JP7544011B2 - Manufacturing equipment for stator cores for rotating electrical machines - Google Patents

Description

The present invention relates to a manufacturing device and a manufacturing method for a stator core for a rotating electric machine.

Conventionally, a stator core for a rotating electric machine is manufactured by laminating and welding thin, annular core sheets of electromagnetic steel.
Generally, when manufacturing a stator core, when a large number of unwelded core sheets are stacked, the stack height can reach, for example, 200 mm, which tends to cause problems such as a decrease in the perpendicularity between the bottom surface of the stacked core and the stacking direction, or the core sheets becoming twisted in the stacking direction.

When stacking unwelded core sheets, there is no known technology to improve the straightness of the stacked cores or to reduce the error in the degree of twist relative to the axial centerline in the stacking direction.

Here, the "straightness" of the laminated core refers to the precision of the perpendicularity in the lamination direction relative to the bottom surface of the laminated core sheets. "Twist degree" refers to the degree of error in the twist in the lamination direction relative to the bottom surface of the laminated core sheets.

JP 2010-200505 A JP 2015-33290 A

The conventional method of laminating thick materials involves laminating low-thickness cores that have already been joined to a thickness of a few tens of millimeters and then welding the multiple low-thickness cores together. However, the process of manufacturing a single stator core involves two joining steps, which increases the number of steps and complicates the process.

Patent document 1 discloses a technique for inserting slot paper into the slots of a stator core to ensure insulation. Patent document 2 discloses a technique for inserting a temperature sensor into a communication passage leading to the slot of the stator core.

In neither Patent Document 1 nor Patent Document 2, the "straightness" and "degree of twist" of the core in which the core sheets are laminated during manufacturing are recognized as issues.

The present invention was made in consideration of the above-mentioned problems, and its purpose is to provide a manufacturing device and manufacturing method for a stator core for a rotating electric machine that improves the linearity of the laminated core and reduces the degree of twist.

The manufacturing device for a stator core for a rotating electric machine of the present invention is a manufacturing device for a stator core for a rotating electric machine, which uses a core holding tool when stacking a number of core sheets (10) having a thin, annular base portion (14) and a number of teeth (11) protruding radially inward from the base portion, with slots (12) between adjacent teeth, and which includes a base (19) on which the core sheets can be loaded, and a number of inner diameter guides (191) that rise vertically from the top surface of the base at the same radial position in the radial outward direction from a center line (3) perpendicular to the top surface of the base, and whose radial distance (r1) from the center line can be changed on the top surface. The core sheet has a structure including: (32, 33, 34, 35), a plurality of slot guides (42, 43, 44, 45) rising vertically from the upper surface of the base at the same radial position in the radial outward direction from a center line perpendicular to the upper surface of the base and capable of changing the radial distance (r2) from the center line on the upper surface, a plurality of upper guides (62, 63, 64, 65) that can be inserted between adjacent teeth (11) of the core sheets to be stacked, a link mechanism (8) that can change the radial distance from the center line of the plurality of inner diameter guides and the plurality of slot guides, and a drive unit (9) that drives the link mechanism.

With the manufacturing device for stator cores for rotating electrical machines having the above configuration, when a predetermined number of core sheets are placed on a base, multiple inner diameter guides are pressed radially outward against the inner walls of the teeth of the core sheets, and multiple slot guides are fitted into multiple slots between adjacent teeth of the core sheets. This allows accurate positioning of each core sheet to be stacked, improving the straightness of the stacked cores and reducing the degree of twist.

When manufacturing a stator core, the process of stacking core sheets before welding reduces the number of steps, and a simple process can be used to manufacture a pre-welded stacked core (laminated core) with high linearity and reduced twisting.

The manufacturing method of a stator core for a rotating electric machine of the present invention includes the steps of stacking a number of thin, annular core sheets, pressing an inner diameter guide against the inner wall of the stacked core sheets to guide them, inserting an upper guide between adjacent teeth of the stacked core sheets to prevent misalignment of the core sheets, inserting and guiding a slot guide between adjacent teeth of the stacked core sheets, measuring the core lamination thickness of the stacked core sheets, and, when the measurement shows that the core lamination thickness (thickness of the laminated core) is greater than the target core lamination thickness, removing a laminated core of the remaining lamination thickness.

The manufacturing device for stator cores for rotating electrical machines of the present invention has the effect of increasing the precision of perpendicularity and twist by providing an overhead guide above the base of the core holding jig.

The manufacturing device for rotating electric machine stator cores of the present invention has the effect of adjusting the thickness of the core laminations by using a loading device that can insert and remove core sheets.

