JP7702841B2 - Laminated core manufacturing device and method for manufacturing a rotating electric machine - Google Patents

Description

This application relates to a laminated core manufacturing device and a method for manufacturing a rotating electric machine.

In recent years, there has been an increasing demand for higher efficiency in rotating electrical machines such as electric motors and generators. To achieve higher efficiency, the cores used in rotating electrical machines have often been constructed of laminated cores using electromagnetic steel sheets with a thickness of about 0.35 mm to 0.5 mm. However, in order to meet the demand for even higher efficiency, there has been an increase in the use of electromagnetic steel sheets with a thickness of 0.35 mm or less in recent years.

A widely known method for fixing the spaces between the multiple electromagnetic steel sheets that make up a laminated core is to provide recesses and protrusions in the thickness direction of each core piece, and then to clamp the spaces between the laminations at the same time as punching out the core pieces.

However, when the recesses and protrusions provided in the thickness direction of the core pieces are crimped to fix them, eddy current loss occurs in the fitting area, reducing the efficiency of the rotating electric machine. Furthermore, when the plate is thin, 0.3 mm or less, the strength of the crimped area itself decreases, making it difficult to ensure sufficient fixing strength. For this reason, a method is used in which the laminations are not fixed at the same time as punching, but rather the laminations of multiple core pieces are fixed by adhesive or other fixing means after punching.

Patent document 1 discloses a rotating electric machine in which the core pieces punched out in sequence in the direction of gravity are ejected horizontally from the die through a cylindrical guide that is bent horizontally from the direction of gravity.

In this document, by using a slot defined as a specific slot among multiple slots provided in the core piece to position the guide and the core piece while ejecting them from the die, each core piece can be ejected from the die in an aligned state even if the laminations are not fixed by crimping at the same time as punching.

JP 2012-34497 A

In Patent Document 1, the core pieces are punched in the direction of gravity. Because the thickness direction of the plate material is aligned with the direction of gravity, the plate material warps. In particular, when using plate material with a thickness of 0.35 mm or less, many other guides are required to suppress the warping, which creates a problem of complicated dies and increased manufacturing costs for laminated cores. Furthermore, providing many guides increases resistance in the direction in which the material is fed, making the plate material more likely to buckle. In particular, with thin plates, the buckling load itself is small, so when resistance in the direction in which the plate material is fed increases, buckling occurs frequently, resulting in a problem of reduced productivity of laminated cores.

This application discloses technology to solve the above problems, and aims to provide a laminated core manufacturing device and a method for manufacturing a rotating electric machine that can manufacture laminated cores that constitute a rotating electric machine at low cost and with high productivity.

The laminated core manufacturing apparatus disclosed in the present application is
a press machine including a punch and a die for punching out the iron core pieces from the plate material in a thickness direction of the plate material;
A plate material supplying device is provided which supplies the plate material to the press machine with the plate thickness direction of the plate material perpendicular to the gravity direction,
The press machine includes a guide that aligns the core pieces discharged from the die in a punching direction by the punch while maintaining the punched posture to stack a group of core pieces,
The guide has two inner surfaces that contact the core pieces in the direction of gravity, and the guide is open upward in the direction of gravity so as to support the core pieces in the direction of gravity on the surfaces of the core pieces that face the two inner surfaces diagonally with respect to the direction of gravity .

The laminated core manufacturing apparatus and the method for manufacturing a rotating electric machine disclosed in this application can provide a laminated core manufacturing apparatus and a method for manufacturing a rotating electric machine that can manufacture laminated cores that constitute highly efficient rotating electric machines at low cost and with high productivity.

