JP5964221B2 - Armature manufacturing method and progressive mold apparatus - Google Patents

Description

  The present invention relates to a method for manufacturing an armature constituting a rotating electric machine and a progressive mold apparatus for realizing the manufacturing method.

  The armature (stator or rotor) of a rotating electrical machine is manufactured as a laminated iron core made of magnetic steel sheet hoop material (strip-shaped thin steel sheet) because cutting of teeth such as teeth to which winding is applied is complicated and difficult. Often done. Laminated iron cores for armature usually perform punching and half punching of pilot holes, center holes, slots, teeth, external shapes, caulking projections, etc. sequentially on the hoop material that is intermittently transferred in the progressive die. In general, it is produced by continuously obtaining a large number of core thin plates by laminating these core thin plates in a die and a squeeze ring while being stacked (caulking and bonding) (Patent Document 1,). 2).

U.S. Pat.No. 3202851 Japanese Patent Publication No.34-2760

  In a rotating electrical machine, in order to increase the amount of winding of the winding applied to the teeth while suppressing the axial dimension (that is, to improve the performance), a portion of the teeth where the winding is applied (hereinafter referred to as a winding portion). It is desirable to reduce the axial dimension of When manufacturing such an armature as a laminated iron core, a complete number (full form) of iron core thin plates (hereinafter referred to as full form iron core thin plates) are laminated on a predetermined number of sides, and other than the winding parts on both end faces. A method of further laminating a plurality of iron core thin plates (hereinafter referred to as partial thin plates) forming the above-mentioned parts (magnetic pole part and cylindrical part) is conceivable.

  However, it is difficult to stack the partial thin plates with respect to the full iron core thin plate in the progressive die apparatus for the following reason. For example, when the magnetic pole part in the teeth and the annular part around the shaft hole in the rotor are partially thin plates, each magnetic pole part and the annular part are separated from each other. Cannot be caulked and combined. Therefore, after manufacturing a laminated body of all-type core thin plates by a progressive die apparatus, the magnetic pole part and the annular part are individually crimped to this laminated body, and the manufacturing man-hours have been greatly increased.

  The present invention has been made in view of such a background, and relates to a method of manufacturing an armature constituting a rotating electric machine and a progressive mold apparatus for realizing the manufacturing method, and a shaft of a winding portion in a tooth. An object is to manufacture an armature having a small directional dimension by using a progressive die apparatus.

  The first aspect of the present invention includes an annular portion (3) fixed to a shaft or casing of a rotating electrical machine, a radially projecting portion from the outer peripheral side or inner peripheral side of the annular portion, and a magnetic pole portion (5) and An armature (1) having a plurality of teeth (4) on which a winding part (6) is formed, wherein the axial dimension (L2) of the winding part is smaller than the axial dimension (L1) of the magnetic pole part. ) Using a progressive die apparatus, and sequentially punching out the entire thin core sheet (11) including a portion constituting the teeth and a portion constituting the annular portion from a band-shaped metal plate; A step of sequentially punching a connecting thin plate (20) having a plurality of partial thin plates (12, 13) including a portion constituting only the magnetic pole portion and a connecting portion (21) for connecting these partial thin plates from the metal plate. And the connecting thin plate A step of half-cutting the partial thin plate or the connecting portion, and a parting line between the partial thin plate and the connecting portion by pushing back the half-cut partial thin plate or the connecting portion with respect to the connecting thin plate. (22, 23), a step of laminating a predetermined number of the whole core thin plates, and a step of laminating a predetermined number of the connecting thin plates on at least one end surface of the laminated whole core thin plates. And a step of causing.

  According to a second aspect of the present invention, a step of forming a caulking portion (24 ', 25') on the whole core thin plate and a step of forming a caulking portion (24 ', 25', 26 ') on the connecting thin plate. And.