According to the manufacturing device for stator cores for rotating electric machines of the present invention, the overhead guide installed on the base of the core holding jig has the effect of preventing the core sheet from shifting position when the unjoined core is lifted by the loading device.

The manufacturing device for a stator core for a rotating electric machine of the present invention has the effect of preventing the core from coming off the overhead guide by lowering the overhead guide to the position of the core on the base of the core holding jig.

The manufacturing device for rotating electric machine stator cores of the present invention has the effect of increasing the thickness of the core laminations by adding core sheets using a loading device while the overhead guide is lowered.

The manufacturing device for stator cores for rotating electrical machines of the present invention has the effect of reducing the thickness of the core laminations by removing the core sheet with the loading device while the overhead guide is lowered.

In the manufacturing device for stator cores for rotating electrical machines of the present invention, the upper guide is subject to a long deflection, so by providing a guide device, when the core is lifted, the guide device descends to a position above the base of the core holding jig, which has the effect of restricting the deflection of the upper guide.

1 is a front view of a manufacturing apparatus for a stator core for a rotating electric machine according to a first embodiment of the present invention; 1 is a perspective view showing a core holding jig and an upper guide of a manufacturing apparatus for a stator core for a rotating electric machine according to a first embodiment of the present invention; 4 is a cross-sectional view showing a core holding jig and an upper guide of the manufacturing apparatus for a stator core for a rotating electric machine according to the first embodiment of the present invention when the upper guide is lowered. FIG. FIG. 2 is a front view of a workpiece unloading and loading device of the manufacturing apparatus for a stator core for a rotating electric machine according to the first embodiment of the present invention. FIG. 2 is a plan view of a core sheet according to the first embodiment of the present invention. 6 is a view taken in the direction of an arrow VI in FIG. 5 . 1 is a perspective view of a laminated core manufactured by the manufacturing apparatus for a stator core for a rotating electric machine according to a first embodiment of the present invention; 4 is a flowchart showing steps for manufacturing a laminated core by the manufacturing apparatus for a stator core for a rotating electric machine according to the first embodiment of the present invention.

The manufacturing device for a stator core for a rotating electric machine according to an embodiment of the present invention will be described below with reference to the drawings. Note that the same reference numerals are used to designate substantially the same components in multiple embodiments, and descriptions thereof will be omitted.

First Embodiment
A first embodiment of the present invention will be described with reference to FIGS. 1 to 8. FIG.
As shown in FIG. 1 , the manufacturing apparatus for a stator core for a rotating electric machine includes a first core holding jig 16 having a base 19, a second core holding jig 26 having the base 19, an overhead mechanism 51, a work input loading device 30, and a work output loading device 50.

Figures 5 and 6 show a single core sheet made of thin electromagnetic steel material that is fed into the stator core manufacturing equipment.

The core sheet 10, which corresponds to the workpiece, is made of electromagnetic steel sheet and has a basic thin, annular shape. The core sheet 10 has 48 teeth 11 protruding radially inward at equal intervals in the circumferential direction from the annular base portion 14. 48 slots 12 are formed between adjacent teeth 11. The inner walls 110, which are the radially inward ends of the teeth 11, form the actual inner wall 13 of the core sheet 10.

Figure 7 shows a laminated core manufactured by the stator core manufacturing device of the first embodiment. The laminated core 20 is made so that the multiple stacked annular core sheets 10 have the same central axis, and adjacent teeth in the central axis direction overlap each other, so that when viewed from above in Figure 7, the slots 12 formed by the side walls of the teeth are formed in a groove shape that is straight and free of irregularities.

As shown in FIG. 1, the stator core manufacturing device 1 includes a work input loading device 30 that inputs a core sheet 10 corresponding to the workpiece into a second core holder 26, a station 40 that manufactures the desired laminated core, and a work output loading device 50 that outputs the laminated core 20 from station 40.

The workpiece input loading device 30 inputs the required number of core sheets 10 into the first core holding jig 16 in one or more batches.
The core holding jigs 16 and 26 have a jig body 17 that is movable along the transport path.

As shown in FIG. 2, the first holding jig 16 has a link mechanism 8 on the base 18 of the jig body 17. This link mechanism 8 is driven by a servo motor 9, which corresponds to a drive unit. A disk-shaped base 19 on which the core sheet 10 can be placed is provided on the base 18.

The base 19 has a guide hole 29 that connects the top surface to the bottom surface. The guide hole 29 passes through four inner diameter guides 32, 33, 34, and 35 and four slot guides 42, 43, 44, and 45.

The inner diameter guides 32, 33, 34, and 35 are long guide members with a basic circular cross-sectional shape, which when activated come into contact with the inner walls 110 of the teeth 11 of the multiple stacked core sheets 10, correcting any misalignment of each core sheet 10.