1 is a schematic front view of a laminated core manufacturing apparatus according to embodiment 1; FIG. 1 is a perspective view of a press machine according to a first embodiment. FIG. 1 is a side view of a press machine according to a first embodiment. FIG. 4 is a schematic cross-sectional view of a main part of a press machine according to the first embodiment (a cross-sectional view taken along the line AA in FIG. 3 ). This is a cross-sectional view taken along line B-B of FIG. This is a cross-sectional view taken along the line CC of FIG. 5 is a schematic diagram showing the positional relationship between a die, a plate material, and a plate material guide according to the first embodiment. FIG. 13 is a schematic diagram showing a comparative example in which a plate material is transported in a horizontal direction and iron core pieces are punched out. FIG. 9 is a detailed view of the portion circled in a circle D in FIG. 4. FIG. 9A is a view showing a state when a plate material is fed. FIG. 9B is a view showing a state immediately before pressing the core piece. FIG. 9C is a view showing a state immediately after pressing the core piece 5P. 1 is a schematic front view of an application example of the laminated core manufacturing apparatus according to embodiment 1. FIG. 10 is a schematic diagram showing the balance of forces acting on a group of core pieces on a guide. FIG. FIG. 11 is a schematic front view of a laminated core manufacturing apparatus according to a second embodiment. FIG. 13 is a plan view of the laminated core manufacturing apparatus shown in FIG. 12 . FIG. 11 is a schematic front view of a press machine according to a third embodiment. Fig. 15 is a schematic diagram of a die operation of a press machine according to embodiment 3. Fig. 15A is a schematic diagram showing a state before a core piece is punched out. Fig. 15B is a schematic diagram showing a state during punching out of the core piece. Fig. 15C is a schematic diagram showing a state in which a plurality of core pieces are punched out and discharged. 13 is a schematic cross-sectional view of a main portion of a laminated core manufacturing apparatus according to embodiment 4. FIG. This is a cross-sectional view taken along the line E-E of Figure 16. This is a cross-sectional view taken along the line FF in FIG. 16. Fig. 19A is a diagram showing another example of a bonding method, and Fig. 19B is a cross-sectional view taken along line GG of Fig. 19A. FIG. 13 is a schematic cross-sectional view of a main portion of a laminated core manufacturing apparatus according to embodiment 5. FIG. This is a cross-sectional view taken along line HH of Figure 21. FIG. 13 is a view of the sixth embodiment corresponding to the cross section taken along line BB of FIG. 4 of the first embodiment. FIG. 13 is a view of a sixth embodiment corresponding to the CC cross section of FIG. 4 of the first embodiment. FIG. 21 is another view of the sixth embodiment corresponding to the cross section taken along line BB of FIG. 4 of the first embodiment. FIG. 21 is another view of the sixth embodiment corresponding to the CC cross section of FIG. 4 of the first embodiment. 1A and 1B are diagrams illustrating examples of annular core pieces.

Embodiment 1.
Hereinafter, the laminated core manufacturing apparatus and the rotating electrical machine manufacturing method according to the first embodiment will be described with reference to the drawings.
FIG. 1 is a schematic front view of a laminated core manufacturing apparatus 100. As shown in FIG.
FIG. 2 is a perspective view of the press machine 10 constituting the laminated core manufacturing apparatus 100. As shown in FIG.
FIG. 3 is a side view of the press 10.
FIG. 4 is a schematic cross-sectional view of a main part of the press machine 10, taken along the line AA in FIG.
FIG. 5 is a cross-sectional view taken along line BB of FIG.
FIG. 6 is a cross-sectional view taken along the line CC of FIG.
FIG. 7 is a detailed view of the portion circled D in FIG.
In the following description, the punching direction of the core piece P by the punch 13P and the thickness direction of the plate material 5 are always the same, so the same symbol W is used.

The laminated core manufacturing apparatus 100 shown in FIG. 1 includes a press machine 10 that punches out core pieces from a plate material 5 and a material supplying device 20 that supplies the plate material 5 to the press machine 10 .
The material supply device 20 includes an uncoiler 21 to which the coiled sheet material 5 is rotatably attached and which supplies the sheet material 5 to the press machine 10 while unwinding it, and multiple pairs of rollers 22 that clamp and guide the sheet material.

The press 10 includes a mounting table 11, a frame 12 placed on the mounting table 11, a die 13 fixed inside the frame 12 and used to punch out core pieces 5P from the plate material 5, a guide 10G that aligns the punched core pieces 5P in the punching direction W while maintaining the punched position, and stacks the groups of core pieces 5P in sequence, a material feed device 14 that feeds the plate material 5 to the die 13 in sequence, a plate material guide 15 that guides the plate material 5 from the material feed device 14 to the die 13, and a motor 16 and crank cam 17 that drive the punch of the die 13.

Next, the details of the die 13 will be described. As shown in Figs. 1 and 4, the die 13 is composed of a punch 13P, a die 13D, a first plate 13A, and a second plate 13B. The punch 13P is fixed to the first plate 13A, and the die 13D is fixed to the second plate 13B. The first plate 13A is further fixed to a slide 18 connected to a crank cam 17, and the second plate 13B is fixed to a bolster 19. The bolster 19 is also fixed to the frame 12. The slide 18 is connected to the crank cam 17, and the slide 18 can be driven in the horizontal direction H (the left-right direction in Fig. 1) by rotating the crank cam 17 by the motor 16.

In this way, by driving the motor 16 of the press 10, the slide 18 is moved relative to the frame 12 in the horizontal direction H via the crank cam 17, and the plate material 5 is punched in one direction in the plate thickness direction W by the punch 13P and the die 13D, and the punched core piece 5P is then pushed into the die 13D as shown in FIG. 5.