  According to a third aspect of the present invention, there is provided an annular portion (3) fixed to a shaft or casing of a rotating electrical machine, a radially projecting portion from the outer peripheral side or inner peripheral side of the annular portion, and a magnetic pole portion (5) and An armature (1) having a plurality of teeth (4) on which a winding part (6) is formed, wherein the axial dimension (L2) of the winding part is smaller than the axial dimension (L1) of the magnetic pole part. ), A punching means for sequentially punching out the whole core thin plate (11) including the teeth and the annular portion from a strip-shaped metal plate (W), Punching means for sequentially punching a connecting thin plate (20) having a plurality of partial thin plates (12, 13) including a portion constituting only the magnetic pole portion from a metal plate and a connecting portion (21) connecting these partial thin plates. And the portion with respect to the connecting thin plate A half-drawing means for half-pulling the plate or the connecting portion, and a partial line between the partial thin plate and the connecting portion by pushing back the half-punched partial thin plate or the connecting portion with respect to the connecting thin plate ( 22 and 23), and a lamination coupling means (43) for coupling the whole core thin sheet and the connection thin sheet while laminating a predetermined number of sheets.

  According to the first and third aspects of the present invention, an armature having a small axial dimension of a winding portion in a tooth can be manufactured using a progressive die apparatus. Further, according to the second aspect, since the full core thin plate and the connecting thin plate are coupled within the squeeze ring of the progressive die apparatus, the manufacturing process can be simplified.

It is a perspective view of the rotor which concerns on embodiment. It is a half cut longitudinal cross-sectional view of the rotor which concerns on embodiment. It is a strip layout figure concerning an embodiment. It is a top view of the connection thin plate concerning an embodiment. It is a strip layout figure concerning an embodiment. It is a top view of the full form iron core thin plate which concerns on embodiment. It is a top view of the rotor of the semi-finished product which concerns on embodiment. It is a top view which shows the state which removes a connection part from the rotor of a semi-finished product.

  Hereinafter, an embodiment in which the present invention is applied to a method for manufacturing an electric motor rotor will be described in detail with reference to the drawings.

≪Rotor≫
As shown in FIG. 1, the rotor 1 (armature) of this embodiment is a laminated iron core formed by laminating iron core thin plates made of a hoop material, and a shaft hole 2 into which a motor shaft (not shown) is fitted in the shaft center. Are formed, and eight teeth 4 projecting from the outer periphery of the annular portion 3 at equal angular intervals. Each tooth 4 is composed of a magnetic pole portion 5 extending on both sides in the circumferential direction facing a stator (not shown) and a winding portion 6 having a rectangular cross section on which winding is applied.

  As shown in FIG. 2, the rotor 1 is composed of 10 sheets of the entire core thin plate 11 in which the annular portion 3 and each tooth 4 are integrally formed, and 5 annular members laminated on both end faces of the annular portion 3. The partial thin plate 12 (partial thin plate) and the five magnetic pole portion thin plates 13 (partial thin plates) stacked on both end faces of each magnetic pole portion 5 are integrated by caulking.

  As shown in FIG. 2, the axial dimension L1 of the magnetic pole part 5 on which the magnetic pole part thin plates 13 are laminated is set to be larger than the axial dimension L2 of the winding part 6 (doubled in the illustrated example). . Further, the center side of the annular portion 3 (that is, the portion where the annular portion thin plate 12 is laminated) also has the same axial dimension L1 as the magnetic pole portion 5. Since the axial dimension L2 of the winding part 6 is set smaller than the magnetic pole part 5 and the annular part 3, the amount of winding applied to the winding part 6 is increased in order to improve the performance. However, it is difficult for the winding to protrude from the end face of the rotor 1, and the axial dimension of the electric motor is suppressed.

≪Punching process with progressive die device≫
Next, the punching process of the connecting thin plate and the full core thin plate by the progressive die apparatus will be described with reference to FIGS.

<Connecting sheet forming process>
As shown in FIG. 3, in the progressive die apparatus 19, the connecting thin plate 20 is obtained by sequentially performing the punching process and the half-punching process on the intermittently fed hoop material W. As shown in FIG. 4, the connecting thin plate 20 is formed by connecting the annular portion thin plate 12 and each magnetic pole portion thin plate 13 by the connecting portion 21, and the annular portion thin plate 12 and each magnetic pole portion thin plate 13 and the connecting portion 21. Between them, dividing lines 22 and 23 by pushback processing (described later) are respectively provided.

  The annular thin plate 12 is formed with eight measuring holes 24 (through holes) by punching or eight caulking portions 24 ′ (unevenness for caulking) by half punching at equiangular intervals (that is, 45 ° intervals). . Each magnetic pole part thin plate 13 is formed with a pair of measuring holes 25 (or caulking parts 25 ').

