the steel plates needs to be provided separately. For this reason, the magnetic properties of the iron core are remarkably deteriorated by processing both the united locking portion and the crimping.
- the present invention uses the projections finally used as caulking as a means for bonding and fixing the steel plates even during the punching process, the deterioration of the magnetic properties of the iron core and the normal caulking core It is suppressed to the same extent.
- the steel plates are bonded together by a method with little deterioration of magnetic properties such as spot welding or partial application of adhesive on both sides sandwiching a portion (closed curve L) subjected to shearing before punching.
- the method of fixing the steel plates to each other is formed by forming protrusions that eventually become crimps for iron core manufacture, and using this.
- Fixing method by adhesive, fixing method by spot welding, and fixing method by forming caulking projections can be used in combination.
- fixing part outside the iron core is fixing method by spot welding, and fixing inside iron core is by forming caulking projections It is good also as a fixing method.
- the present invention can be used as a method for manufacturing an integrated laminated core by fixing the core pieces punched by the above method to each other inside the mold.
- a manufacturing method of an integral laminated iron core a method using an adhesive, a method of welding the side surfaces of laminated steel plates, or a case where a protrusion for caulking fastening is provided in the middle of a mold, a final pressing step A method of bonding steel plates to each other by caulking protrusions can be implemented.
- the mold in the present invention is a mold that realizes the above-described method.
- spot welding, fast-drying adhesive application, or a plurality of steel plates are stacked on both sides of the closed curve L that is the outermost periphery of the iron core.
- the closed curve L that is the outermost periphery of the iron core.
- the outermost outer periphery of the core piece is cut from the steel plate by shearing (shearing).
- Example 1 The apparatus shown in FIG. 1 is used to simultaneously punch two magnetic steel sheets having a thickness of 0.20 mm and a width of 210 mm, and caulking is performed in the mold, and the brushless DC shown in FIGS. 2 (a) and 2 (b).
- a motor stator core (outer diameter 200 mm, 12 slots, teeth width 14 mm, back yoke width 10 mm) was produced.
- the die for punching has a structure in which press working is sequentially performed in all five steps of progressive feeding.
- the first step of the mold has a function of applying an adhesive to a predetermined position of the steel plate, and the fixed portions F A and F B shown in FIGS. 2A and 2B with respect to the final shape of the stator core.
- FIG. 2 (a) disposed at a position outside from the outermost periphery of the fixing portion F A is the core (b), the fixing unit F B is disposed at a position inside the core, segment AB
- the length of was as shown in FIGS. 2 (a) and 2 (b). It was also performed processed without the fixing portion F A or the fixed part F B for comparison.
- a rare earth magnet embedded motor was manufactured using the stator core manufactured above, and the motor efficiency at the rated output was measured. The results are shown in Table 1 below. Furthermore, also described details about the fixing portion F A, F B provided in the outer and the stator core of the outermost periphery of the stator core in Table 1. As shown in Table 1, with respect to the set of fixed portions F A and F B existing on both sides of the closed curve L, the set of the closed curve L defined by the present invention is a set in which the line segment AB is 400 times or less the average plate thickness of the steel plate. It was confirmed that particularly high motor efficiency can be obtained when the length is 0.5 or more per 100 mm.
- a brushless DC motor shown in FIGS. 3 (a) to 3 (c) is obtained by simultaneously punching three electromagnetic steel plates having a thickness of 0.15 mm and a plate width of 210 mm using the apparatus shown in FIG.
- Stator cores outer diameter 200 mm, 12 slots, teeth width 12 mm, back yoke width 8 mm
- round caulking (diameter is provided at the positions of fixing portions F A and F B shown in FIGS.
- the inner periphery of the core, the slot portion, and the outer periphery of the core were punched.
- round caulking protrusions were fitted in the mold to produce an integral stator iron core.
- stator iron core Using the obtained stator iron core, a rare earth magnet embedded motor was manufactured, and the motor efficiency was measured under rated output conditions. As a result, the stator core shown in FIG. 3A (example) is 92.8%, the stator core shown in FIG. 3B (comparative example) is 91.8%, and shown in FIG. The stator core (comparative example) was 91.5%, and particularly excellent motor characteristics were obtained with the stator core shown in FIG.