As shown in FIG. 1, the sheet material 5 wound into a coil is placed on the uncoiler 21, and the sheet material 5 is supplied to the press machine 10. The sheet material 5 is fed a predetermined length by the material feed device 14, and then punched into the shape of the iron core piece 5P by the die 13. At this time, the sheet material 5 is fed in the direction of gravity G. As a result, the thickness direction W of the sheet material 5 becomes perpendicular to the direction of gravity G, i.e., the horizontal direction H.

The punched plate material 5 is again fed by the material feeder 14 by a predetermined length, and the next core piece 5P is punched out by the die 13. By repeating this operation, the core pieces 5P are stacked in the guide 10G to the left in FIG. 1. At this time, the core pieces 5P ejected from the die 13 are supported by both inner surfaces 10GS of the guide 10G at both ends 5PYE of the yoke portion 5PY as shown in FIG. 6, and are sequentially pushed out of the guide 10G to the left in FIG. 1. At this time, the angle formed by both inner surfaces 10GS of the guide 10G and the angle formed by both ends 5PYE of the yoke portion 5PY of the core piece 5P are both equal to the angle α. Therefore, the core piece 5P is held by the guide 10G with the teeth portion 5PT straight toward the direction of gravity G.

Although a typical crank cam 17 is used to drive the slide 18, a drive source such as a hydraulic cylinder or a ball screw may be used as a means for driving the slide 18. In addition, by appropriately arranging a plate guide 15 between the material feed device 14 and the die 13, it is possible to suppress the fluttering of the plate 5 and feed the plate 5 stably.

By repeating the above cycle, the core pieces 5P are punched out of the plate material 5, and the already punched core pieces 5P are continuously pushed out to the left in FIG. 6. The pushed out core pieces 5P are configured so that at least a portion of the outer circumferential surface of the core pieces 5P contacts the guide 10G in the direction of gravity G. The group of core pieces 5P can be discharged outside the press machine 10 via this guide 10G, making it possible to remove them.

Here, it is desirable that the core pieces 5P punched out by the punch 13P are punched out horizontally and ejected straight. Compared to the prior art document in which the sheet material is fed horizontally, the core pieces punched out in the direction of gravity G by the punch are then bent 90 degrees by a guide to be ejected, there is no "catching" or "clogging," and this has the effect of improving the productivity of laminated cores.

In addition, by providing a guide 10G that contacts at least a portion of the outer circumferential surface of the core piece 5P in the direction of gravity G, the core piece 5P can be guided while being ejected from the press machine 10 even if the core piece 5P itself does not have a guide groove or hole, so there are no shape restrictions on the core piece 5P, and this has the effect of improving design freedom.

When the core pieces are punched out in the direction of gravity G, the core pieces are moved in the direction of gravity G. In this case, it is not possible to provide a guide in the direction of gravity G. As a result, the punched core pieces fall freely and get caught at an angle against the bending guide. If the punched core pieces pile up in this state, excessive force acts on the guide or die, leading to breakdowns such as breakage and deformation, and reducing productivity.

To avoid this, one possible method would be to make the guide width smaller than the width of the core pieces, and hold the core pieces in place using the frictional force of the guide. However, in press working, lubricants are often applied to extend the life of the die. In this case, the frictional force is small and unstable. As a result, the guide width needs to be adjusted frequently, which can lead to problems with reduced productivity.

Furthermore, if the core pieces are moved continuously while friction is generated between the guide and the laminated core pieces, the guide will wear out significantly and will need to be replaced frequently, which will reduce the productivity of the laminated core. Compared to prior art documents in which the core pieces are punched in the direction of gravity and then discharged in a direction perpendicular to the direction of gravity, this application reduces the frequency of guide adjustment and replacement, which has the effect of improving the productivity of the laminated core.

In addition, the laminated core manufacturing device 100 can eject the group of iron core pieces 5P that are stacked perpendicular to the direction of gravity G (horizontal direction H), which has the effect of lowering the height of the press 10. On the other hand, if punching is performed vertically as in the prior art documents, a space must be provided below for ejection, which increases the height of the press. As the height of the device increases, the rigidity of each part decreases, which creates the problem of increased vibration and noise from the press.

In this case, practical problems arise, such as the inability to transport the equipment into the building. Furthermore, in order to remove the core pieces, it is necessary to crawl under the press machine, which makes it difficult to work and extremely difficult to configure the equipment. Even if an iron core piece ejection device is placed under the press machine, there is the problem that maintenance is difficult. On the other hand, with the laminated core manufacturing equipment 100 according to embodiment 1, the iron core pieces 5P are directly ejected in the horizontal direction H, allowing work to be done next to the equipment, which makes it easy to work. In addition, the equipment for removing the laminated cores is easy to configure, which has the effect of improving the productivity of laminated cores.