  In the connecting portion 21, eight measuring holes 26 (or caulking portions 26 ′) are formed at equiangular intervals on the center side, a fan-shaped hole 27 located on the inner peripheral side of the magnetic pole portion 5 and an adjacent magnetic pole. Eight oval punch holes 28 located between the portions 5 are formed at equiangular intervals. The connecting portion 21 includes an inner ring portion 29 adjacent to the outer periphery of the annular thin plate 12, an outer ring portion 30 adjacent to the inner periphery of the magnetic pole portion thin plate 13, and spokes extending radially from the outer periphery of the inner ring portion 29. And the outer end of the spoke part 31 is located between the adjacent magnetic pole part thin plates 13. In addition, as will be described later, the fan-shaped hole 27 and the oval hole 28 are provided to make the spoke part 31 brittle so that the connecting part 21 can be easily removed from the rotor 1 after lamination.

When the progressive die apparatus 19 is activated, the connecting thin plate 20 is manufactured by sequentially performing the steps shown in FIG. 3 on the hoop material W.
(1) First step: The pilot hole 35 is drilled.
(2) Second step: An oblong hole 28 is drilled in a portion to be the connecting portion 21. Note that the punch for punching the oval hole 28 may protrude from an upper mold (not shown) by a cam mechanism or the like so that the oval hole 28 is not punched in the hoop material W.
(3) Third step: A fan-shaped hole 27 is drilled in a portion to be the connecting portion 21. Note that the punch for punching the fan-shaped hole 27 may also appear and disappear from an upper mold (not shown) by a cam mechanism or the like so that the fan-shaped hole 27 is not punched in the hoop material W.
(4) The fourth step is for punching a slot 32 of the full-form iron core thin plate 11 to be described later, and is not performed because the punch is submerged in the upper die when the connecting thin plate 20 is manufactured.

(5) Fifth step: A dividing line 22 between the annular thin plate 12 and the connecting portion 21 is formed by pushback processing. The pushback process in the present embodiment is to push back the connection portion 21 after half-cutting the annular portion thin plate 12, and the annular portion thin plate 12 and the connection portion 21 are coupled with a relatively weak coupling force. Note that the punch for forming the parting line 22 can also appear and disappear from an upper mold (not shown) by a cam mechanism or the like so that the parting line 22 is not formed on the hoop material W.
(6) Sixth step: The dividing line 23 between the magnetic pole part thin plate 13 and the connecting part 21 is formed by pushback processing. Note that the punch for forming the parting line 23 can also appear and disappear from an upper mold (not shown) by a cam mechanism or the like so that the parting line 23 is not formed on the hoop material W.
(7) Seventh step: The shaft hole 2 is drilled in the axial center of the annular portion 3.

(8) Eighth step: The measurement holes 24, 25, and 26 are drilled in the annular thin plate 12, the magnetic pole thin plate 13, and the connecting portion 21, respectively. The measuring holes 24, 25, and 26 determine the number of stacked rotors 1 (20 in the present embodiment), and are drilled on only one of the lower ends. It should be noted that the punch for punching the measurement holes 24, 25, 26 protrudes from an upper mold (not shown) by a cam mechanism or the like so that the measurement holes 24, 25, 26 are not punched in the hoop material W. You can also. Further, the punch for drilling the measuring hole 26 of the connecting portion 21 is adapted to appear and disappear from the upper mold independently of the punch for drilling the other measuring holes 24 and 25.

(9) Ninth step: The caulking portions 24 ′, 25 ′, and 26 ′ are formed in the annular portion thin plate 12, the magnetic pole portion thin plate 13, and the connecting portion 21, respectively. Note that the punches that form (half-punch) the caulking portions 24 ′, 25 ′, and 26 ′ appear and disappear from an upper mold (not shown) by a cam mechanism or the like, and are caulked to the hoop material W. It is possible to prevent the formation of '. Further, the punch that forms the caulking portion 26 ′ of the connecting portion 21 appears and disappears from the upper die independently of the punches that form the other caulking portions 24 ′ and 25 ′.
(10) Tenth step: The connecting thin plate 20 is punched into the outer punching die 42 and the squeeze ring 43 by the outer punching punch 41. (See Figure 5)

<Formation process of all-type core sheet>
As shown in FIG. 5, in the progressive die apparatus 19, the entire core thin plate 11 is obtained by sequentially performing punching and half-punching on the intermittently fed hoop material W.
As shown in FIG. 6, the full core thin plate 11 is composed of an annular portion 3 having a shaft hole 2 formed in the shaft center, and eight teeth 4 projecting at equal angular intervals from the outer periphery of the annular portion 3. Has been. Each tooth 4 is composed of a magnetic pole portion 5 extending on both sides in the circumferential direction and a flat plate-like winding portion 6.