- Example 3 For the brushless DC motor shown in FIGS. 4-1 and 4-2, two electromagnetic steel plates having a thickness of 0.20 mm and a width of 260 mm are simultaneously punched using the apparatus shown in FIG. the stator core (outer diameter 250 mm, 12 slots, teeth width 15 mm, a back yoke width 11 mm) to prepare a fixing portion F a shown in FIG.
- the stator core outer diameter 250 mm, 12 slots, teeth width 15 mm, a back yoke width 11 mm
- stator iron core Using this stator iron core, a rare earth magnet embedded motor was fabricated, and the motor efficiency was measured under rated output conditions.
- FIG. 5 shows the relationship between the motor efficiency and the number of sets of fixed portions F A and F B that satisfy the conditions of the present invention per 100 mm circumference of the closed curve L and the ratio of the line segment AB to the average plate thickness of the steel sheet.
- the ratio of the line segment AB to the average plate thickness of the steel sheet and the number of sets of fixed portions F A and F B per 100 mm length of the closed curve L are controlled within the range defined in the present invention. Thus, it was confirmed that high motor efficiency can be obtained.
- Example 4 Using the apparatus shown in FIG. 1, three electromagnetic steel sheets each having a plate thickness of 0.10, 0.15, 0.20 mm and a plate width of 260 mm are simultaneously punched and caulked in a mold.
- a stator core for a brushless DC motor shown in FIGS. 1 and 4-2 (outer diameter 200 mm, 12 slots, teeth width 14 mm, back yoke width 10 mm) is manufactured, and a fixed portion F shown in FIGS.
- a rare earth magnet embedded motor was fabricated, and the motor efficiency was measured under rated output conditions.
- the fixing portion F A, of the distance between the distance and the fixed part F B and the closed curve L between the distance (fixed portion F A and the closed curve L between the F B and closed curves L In particular, a high motor efficiency was obtained by setting the shorter one to 250 times or less the average thickness of the steel plate. Further, as shown in FIG. 5, high motor efficiency was obtained by controlling the number of sets of the fixed portions F A and F B per 100 mm in length of the closed curve L within the range defined in the present invention. Further, as shown in FIG.
- the present invention it is possible to provide a punching method for a laminated core and a method for producing a laminated core capable of producing a laminated core with high productivity while minimizing the deterioration of the magnetic properties of the laminated core.
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Abstract