As shown in FIG. 4, a pressing device 10PS may be provided on the side of the guide 10G opposite the die 13 side, and the group of core pieces 5P ejected from the die 13 may be pressed toward the die 13 side. By pressing the group of punched core pieces 5P with the pressing device 10PS, the posture of each core piece 5P becomes more stable and the inclination of each core piece 5P becomes smaller, further reducing the risk of getting caught on the guide 10G and improving the productivity of laminated cores.

FIG. 7 is a schematic diagram showing the positional relationship between the die 13, the plate material 5, and the plate material guide 15. As shown in FIG.
Focusing on the orientation of the plate material 5, the plate thickness direction W is perpendicular to the gravity direction G. Therefore, the plate material 5 sags due to its own weight. This prevents the plate material 5 from bending, suppressing the possibility of buckling of the plate material 5 and improving the productivity of the laminated core.

FIG. 8 is a schematic diagram showing a comparative example in which a plate material is transported in a horizontal direction and core pieces are punched out.
As shown in Fig. 8, when the weight direction (gravity direction G) and the plate thickness direction W coincide with each other, plate material 5 having a thickness of 0.35 mm or less in particular is greatly bent by its own weight, and buckling of the plate material is likely to occur. By providing multiple guides in the plate thickness direction W, the number of support points can be increased and the load can be dispersed, but if the number of plate material guides 15 is increased, the load required for feeding the plate material also increases, and this may cancel out the effect.

In addition, as the load required for material feeding increases, slippage may occur within the material feeding device, which may result in improper feeding of the plate material and poor punching results. On the other hand, in this embodiment 1, the gravity direction G in which the weight is applied and the plate thickness direction W are perpendicular, so the number of plate material guides 15 can be reduced, the load required for feeding the plate material 5 can be reduced, and the possibility of slippage occurring within the material feeding device 14 can be reduced, which has the effect of improving the productivity of laminated cores.

In this embodiment 1, the feed direction of the plate material 5 and the direction in which its own weight is applied are the same, so there is no frictional force acting on the plate material guide 15 due to its own weight, and the feed load can be reduced by the force applied in the feed direction due to its own weight. This further reduces the load required for material feed and reduces the possibility of slippage occurring within the material feed device 14, which has the effect of improving the productivity of laminated cores.

FIG. 9 is a detailed view of the portion circled D in FIG.
FIG. 9A is a diagram showing a state during feeding of the plate material 5. As shown in FIG.
FIG. 9B is a diagram showing the state of the core piece 5P immediately before pressing.
FIG. 9C is a diagram showing the state immediately after the core piece 5P is pressed.
As shown in Figures 1 and 9A to 9C, an upper cutter 10CUP is attached to the bolster 19, and a lower cutter 10CDW is attached to the slide 18. When the sheet material 5 is fed, it is fed between the upper cutter 10CUP and the lower cutter 10CDW (Figure 9A). Then, when the core piece 5P is punched out (Figure 9B), the sheet material 5 is cut by the upper cutter 10CUP and the lower cutter 10CDW by approximately the feed pitch in conjunction with this operation (Figure 9C).

By providing the upper cutter 10CUP and the lower cutter 10CDW in this configuration, the sheet material 5 can be cut into small pieces after punching out the core pieces 5P, which has the effect of making it easier to collect scrap sheet material 5.

In addition, since the upper cutter 10CUP is attached to the bolster 19 and the lower cutter 10CDW attached to the slide 18 is installed on the feed direction side of the plate material 5, the shredded scrap falls naturally under its own weight in the direction away from the lower cutter 10CDW.
Therefore, compared to when two cutters are moved back and forth in the direction of gravity G, problems such as scrap material sticking to and getting caught in the lower cutter 10CDW can be suppressed, which has the effect of improving the productivity of laminated cores.

FIG. 10 is a schematic front view of an application example of the laminated core manufacturing apparatus according to the first embodiment.
The configuration of the laminated core manufacturing apparatus 100 is almost the same as the laminated core manufacturing apparatus 100 described so far. In Fig. 10, the punching direction of the core pieces 5P is not completely perpendicular to the direction of gravity G. In this way, it is sufficient that the punching direction of the core pieces 5P does not coincide with the direction of gravity G but is a different direction. By making the punching direction different from the direction of gravity G, at least a part of the punching direction of the core pieces 5P includes a component perpendicular to the direction of gravity G, so that the same effect as that described so far can be obtained. In this case, the supply direction F of the sheet material 5 to the press machine 10 is also inclined.

FIG. 11 is a schematic diagram showing the balance of forces acting on the group of core pieces 5P on the guide 10G.
Here, the angle between the longitudinal direction of the guide 10G (the direction in which the core pieces 5P are discharged) and the horizontal direction is θ, the weight of the group of core pieces 5P is M, and the gravitational acceleration is g.
Of the force component Mg*sin θ in the longitudinal direction of the guide 10G and the force component Mg*cos θ in a direction perpendicular to the longitudinal direction of the guide 10G, it is desirable that the force component in the longitudinal direction of the guide 10G be smaller.