The slot guides 42, 43, 44, and 45 are long guide members with a rectangular cross-sectional shape that, when activated, are inserted into the slots 12 of the multiple core sheets 10 that are stacked together to correct any misalignment of the individual core sheets.

The inner wall of the guide hole 29 of the base 19 restricts the four inner diameter guides 32, 33, 34, and 35 so that they can move radially. The inner wall of the guide hole 29 also restricts the four slot guides 42, 43, 44, and 45 so that they can move radially.

The radial distances from the center line 3 of the four inner diameter guides 32, 33, 34, 35 and the four slot guides 42, 43, 44, 45 are variable via a link mechanism 8 driven by a servo motor 9. The same radial distance r1 of the four inner diameter guides and the same radial distance r2 of the four slot guides are adjusted according to the shape of the core sheet.

The four inner diameter guides 32, 33, 34, 35 rise perpendicularly to the upper surface 191 of the base 19 at the same radial position in the radially outward direction from a center line 3 perpendicular to the upper surface 191 of the base 19, and the radial distance from the center line 3 on the upper surface 191 can be changed.
The four slot guides 42 , 43 , 44 , 45 rise perpendicularly to the upper surface 191 of the base 19 at the same radial position in the radially outward direction from the center line 3 perpendicular to the upper surface 191 , and the distance from the center line 3 on the upper surface 191 can be changed.

In FIG. 1, the first holding jig 16 can move back and forth on the conveying path between the work input loading device 30 and the station 40. The configuration of the second holding jig 26 is similar to that of the first holding jig, so a description thereof will be omitted. The second holding jig 26 can move back and forth on the conveying path between the station 40 and the work discharge loading device 50.

Station 40 carries in a first holding jig on which a number of stacked core sheets are placed.
As shown in FIG. 2, the station 40 includes an overhead mechanism 51 .

The upper mechanism 51 is equipped with a plate 52 that can apply pressure to the multiple stacked core sheets when in operation. The plate 52 applies pressure to the stacked core sheets 10 by pressing from the top surfaces of the multiple core sheets 10 stacked on the base 19. This bonds the stacked core sheets.

The overhead mechanism 51 has four overhead guides 62, 63, 64, and 65 that hang down from the plate 52. As shown in FIG. 3, the overhead guides 62, 63, 64, and 65 fit into the slots 12 when in operation, and can reduce the degree of "twist" of the stacked core sheets 10.

Figure 3 shows a cross section of a number of core sheets stacked on a base 19 at station 40, with the above-mentioned inner diameter guides 32, 33, 34, 35, slot guides, and overhead guides 62, 63, 64, 65 acting on them. For convenience, hatching of the cut surfaces of the core sheets is omitted in Figure 3 to avoid the line drawing becoming complicated.

The upper guides 62, 63, 64, and 65 enter the slots of the core sheets to prevent the core sheets from shifting position when the unjoined stacked core sheets are lifted by a loading device (not shown).

The upper guides 62, 63, 64, and 65 are lowered to the position of the laminated core (not shown) stacked on the base 19 of the first core holding jig 16, preventing the laminated core from coming off the upper guides 62, 63, 64, and 65.

The guide device 28 regulates the deflection of the upper guides 62, 63, 64, and 65 when descending.

Station 40 is equipped with a loading device (not shown) that cuts the stacked core sheets to the desired core thickness.

If the measurement shows that the core stack thickness is smaller than the target stack thickness, the upper guides 62, 63, 64, and 65 are lowered and the loading device adds core sheets to increase the core stack thickness.

If the measurement shows that the core stack thickness is greater than the target stack thickness, the upper guides 62, 63, 64, and 65 are lowered and the loading device removes the core sheet, reducing the core stack thickness.

The operation at station 40 is as follows.
8, the first core holding jig 16 on which the core sheets 10 are placed is carried into the station 40 (step S90). The plate 52 descends onto the carried-in stacked core sheets 10, applying pressure to the stacked core sheets 10 to bond the stacked core sheets 10.

At this time, the inner diameter guides 32, 33, 34, 35 and the slot guides 42, 43, 44, 45 ensure "straightness" and reduce "twisting" for the stacked core sheets of the desired core lamination thickness.

When measuring the core thickness (axial length of the core) of a laminated core (step S91). The core lamination thickness of the laminated core is measured, and when a laminated core with a core lamination thickness of, for example, 250 mm is brought in, if the target core lamination thickness is, for example, 200 mm, the blade tip of a loading device (not shown) is placed at a position 200 mm from the top of the laminated core, the laminated core with a core lamination thickness of 200 mm to be removed is cut out and lifted up with the blade tip (step S92).