In the manufacture of the whole core sheet 11, the process shown in FIG.
(1) First step: The pilot hole 35 is drilled.
(4) Fourth step: Slots 32 forming the contours of the annular portion 3 and the teeth 4 are drilled. Note that the punch for punching the slot 32 may appear and disappear from an upper mold (not shown) by a cam mechanism or the like so that the slot 32 is not punched for the hoop material W.
(9) Ninth step: Caulking portions 24 ′ and 25 ′ are formed in the annular portion 3 and the magnetic pole portion 5 of the tooth 4, respectively. The strip layout of the ninth step is the same as that of the connecting thin plate 20, and is not shown in FIG.
(10) Tenth step: The whole core thin plate 11 is punched into the outer punching die 42 and the squeeze ring 43 by the outer punching punch 41.

≪Laminated caulking≫
In manufacturing the rotor 1, the manufacturing control device of the progressive die device 19 first continuously manufactures the five connecting thin plates 20 and punches them into the outer punching die 42 and the squeeze ring 43. At this time, the caulking portions 24 ′, 25 ′ and 26 ′ are drilled in the connecting thin plate 20 excluding the lowermost one, but the measurement holes 24, 25 and 26 are drilled in the lowermost connecting thin plate 20. Thus, caulking and bonding are prevented from occurring with the connecting thin plate 20 punched out. The punched connection thin plates 20 are caulked and joined to each other through caulking portions 24 ′, 25 ′, and 26 ′ by applying resistance from the squeeze ring 43.

  Next, the production control device continuously manufactures the ten sheets of the entire core sheet 11 and punches them into the outer punching die 42 and the squeeze ring 43. The punched full-form iron core thin plate 11 is caulked and coupled to the connecting thin plate 20 having the lowermost end punched first, and is also caulked to each other via caulking portions 24 ′ and 25 ′.

  Next, the manufacturing control device continuously manufactures the five connecting thin plates 20 again, and punches them into the outer punching die 42 and the squeeze ring 43. At this time, the caulking portions 24 ′, 25 ′ and 26 ′ are perforated in the connecting thin plate 20 except for the lowermost end, but the caulking portions 24 ′ and 25 ′ and the measuring holes 26 are formed in the lowermost connecting thin plate 20. So as not to interfere with the whole core sheet 11 punched out first. Each of the punched connecting thin plates 20 is caulked and joined to the whole core thin plate 11 having the lowermost one punched first, and is also caulked to each other via caulking portions 24 ′, 25 ′, and 26 ′.

≪Removal of connecting part≫
When the progressive die device 19 continues to operate, the semi-finished rotor 1 shown in FIG. 7 in which five connecting thin plates 20 are caulked and joined to both ends of the ten full core thin plates 11 is continuously manufactured. The squeeze ring 43 is discharged from the lower end (discharge port). Next, the manufacturing operator fixes (clamps) the annular portion 3 (annular portion thin plate 12) and the magnetic pole portion 5 (magnetic pole portion thin plate 13) of the semifinished rotor 1 with a jig (not shown), and then pulls it (not shown). A peeling force from the rotor 1 is applied to the connecting portion 21 using a peeling hydraulic tool or the like. As a result, the connecting portion 21 includes the annular portion thin plate 12 and the magnetic pole portion thin plate 13 at the dividing lines 22 and 23 because the spoke portion 31 is elastically deformed or plastically deformed around the fan-shaped hole 27 and the oblong hole 28. As shown in FIG. 8, the finished rotor 1 is obtained relatively easily. At this time, as shown in FIG. 7, the rotation phase between the spoke portion 31 of the connecting portion 21 and the winding portion 6 of the tooth 4 is shifted by a predetermined angle (45 ° in the illustrated example). It becomes easy to engage with the spoke part 31 (connecting part 21).