If the force component in the longitudinal direction of the guide 10G becomes large, the longitudinal direction of the guide approaches the direction of gravity G, as in the prior art document, making it difficult to obtain the effect of the present application. In other words, it is desirable to keep θ within a range of 45° above or below the horizontal direction.

In addition, if the guide 10G is tilted so that the side in the direction of travel of the core pieces 5P faces downward, and the sliding force Mg*sinθ is greater than the holding force μMg*cosθ due to friction acting on the core pieces 5P, the core pieces 5P will slip against the guide 10G, making it difficult to achieve the effects of this application. For this reason, it is desirable to make tanθ<μ. It is generally known that the coefficient of friction has a value of about 0.1 to 0.9, so it is desirable to make tanθ<0.9.

In this embodiment 1, one sheet of plate material 5 wound in a coil shape is rotatably attached to the material supply device 20, but if multiple sheets of plate material 5 wound in a coil shape are used, it is also possible to punch out multiple core pieces 5P simultaneously with a pair of punch and die.
Further, in the present embodiment, an example of manufacturing a laminated core for a rotating electrical machine has been shown, but the laminated core manufacturing apparatus 100 can also be used to manufacture cores for transformers and the like.

Embodiment 2.
The laminated core manufacturing apparatus and the rotating electrical machine manufacturing method according to the second embodiment will be described below, focusing on the differences from the first embodiment.
FIG. 12 is a schematic front view of the laminated core manufacturing apparatus 200. As shown in FIG.
FIG. 13 is a plan view of the laminated core manufacturing apparatus 200 shown in FIG.
In the first embodiment, the plate material 5 is supplied to the press machine 10 from above in the direction of gravity G, but in the present embodiment, the plate material 5 is supplied to the press machine 210 with its longitudinal direction (feed direction) facing the horizontal direction H. As in the first embodiment, the plate material 5 is supplied to the press machine 210 with its thickness direction W perpendicular to the direction of gravity G.

The uncoiler 221 of the material supply device 220 has a rotation axis facing the direction of gravity G. The sheet material 5 unwound from the uncoiler 221 is supplied to the die 213 by the material supply device 214 of the press machine 210 with the feed direction of the sheet material 5 perpendicular to the direction of gravity G (horizontal direction H) and with the width direction of the sheet material 5 facing the direction of gravity G.

As a result, the plate material 5 does not bend due to its own weight, which reduces the possibility of buckling of the plate material 5 and improves the productivity of the laminated core.

Furthermore, as in the first embodiment, the number of rollers 222 that guide the plate material 5 can be reduced, which has the effect of improving the productivity of the laminated core. Furthermore, since the feed direction of the plate material 5 and the direction of gravity G are perpendicular to each other, the height of the laminated core manufacturing device 200 can be reduced, which has the effect of making the laminated core manufacturing device 200 more compact. Furthermore, the thickness direction of the plate material 5 is perpendicular to the direction of gravity G until it is supplied from the material supply device 220 to the mold 213 via the material feed device 214.

As a result, the plate material 5 does not bend under its own weight even during the process from when it is supplied from the material supply device 220 to the mold 213, which reduces the possibility of buckling of the plate material 5 and improves the productivity of the laminated core.

Embodiment 3.
The laminated core manufacturing apparatus and the rotating electrical machine manufacturing method according to the third embodiment will be described below, focusing on the differences from the first embodiment.
FIG. 14 is a schematic front view of a press 310 according to the third embodiment.
In the first embodiment, a fixed bolster 19 and a moving slide 18 are combined, but in the third embodiment, two moving slides 318A and 318B are used, both of which are slid in the horizontal direction H and driven in opposite phases, so that the excitation force applied to the press 310 by the operation of the slides 318A and 318B can be offset. Reducing the excitation force applied to the press 310 has the effect of stabilizing the punching accuracy of the core pieces 5P and improving the accuracy of the laminated core. In addition, it has the effect of reducing the vibration and noise of the press 310 and quieting down the manufacturing environment.

FIG. 15 is a schematic diagram of the die operation of the press machine 310 according to the third embodiment.
FIG. 15A is a schematic diagram showing the state of the core piece 5P before being punched out.
FIG. 15B is a schematic diagram showing the state when the core piece 5P is punched out.
FIG. 15C is a schematic diagram showing a state in which a group of core pieces 5P is punched out and discharged.
14, a first plate 313A is attached to a slide 318A, and a second plate 313B is attached to a slide 318B. The first plate 313A and the second plate 313B are movable opposite each other in the horizontal direction.