Description
始めに、図1を参照して、本発明の適用範囲について説明する。
次に、本発明における打抜き加工前の鋼板の固定部について説明する。
次に、固定部FAと固定部FBとの間の距離について説明する。
次に、固定部FA,FBと閉曲線Lとの間の距離について説明する。
次に、鋼板同士の固定方法について説明する。
本発明は、上記方法で打抜いた鉄心用素片を金型内部で互いに固定することによって一体の積層鉄心を製造する方法として利用可能である。一体の積層鉄心の製造方法としては、接着剤を用いる方法や積層された鋼板の側面を溶接する方法、又は、金型内の途中工程でカシメ締結のための突起を設ける場合、最終プレス工程で鋼板同士をカシメ突起により互いに結合させる方法が実施可能である。
本発明における金型は上記の方法を実現する金型であり、最終的に鉄心の最外周となる閉曲線Lを挟む両側にスポット溶接や速乾性の接着剤の塗布、又は鋼板を複数枚重ね合わせた状態でカシメ突起を設けて互いに固定する機能を有し、この後に金型内工程の最終工程で鉄心用素片の最外周を剪断加工によって鋼板から分断することによる打抜き(剪断)加工を施すことによって、複数枚の鋼板を重ね合わせた状態で打抜き加工を行うことによる鉄心の磁気特性の劣化を最小限とすることが可能である。
図1に示す装置を用いて板厚0.20mm、板幅210mmの電磁鋼板2枚を同時に打抜き加工すると共に、金型内でカシメを施して図2(a),(b)に示すブラシレスDCモータ用固定子鉄心(外径200mm,12スロット,ティース幅14mm,バックヨーク幅10mm)を作製した。打抜き加工を行う金型は順送りの全5工程によって順次プレス加工を行う構造とした。金型の1工程目は鋼板の所定位置に接着剤を塗布する機能を有し、最終的な固定子鉄心の形状に対して図2(a),(b)の固定部FA,FBの位置の直径5mmの範囲に速乾性の接着剤を塗布して鋼板2枚を互いに接着した後、金型の最終5工程目で最外周(閉曲線L)の打抜き加工を行った。ここで、図2(a),(b)に示すように固定部FAは鉄心の最外周よりも外側の位置に配置し、固定部FBは鉄心内部の位置に配置し、線分ABの長さは図2(a),(b)に示す通りとした。また、比較のため固定部FA又は固定部FBを設けない加工も実施した。
図1に示す装置を用いて板厚0.15mm、板幅210mmの電磁鋼板3枚を同時に打抜き加工すると共に金型内でカシメを施して図3(a)~(c)に示すブラシレスDCモータ用固定子鉄心(外径200mm,12スロット,ティース幅12mm,バックヨーク幅8mm)を作製し、図3(a)~(c)に示す固定部FA,FBの位置に丸カシメ(直径1.2mm,深さ0.10mm)を設けて3枚の鋼板同士を互いに固定した後、鉄心内周及びスロット部分、鉄心外周の打抜き加工を行った。鉄心外周の打抜きと同時に金型内で丸カシメ突起同士を嵌合させて一体の固定子鉄心を作製した。
図1に示す装置を用いて板厚0.20mm、板幅260mmの電磁鋼板2枚を同時に打抜き加工すると共に金型内でカシメを施して図4-1,4-2に示すブラシレスDCモータ用固定子鉄心(外径250mm,12スロット,ティース幅15mm,バックヨーク幅11mm)を作製し、図4-1,4-2に示す固定部FA,FBの位置に関し、順送りの金型内の工程の1工程目で固定部FAをスポット溶接して2枚の鋼板同士を互いに固定した後、鉄心内周及びスロット部分の打抜き加工を行い、金型内4工程目で最終的に鉄心となる部分の内部にVカシメ(幅:1mm,長さ:2mm,深さ:0.3mm)を設けて2枚の鋼板同士を互いに固定した。そして、最終の5工程目で鉄心外周の打抜き加工を行い、この最外周の打抜き加工でのパンチ下降動作を利用してVカシメ突起同士を嵌合させて積層鋼板に対して仮の一体化を行った後、これを金型から取り出してプレス装置にて押圧することでカシメ突起同士を完全に嵌合させて一体の固定子鉄心を作製した。この固定子鉄心を用いて希土類磁石埋込み型モータを作製し、定格出力条件でのモータ効率を測定した。
図1に示す装置を用いて板厚がそれぞれ0.10,0.15,0.20mm、板幅が260mm幅の電磁鋼板3枚を同時に打抜き加工すると共に金型内でカシメを施して図4-1,4-2に示すブラシレスDCモータ用固定子鉄心(外径200mm,12スロット,ティース幅14mm,バックヨーク幅10mm)を作製し、図6(a)~(c)に示す固定部FA,FB,FAN,FBN(N=1~6)の位置について固定部FA及び鉄心内部の固定をいずれもVカシメ(幅:1mm,長さ:2mm,深さ:0.15mm)を設けて2枚の鋼板同士を互いに固定した後、鉄心内周及びスロット部分、鉄心外周の打抜き加工を行った。そして、この最外周の打抜き加工でのパンチ下降動作を利用してVカシメ突起同士を嵌合させて固定子鉄心を作製した。また、以上において、図6(a)に示す基本位置に対して図6(b)に示す形態で固定部FA,FBと最外周の閉曲線Lとの間の距離(固定部FA,FBと最外周の閉曲線Lとの間の距離の最小値)を変化させた。また、図6(c)に例を示す形態で固定部FA,FBの組の分布状態を変化させた。図6(c)に示す形態において、閉曲線Lと固定部FAN,FBN(N=1~6)との交点PNを求め、隣接する交点PN間の円弧長が最も長いもの(円弧長順位1位)と円弧長が次に長い部分(円弧長順位2位)との和を算出し、閉曲線L全長に対する和の比率を求めた。この固定子鉄心を用いて希土類磁石埋込み型モータを作製し、定格出力条件でのモータ効率を測定した。
2a,2b,2c 鋼板
3a,3b,3c 払い出し装置
4 ピンチロール
5 プレス機
6 金型
7,7a,7b,7c パンチ
7d カシメ締結用パンチ
8 板押さえ
9 ダイ
10 ダイホール
10a,10b 孔
21 下型
23 上型
25 カシメ用突起
Claims (5)
- 複数枚の鋼板を連続的に金型内に送り込み、該金型内に設けた複数の工程において重ね合わせた状態で複数枚の鋼板の打抜き加工を行う積層鉄心用の打抜き加工方法であって、
