JP7812470B2 - LAMINATE MANUFACTURING METHOD AND LAMINATE MANUFACTURING APPARATUS - Google Patents

Description

The present disclosure relates to a method for manufacturing a laminate and an apparatus for manufacturing a laminate.

In order to obtain motor cores (rotor cores or stator cores) used in motors installed in electric vehicles, etc., it has been conventional to manufacture laminates by stacking multiple iron core components.

JP 2019-118169 A describes the use of a plate stacking device to manufacture the laminations that make up a stator core. This plate stacking device is equipped with a sensor that detects the passage of plates conveyed from a cylinder serving as a conveying path, and a cutting mechanism that supports the plates, located near the exit of the cylinder. Based on the detection results of this sensor, the cutting mechanism is caused to protrude onto the plate conveying path at any time to stop the plate conveyance, thereby controlling the number of plates supplied to the jig and the timing of supply.

As in JP 2019-118169 A, if the timing of the protrusion of the separating mechanism is determined solely based on the detection results of a sensor that detects the passage of a plate discharged from the cylinder, the time from detecting the passage of the plate to completing the operation of the separating mechanism becomes extremely short when the plate discharge speed from the cylinder is relatively fast. Therefore, the actuators and sensors of the separating mechanism, as well as their control devices, are required to have fast response speeds, making their control more difficult. Furthermore, if the operating speed of the separating mechanism slows down due to, for example, deterioration of the separating mechanism's actuator over time, a plate whose transport should be stopped may arrive before the separating mechanism's operation is completed, potentially making it impossible to stop the transport of that plate. Furthermore, to operate the separating mechanism accurately, it becomes necessary to frequently check for deterioration of the separating mechanism's actuator over time, resulting in increased maintenance frequency.

The present disclosure provides a laminate manufacturing method and laminate manufacturing apparatus that enable accurate and efficient stacking of iron core components without the need for special equipment.

A method for manufacturing a laminate according to a first aspect of the present disclosure is a method for manufacturing a laminate in which a plurality of core members, including locking core members having locking pieces at multiple locations on their outer periphery and non-locking core members without the locking pieces, are selectively punched out from a metal plate conveyed along a first conveyance direction, and the punched-out core members are stacked together. When forming the non-locking core members, the method includes a step of punching out the locking piece forming regions of the metal plate where the locking pieces are formed using a first die capable of forming the non-locking core member side contour shape formed on the outer periphery of the non-locking core member; and a step of stacking the locking core members and the non-locking core members. The method includes a step of punching out a locking piece forming region using a second mold capable of forming a locking core member side contour shape including the locking piece formed on the outer peripheral surface of the locking core member, wherein the locking core member side contour shape includes a portion that is located outside the non-locking core member side contour shape in a planar view when the locking core member and the non-locking core member are stacked; a step of punching out the metal plate using a third mold to separate the locking core member and the non-locking core member from the metal plate; and a step of controlling the timing of supplying the locking core member and the non-locking core member to a receiving member by supporting the locking piece of the locking core member separated from the metal plate.

In the manufacturing method of the laminate described above, two core members with different shapes are selectively punched out and the timing of supply of the core members can be controlled by supporting the locking pieces of the locking core members. This allows the timing of supply of the core members to be adjusted without using special equipment, and the stacking of the core members can be carried out efficiently without stopping the equipment. Furthermore, two core members can be manufactured continuously simply by controlling whether or not punching using the first die is required, eliminating the need for complex control when selectively punching out and forming the two core members.

A method for manufacturing a laminate according to a second aspect of the present disclosure is the same as the method for manufacturing a laminate according to the first aspect of the present disclosure, except that first to third punching regions are provided along the first conveying direction in order from the upstream side of the first conveying direction, and the step of punching the metal plate using the first die is carried out in the first punching region, the step of punching the metal plate using the second die is carried out in the second punching region, and the step of punching the metal plate using the third die is carried out in the third punching region.

In the manufacturing method of the laminate described above, the molds for forming the contour shape of the locking piece forming area of each core member are located in separate locations from the molds used for punching the outer diameter, allowing the contour shape of the locking piece forming area to be punched out with high precision.

A method for manufacturing a laminate according to a third aspect of the present disclosure is the same as the method for manufacturing a laminate according to the first aspect of the present disclosure, except that first and fourth punching regions are provided in the first conveying direction in that order from the upstream side of the first conveying direction, and the step of punching the metal plate using the first die is carried out in the first punching region, and the step of punching the metal plate using the second die and the step of punching the metal plate using the third die are carried out in the fourth punching region by a fourth die composed of the second die and the third die.

In the manufacturing method of the laminate described above, the punching process using the second die and the punching process using the third die can be carried out at the same time by using a fourth die, thereby reducing the number of steps required for punching molding.

A method for manufacturing a laminate according to a fourth aspect of the present disclosure is a method for manufacturing a laminate according to any one of the first to third aspects of the present disclosure, wherein the step of controlling the timing of supplying the locking core members and the non-locking core members to the receiving member includes the steps of supplying the locking core members and the non-locking core members separated from the metal plate to a squeeze box, and supplying the core members to the receiving member from the downstream end of the squeeze box in a second transport direction that intersects with the first transport direction, and the squeeze box includes an upstream squeeze box portion located upstream of the second transport direction of the squeeze box and supporting from the sides the multiple locking core members and the non-locking core members passing through the squeeze box, and a downstream squeeze box portion located downstream of the second transport direction of the squeeze box and supporting from the sides the locking pieces of the locking core members passing through the squeeze box.