The first punch 313PA, the first die 313DA, and the first guide 310GA are attached to the first plate 313A, and the second punch 313PB, the second die 313DB, and the second guide 310GB are attached to the second plate 313B.

As shown in FIG. 15A, sheet material 5 is supplied from above, and as shown in FIG. 15B, first plate 313A and second plate 313B are moved toward each other, whereby two core pieces 5P are punched out simultaneously by first punch 313PA and first die 313DA, and second punch 313PB and second die 313DB. By repeating this operation, the core pieces 5P are sequentially discharged toward first guide 310GA and second guide 310GB. First guide 310GA and second guide 310GB extend horizontally in opposite directions.

The two core pieces 5P punched out at the same time are discharged separately in the left and right directions, as shown in FIG. 15C. Compared to when they are discharged from only one side, this allows for a larger removal space, making it easier to remove the core pieces 5P. This has the effect of improving the productivity of laminated cores.

Embodiment 4.
The laminated core manufacturing apparatus and the rotating electrical machine manufacturing method according to the fourth embodiment will be described below, focusing on the differences from the first embodiment.
FIG. 16 is a schematic cross-sectional view of a main part of a laminated core manufacturing apparatus 400 according to the fourth embodiment.
FIG. 17 is a cross-sectional view taken along line E--E of FIG.
FIG. 18 is a cross-sectional view taken along line FF of FIG.
The core pieces 5P are sequentially discharged in the horizontal direction along the guide 10G, with both ends 5PYE of the yoke portion 5PY supported by both inner surfaces 10GS of the guide 10G. A second pressing portion 410PS is provided above the guide 10G, and the alignment of the core pieces 5P is improved by pressing the core pieces 5P in the direction of gravity G. The guide 10G is equipped with an application nozzle 6N and a hot air blower 40 as a bonding device. A heat-curing adhesive 61 is applied by the application nozzle 6N to the circumferential center of the yoke portion 5PY of the aligned core pieces 5P.

The core pieces 5P coated with adhesive 61 are sequentially discharged to the left in FIG. 16, and while aligned, are heated by hot air supplied from the hot air blower 40 through the air nozzle 41, hardening the adhesive 61. The hardened core pieces 5P with the gaps between the layers fixed are cut to a predetermined length by a cutting tool 70 to become laminated cores 50, and are transported to the next process by a belt conveyor 80.

Here, the laminated core 50 is discharged with the gap between the layers fixed, which makes it easy to transport to the subsequent process, thereby improving the productivity of the subsequent process. In addition, each device can be arranged horizontally, which improves the maintainability of the laminated core manufacturing device 400. Furthermore, since the lamination direction of the laminated core 50 is perpendicular to the direction of gravity G, there is no gap between the layers of the laminated core 50 or the laminated core 50 becoming tilted due to the influence of gravity, which has the effect of improving the shape precision of the laminated core 50 while stabilizing the bonding strength.

In the above example, a heat-curing adhesive 61 is used, but any type of adhesive can be used as long as it can fix the layers together. When a room temperature curing or two-liquid mixing adhesive is used, no curing means is required, which has the effect of improving the productivity of the laminated core 50. When a light-curing adhesive is used, the adhesive can be cured continuously in the same way by using a UV light instead of the hot air blower 40.

FIG. 19A is a diagram showing another example of the bonding method.
FIG. 19B is a cross-sectional view taken along line GG of FIG. 19A.
19B, the surfaces of adjacent core pieces 5P may be bonded to each other by applying an adhesive between the laminations of the core pieces 5P in advance or by allowing a low-viscosity adhesive to penetrate between the laminations. This configuration has the effect of further improving the rigidity of the laminated core 50.

Figure 20 is a cross-sectional view of a rotating electric machine 90 assembled using a laminated core manufactured using the laminated core manufacturing device described above. The rotating electric machine 90 is used as a motor or a generator. The rotating electric machine 90 includes a stator 90A and a rotor 90B rotatably supported with its outer peripheral surface facing the inner peripheral surface of the stator 90A. The laminated core 50, which is made by stacking iron core pieces 5P and bonding them by a fixing means, is covered with an insulating member 81 and wound with a coil 82. The coil 82 is electrically connected by a connecting member 83 and connected to a current control device such as a power source or an inverter. A plurality of laminated cores 50 arranged in a circular ring shape are fixed in a frame 84 and supported rotatably relative to the frame 84 and a shaft 87 supported by bearings 86 provided on brackets 85 that close the opening of the frame 84.

A rotor core 88 and magnets M are fixed to the shaft 87. In this configuration, passing an alternating current through the coil 82 generates a rotating magnetic field, which generates an attractive force between the magnets M and the laminated core 50, applying torque to the shaft 87 and converting electrical energy into rotational energy. Here, the laminated core 50, to which the iron core pieces 5P are fixed by adhesion, does not electrically short-circuit between the laminations, reducing iron loss and improving the efficiency of the rotating electric machine 90.