積層鉄心の最外周に相当する閉曲線の外側に位置する第1の固定部と最終的に積層鉄心となる部分に位置する第2の固定部において重ね合わされた複数枚の鋼板を互いに固定させた後に積層鉄心の最外周の打抜き加工を行うステップを含むことを特徴とする積層鉄心用の打抜き加工方法。 - 前記第1の固定部と前記第2の固定部とを結ぶ線分の長さが複数枚の鋼板の平均板厚の400倍以下である第1の固定部と第2の固定部との組の数を、前記閉曲線の長さ100mm当たりの平均で0.5個以上とすることを特徴とする請求項1に記載の積層鉄心用の打抜き加工方法。
- 前記第1の固定部と前記第2の固定部とを結ぶ線分の長さが複数枚の鋼板の平均板厚の400倍以下である第1の固定部と第2の固定部との組について、前記第1の固定部と前記閉曲線との間の距離及び前記第2の固定部と前記閉曲線との間の距離のうちの短い方を固定部と前記閉曲線との間の距離としたとき、前記固定部と前記閉曲線との間の距離の平均値を複数枚の鋼板の平均板厚の250倍以下とすることを特徴とする請求項1又は2に記載の積層鉄心用の打抜き加工方法。
- 前記第2の固定部における複数枚の鋼板の固定方法が、積層鉄心を形成するためのカシメ用の突起を用いた固定方法であることを特徴とする請求項1~3のうち、いずれか1項に記載の積層鉄心用の打抜き加工方法。
- 請求項1~4のうち、いずれか1項に記載の積層鉄心用の打抜き加工方法によって打抜き加工が施された鋼板を積層、一体化することによって積層鉄心を製造するステップを含むことを特徴とする積層鉄心の製造方法。
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US15/538,530 US10898939B2 (en) | 2014-12-26 | 2015-12-25 | Punch processing method for laminated iron core and method for manufacturing laminated iron core |
CN201580070267.0A CN107107154B (zh) | 2014-12-26 | 2015-12-25 | 层叠铁芯用的冲裁加工方法及层叠铁芯的制造方法 |
MX2017008359A MX2017008359A (es) | 2014-12-26 | 2015-12-25 | Metodo para procesamiento de perforaciones para un nucleo de hierro laminado y metodo para fabricar el nucleo de hierro laminado. |
KR1020177016743A KR101951823B1 (ko) | 2014-12-26 | 2015-12-25 | 적층 철심용의 펀칭 가공 방법 및 적층 철심의 제조 방법 |
CA2971381A CA2971381C (en) | 2014-12-26 | 2015-12-25 | Punch processing method for laminated iron core and method for manufacturing laminated iron core |
EP15873254.5A EP3238847B1 (en) | 2014-12-26 | 2015-12-25 | Punch processing method for laminated iron core and method for manufacturing laminated iron core |
RU2017126492A RU2678115C1 (ru) | 2014-12-26 | 2015-12-25 | Способ обработки вырубкой многослойного железного сердечника и способ изготовления многослойного железного сердечника |
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Cited By (2)
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EP3588520A4 (en) * | 2017-02-24 | 2020-01-01 | Panasonic Corporation | LAMINATED ELEMENT, METHOD FOR THE PRODUCTION THEREOF, LAMINATED BODY AND ENGINE |
US11225049B2 (en) | 2017-02-24 | 2022-01-18 | Panasonic Corporation | Laminated member, laminated body, and motor |
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JP6210058B2 (ja) | 2017-10-11 |
US20170368590A1 (en) | 2017-12-28 |
EP3238847A4 (en) | 2018-08-29 |
CA2971381C (en) | 2019-08-06 |
TW201641180A (zh) | 2016-12-01 |
CA2971381A1 (en) | 2016-06-30 |
KR20170087915A (ko) | 2017-07-31 |
EP3238847B1 (en) | 2021-07-28 |
CN107107154A (zh) | 2017-08-29 |
TWI639474B (zh) | 2018-11-01 |
US10898939B2 (en) | 2021-01-26 |
EP3238847A1 (en) | 2017-11-01 |
JP2016123976A (ja) | 2016-07-11 |
RU2678115C1 (ru) | 2019-01-23 |
KR101951823B1 (ko) | 2019-02-25 |
MX2017008359A (es) | 2017-10-24 |
CN107107154B (zh) | 2019-05-07 |
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