  This is the end of the description of the embodiment and the reference example, but the present invention is not limited to the above-described embodiment and can be widely modified. For example, although the above-described embodiment applies the present invention to the manufacture of a rotor for an electric motor, it is naturally applicable to the manufacture of a rotor for an electric motor and the like, as well as a stator for an electric motor. Further, in the above-described embodiment, the whole core thin plate and the connecting thin plate are integrated by caulking, but they may be integrated by adhesion, laser welding, or the like. Further, in the above embodiment, the connecting portion that is finally removed is also integrated by caulking, but this caulking is used to facilitate the separation of the connecting portion from the annular thin plate and the magnetic pole thin plate. May be abolished. In addition, the specific shape of the annular portion, teeth, the annular portion thin plate, the magnetic pole portion thin plate, the connecting portion, and the like can be changed as appropriate without departing from the gist of the present invention.

1 Rotor (armature)
DESCRIPTION OF SYMBOLS 3 Annular part 4 Teeth 5 Magnetic pole part 6 Winding part 11 Full-form iron core thin plate 12 Annular part thin plate 13 Magnetic pole part thin plate 19 Progressive die apparatus 20 Connecting thin plate 21 Connecting part 22, 23 Parting line 43 Squeeze ring L1 Axial direction of magnetic pole part Dimensions L2 Winding axial dimensions W Hoop material (metal plate)

Claims (3)

An annular portion fixed to the shaft or casing of the rotating electrical machine, and a plurality of teeth protruding radially from the outer peripheral side or inner peripheral side of the annular portion and each having a magnetic pole portion and a winding portion formed thereon, A method of manufacturing an armature in which an axial dimension of the winding part is smaller than an axial dimension of the magnetic pole part using a progressive die device,
A step of sequentially punching out the entire core thin sheet including a portion constituting the teeth and a portion constituting the annular portion from a strip-shaped metal plate;
A step of sequentially punching a connecting thin plate having a plurality of partial thin plates including a portion constituting only the magnetic pole portion from the metal plate, and a connecting portion connecting the partial thin plates;
Half cutting the partial thin plate or the connecting portion with respect to the connecting thin plate;
A step of forming a dividing line between the partial thin plate and the connection portion by pushing back the partial thin plate or the connection portion half-punched against the connection thin plate;
A step of laminating a predetermined number of the whole iron core thin plates, and
The connecting sheet on at least one end face of the laminated Zenkatachi core sheet saw including a step of bonding with a predetermined number of stacked,
The method of manufacturing an armature , wherein the connecting portion constitutes a portion that is removed when obtaining a finished product of the armature. The connecting thin plate further includes an annular portion thin plate, the annular portion thin plate is connected to the plurality of partial thin plates by the connecting portion, and is laminated on an end surface of the annular portion in the connecting step,
A step of half-cutting the annular part thin plate or the connecting part with respect to the connecting thin plate, and pushing back the half-cut annular part thin plate or the connecting part with respect to the connecting thin plate; The armature manufacturing method according to claim 1, further comprising a step of forming a parting line with the connecting portion . An annular portion fixed to the shaft or casing of the rotating electrical machine, and a plurality of teeth protruding radially from the outer peripheral side or inner peripheral side of the annular portion and each having a magnetic pole portion and a winding portion formed thereon, A progressive mold apparatus for manufacturing an armature in which an axial dimension of the winding part is smaller than an axial dimension of the magnetic pole part,
Punching means for sequentially punching out the entire core thin plate including the teeth and the annular portion from a strip-shaped metal plate;
Punching means for sequentially punching a connecting thin plate having a plurality of partial thin plates including only the magnetic pole portion from the metal plate and a connecting portion connecting the partial thin plates;
Half-drawing means for half-pulling the partial thin plate or the connecting portion with respect to the connecting thin plate;
A pushback means that pushes back the partial thin plate or the connecting portion half-punched to the connecting thin plate to form a dividing line between the partial thin plate and the connecting portion;
Laminating and coupling means for coupling the whole shape core sheet and the connecting sheet while laminating a predetermined number of sheets , and
The progressive mold apparatus according to claim 1, wherein the connecting portion constitutes a portion that is removed when a finished product of the armature is obtained .

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