In addition, the laminated core 50 manufactured using the laminated core manufacturing device according to this embodiment has the lamination direction of the iron core pieces 5P perpendicular to the direction of gravity G, so there is no gap between the laminations or tilt due to the influence of gravity. This stabilizes the adhesion strength between the laminations of the iron core pieces 5P, improves the shape accuracy of the laminated core 50, and improves its strength, so that the roundness of the inner diameter of the stator core of the rotating electric machine 90 is high. This has the effect of suppressing the cogging torque and torque pulsation of the rotating electric machine 90.

Embodiment 5.
The laminated core manufacturing apparatus and the rotating electrical machine manufacturing method according to the fifth embodiment will be described below, focusing on the differences from the fourth embodiment.
FIG. 21 is a schematic cross-sectional view of a main part of a laminated core manufacturing apparatus 500 according to the fifth embodiment.
FIG. 22 is a cross-sectional view taken along line HH of FIG.
The fourth embodiment and the fifth embodiment are different in the method of fixing the group of iron core pieces 5P that constitute the laminated core. A laser head 540 is provided as a welding device instead of the bonding device of the fourth embodiment. A laser beam emitted from the laser head 540 is irradiated from above the aligned group of iron core pieces 5P, and the layers are welded and fixed.

The group of core pieces 5P, with the melted portions hardening and the laminations fixed together, is cut to a specified length by a cutting tool 70 to become a laminated core 50, and is transported to the next process by a belt conveyor 80.

In this fifth embodiment, the laminations of the laminated core 50 are firmly fixed together by welding, improving the rigidity of the laminated core 50 and suppressing vibration and noise of the rotating electric machine. In addition, there is no need to add additional members to fasten the laminations together, which has the effect of allowing the laminated core 50 to be produced at low cost.

Embodiment 6.
The laminated core manufacturing apparatus and the rotating electrical machine manufacturing method according to the sixth embodiment will be described below, focusing on the differences from the first embodiment.
The sixth embodiment is a modification of the first embodiment, differing from the first embodiment in the shape of the core pieces and the cross-sectional shape of the guide.
FIG. 23 is a cross-sectional view of the sixth embodiment taken along line BB of FIG. 4 of the first embodiment.
FIG. 24 is a cross-sectional view of the sixth embodiment taken along line CC of FIG. 4 of the first embodiment.
23 and 24, teeth portions 5PT of core pieces 5P are punched out in horizontal direction H. In this case, core pieces 5P are aligned within guide 10G2 with one side surface of teeth portion 5PT, the outer peripheral surface of yoke portion 5PY, and the tips of teeth portion 5PT in contact with guide 10G2, and one side surface 5PTS of teeth portion 5PT serves as a contact surface in the gravity direction G and is supported.

FIG. 25 is another view of the sixth embodiment, which corresponds to the cross section taken along line BB of FIG. 4 of the first embodiment.
FIG. 26 is another view of the sixth embodiment, corresponding to the cross section taken along line CC of FIG. 4 of the first embodiment.
In this case, the tips of the teeth portions 5PT of the core pieces 5P are positioned above the direction of gravity G, and both side surfaces of the teeth portions 5PT and the central portion of the outer peripheral surface of the yoke portion 5PY are in contact with the guide 10G3 so as to be aligned within the guide 10G3, and the central portion 5PYC of the outer peripheral surface of the yoke portion 5PY serves as the contact surface in the direction of gravity G and is supported.

In this way, in the present application, no matter what the orientation of the core pieces 5P is, there is at least a portion that serves as a support in the direction of gravity G. Even when multiple rows are used for the purpose of improving material yield, the orientation of the core pieces 5P relative to the plate width direction can be set as desired, so material yield can be improved without restrictions on the orientation of the core pieces 5P.

FIG. 27 is a diagram showing an example of an annular core piece 605P.
In core piece 605P, outer peripheral surface 605PYO of yoke portion 605PY serves as a contact surface in the direction of gravity G. In this way, even in an annular core piece, if there is a contact surface in the direction of gravity G with guide 10G4, the same effect can be obtained.

In this way, the present application is effective for iron core pieces 5P of any shape and orientation, regardless of the shape of the iron core pieces 5P, the width direction of the material, or the orientation of the iron core pieces 5P. Therefore, compared to the case where a guide is passed through the slot portion, there is an effect of improving the degree of freedom in the shape of the iron core pieces and the material yield.