To prevent the core from coming off the guides when lifting, the upper guides 62, 63, 64, and 65 are lowered to the position of the core (step S93). This prevents the stacked core sheets from shifting position. The upper guides 62, 63, 64, and 65 then rise (step S94), and the stacked core with the target core thickness is removed and transported to the outside by the discharge loading device (step S95).

In the workpiece discharge loading device 50 shown in FIG. 4, an arm 55 equipped with a cutting blade 57 for cutting out the laminated core can be raised and lowered relative to a frame 56. The laminated core removed (manufactured) at station 40 is discharged to the next step.

According to this embodiment, the laminated core, which is made by stacking multiple core sheets, has high linearity, and it is possible to efficiently manufacture high-precision laminated cores that have a large thickness and low degree of twist.

Generally, a stator core is formed by forming a sheet-like electromagnetic steel plate into a desired shape by press working, and then stacking a plurality of the formed electromagnetic steel plates (core sheet) in a lamination device.
The number of laminated core sheets that make up the stator core is changed according to the motor output. For motors with low output, the number of laminated core sheets is reduced to make the stator core thinner. On the other hand, for motors with high output, the number of laminated core sheets is increased to make the stator core thicker.

Other Embodiments
In the above embodiment, an example has been described in which the laminated core has 48 teeth, but the number of teeth of the stator core manufactured by the stator core manufacturing apparatus of the present invention is not limited to this.

In the above embodiment, the number of inner diameter guides, slot guides, and upper guides is four, but in the present invention, the number may be three or six, and the number is not limited.
The material, size, shape, and number of teeth of the core sheet are not limited to those in the above embodiment.

The other basic configurations of the other embodiments are the same as those of the first embodiment.

The present invention is not limited to the above-described embodiment, and can be implemented in various forms without departing from the spirit of the invention.

1. Stator core manufacturing device,
3 center line,
8 link mechanism,
9 servo motor (drive unit),
10 core sheet,
11 Teeth,
12 slots,
16 First core holding jig,
19 Foundation,
20 Laminated core,
26 second core holding jig,
28 Guiding device,
29 guide hole,
30 Work input loading device,
32, 33, 34, 35 Inner diameter guide,
42, 43, 44, 45 Slot guide,
62, 63, 64, 65 Sky Guide,
110 Interior wall.

Claims (6)

A manufacturing device for a stator core for a rotating electric machine uses a core holding jig when stacking a number of core sheets (10) each having a thin, annular base portion (14) and a number of teeth (11) protruding radially inward from the base portion and each having a slot (12) between adjacent teeth ,
A base (19) on which the core sheet can be loaded;
A plurality of inner diameter guides (32, 33, 34, 35) that rise vertically from a center line (3) perpendicular to an upper surface (191) of the base at the same radial position in the radially outer direction from the center line (3) and whose radial distance (r1) from the center line on the upper surface can be changed;
A plurality of slot guides (42, 43, 44, 45) that rise vertically to the upper surface at the same radial position in the radially outer direction from the center line perpendicular to the upper surface of the base and whose radial distance (r2) from the center line on the upper surface is changeable;
A plurality of upper guides (62, 63, 64, 65) that can be inserted between adjacent teeth of the core sheets to be laminated ;
a link mechanism (8) capable of changing a radial distance from the center line of the plurality of inner diameter guides and the plurality of slot guides;
and a drive unit (9) that drives the link mechanism. 2. The manufacturing apparatus for a stator core for a rotating electric machine according to claim 1 , wherein the inner diameter guide is an elongated guide member that guides an inner wall (110) of the tooth. 2. The manufacturing apparatus for a stator core for a rotating electric machine according to claim 1 , wherein the slot guide is an elongated guide member that guides side walls (111) of the teeth that form the slots. The manufacturing device for a stator core for a rotating electric machine according to claim 1, further comprising a plate (52) for applying pressure from the upper surface of the core sheet loaded on the base. 2. The manufacturing apparatus for a stator core for a rotating electric machine according to claim 1 , further comprising a guide device (28) that descends to a position above said base when lifting up the cores to be stacked, and restricts deflection of said upper guide. A step of stacking a number of thin, annular core sheets;
a step of pressing and guiding an inner diameter guide against an inner wall of the laminated core sheets;
A process of inserting an upper guide between adjacent teeth of the laminated core sheets to prevent the core sheets from shifting in position;
a step of inserting and guiding a slot guide between adjacent teeth of the laminated core sheets;
Measuring the core lamination thickness of the laminated core sheets;
and when the measurement result indicates that the core lamination thickness is greater than the target core lamination thickness, removing a laminated core of an amount corresponding to the difference in lamination thickness.

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