Although the present application describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to application to a particular embodiment, but may be applied to the embodiments alone or in various combinations.
Therefore, countless modifications not illustrated are conceivable within the scope of the technology disclosed in the present application, including, for example, modifying, adding, or omitting at least one component, and further, extracting at least one component and combining it with a component of another embodiment.

100, 200, 400, 500 Laminated core manufacturing equipment,
10, 210, 310 Press machine, 10G, 10G2, 10G3, 10G4 Guide,
310GA first guide, 310GB second guide, 10CDW lower cutter,
10CUP upper cutter, 10GS inner surface, 10PS pressing device, 11 placement table,
12 Frame, 13, 213 Mold, 13A, 313A First plate,
13B, 313B second plate, 13D die, 313DA first die,
313DB second die, 13P punch, 313PA first punch,
313PB second punch, 14, 214 material feed device, 15 plate material guide,
16 motor, 17 crank cam, 18, 318A, 318B slide,
19 Bolster, 20, 220 Material supply device, 21, 221 Uncoiler,
22, 222 Roller, 40 Hot air blower. 41 Air nozzle,
410PS second pressing portion, 5 plate material, 5P, 605P iron core piece, 50 laminated core,
540 laser head, 5PY, 605PY yoke part, 5PT teeth part,
5PYE both ends, 5PYC center, 5PTS one side, 61 adhesive,
6N application nozzle, 70 cutting tool, 80 belt conveyor, 81 insulating member,
82 coil, 83 connecting member, 84 frame, 85 bracket, 86 bearing,
87 shaft, 88 rotor core, 90 rotating electric machine, 90A stator,
90B rotor, D circle, M magnet.

Claims (16)

a press machine including a punch and a die for punching out the iron core pieces from the plate material in a thickness direction of the plate material;
A plate material supplying device is provided which supplies the plate material to the press machine with the plate thickness direction of the plate material perpendicular to the gravity direction,
the press machine includes a guide for stacking the core pieces by aligning the core pieces discharged from the die in the punching direction by the punch while maintaining the punched posture,
The guide has two inner surfaces that contact the core pieces in the direction of gravity, and the guide is open upward in the direction of gravity so as to support the core pieces in the direction of gravity on the surfaces of the core pieces that face the two inner surfaces diagonally with respect to the direction of gravity.This is a laminated core manufacturing apparatus. The laminated core manufacturing device of claim 1, wherein the plate material is supplied to the press in the direction of gravity. The laminated core manufacturing device of claim 1, wherein the plate material is fed horizontally to the press. The laminated core manufacturing device according to claim 2, further comprising a cutter that cuts the plate material after the core pieces have been punched out in conjunction with the punching operation of the core pieces. A laminated core manufacturing device according to any one of claims 1 to 4, wherein the punch is fixed to a first plate, the die is fixed to a second plate, and the first plate and the second plate are movable opposite each other in a horizontal direction. The press machine is
A first punch as the punch and a first die as the die, both fixed to a first plate;
A second punch as the punch and a second die as the die are fixed to a second plate,
The laminated core manufacturing apparatus according to claim 1 , wherein the first plate and the second plate are movable opposite to each other in a horizontal direction. The press machine is
The first plate includes a first guide as the guide,
The second plate includes a second guide as the guide,
7. The laminated core manufacturing apparatus according to claim 6, wherein the first guide and the second guide extend in opposite directions to each other. The laminated core manufacturing device according to any one of claims 1 to 7, wherein the guide is provided with a bonding device that bonds the laminated layers of the core piece group from the open side of the guide. The laminated core manufacturing device according to any one of claims 1 to 7, wherein the guide is provided with a welding device for welding between the laminated layers of the core piece group. The laminated core manufacturing device according to any one of claims 1 to 9, further comprising a pressing device that presses the core piece group on the guide in a direction opposite to the direction in which the core piece group is discharged. A laminated core manufacturing device according to any one of claims 1 to 10, wherein the plate material supply device supplies a plurality of plate materials in a stacked manner to the press machine. A laminated core manufacturing device according to any one of claims 1 to 11, in which the angle between the inner sides of the guide is equal to the angle between both ends of the yoke portion of the core piece. A laminated core manufacturing device according to any one of claims 1 to 11, in which the core pieces are ejected from the die with the teeth portion horizontally, and the guide supports one side of the teeth portion of the core pieces. A laminated core manufacturing device according to any one of claims 1 to 13, wherein the angle between the guide and the horizontal direction is θ, and θ is within 45 degrees above or below the horizontal direction. The laminated core manufacturing device according to claim 14, wherein the guide is inclined downward from the horizontal direction and tan θ<0.9. A method for manufacturing a rotating electric machine in which a rotor is rotatably supported with its outer peripheral surface facing the inner peripheral surface of a stator using a laminated core manufactured using the laminated core manufacturing device described in any one of claims 1 to 15.