In the manufacturing method of the laminate described above, the timing of supplying the iron core material to the receiving member can be easily adjusted by passing it through a squeezer, so laminates can be manufactured continuously without stopping the equipment, improving production efficiency.

A laminate manufacturing apparatus according to a fifth aspect of the present disclosure includes a conveying mechanism that conveys a metal plate along a first conveying direction, the metal plate being capable of selectively punching out and forming a plurality of core members, including locking core members having locking pieces at multiple locations on their outer periphery, and non-locking core members that do not have the locking pieces; a first mold that is capable of forming a non-locking core member side contour shape that is formed on the outer periphery of the non-locking core member in multiple locking piece forming regions of the metal plate where the locking pieces are formed; and a second mold that is capable of forming a locking core member side contour shape that includes the locking pieces that are formed on the outer periphery of the locking core member in the locking piece forming regions of the metal plate, the locking core member side contour shape being formed on the outer periphery of the locking core member. The locking core member side contour shape includes the second die, which includes a portion that is located outside the non-locking core member side contour shape in a planar view when the locking core member and the non-locking core member are stacked; a third die that can separate the locking core member and the non-locking core member from the metal plate; a press that can operate the first die, the second die, and the third die; a receiving member that receives the locking core member and the non-locking core member separated from the metal plate; a support mechanism that can support the locking piece of the locking core member separated from the metal plate; and a control device that controls the punching operation by the first die.

In the laminate manufacturing device described above, two core members with different shapes are selectively punched out and formed, and the timing of supply of the core members can be controlled by supporting the locking pieces of the locking core members. This allows the timing of supply of the core members to be adjusted without using special equipment, and the stacking of the core members can be carried out efficiently without stopping the device. Furthermore, two core members can be manufactured simply by controlling the first mold, eliminating the need for complex control.

A laminate manufacturing apparatus according to a sixth aspect of the present disclosure is a laminate manufacturing apparatus according to the fifth aspect of the present disclosure, wherein the support mechanism includes a squeeze that can transport the locking core members and the non-locking core members separated from the metal plate in a second transport direction that intersects the first transport direction, and the squeeze includes an upstream squeeze portion located upstream of the squeeze in the second transport direction and that supports from the sides the multiple locking core members and the non-locking core members passing through the squeeze, and a downstream squeeze portion located downstream of the squeeze in the second transport direction and that supports from the sides the locking pieces of the locking core members passing through the squeeze.

In the laminate manufacturing device described above, the timing of supplying the core material to the receiving member can be easily adjusted by passing it through a squeezer, allowing laminates to be manufactured continuously without stopping the device, improving production efficiency.

The laminate manufacturing method and laminate manufacturing apparatus disclosed herein make it possible to accurately and efficiently stack iron core components without the need for special equipment, etc.

3 is a plan view showing an example of a locking core member punched and formed in the manufacturing method of the laminate according to the first embodiment of the present disclosure. FIG. FIG. 1B is an enlarged view of part A in FIG. 1A. 1 is a plan view showing an example of a non-locking core member punched and formed in a manufacturing method of a laminate according to a first embodiment of the present disclosure. FIG. FIG. 2B is an enlarged view of part B in FIG. 2A. 1 is a schematic explanatory diagram showing an example of a laminate manufacturing apparatus according to a first embodiment of the present disclosure. FIG. 4 is a cross-sectional view taken along line DD in FIG. 3. FIG. 4 is a cross-sectional view taken along line EE in FIG. 3. 3 is a flowchart showing an example of a method for manufacturing a laminate according to the first embodiment of the present disclosure. 7A to 7C are schematic plan views of the metal plate in each operating state shown in FIG. 6, illustrating the state of the metal plate when punching out the locking core member. 7A to 7C are schematic plan views of the metal plate in each operating state shown in FIG. 6, illustrating the state of the metal plate when punching out the locking core member. 7A to 7C are schematic plan views of the metal plate in each operating state shown in FIG. 6, illustrating the state of the metal plate when punching out the locking core member. 7A to 7C are schematic plan views of the metal plate in each operating state shown in FIG. 6, illustrating the state of the metal plate when punching out the locking core member. 7A to 7C are schematic plan views of the metal plate in each operating state shown in FIG. 6, illustrating the state of the metal plate when punching out the non-locking core member. 7A to 7C are schematic plan views of the metal plate in each operating state shown in FIG. 6, illustrating the state of the metal plate when punching out the non-locking core member. 7A to 7C are schematic plan views of the metal plate in each operating state shown in FIG. 6, illustrating the state of the metal plate when punching out the non-locking core member. 7A to 7C are schematic plan views of the metal plate in each operating state shown in FIG. 6, illustrating the state of the metal plate when punching out the non-locking core member. 7 is a flowchart showing an example of a process performed subsequent to each process shown in FIG. 6. 10 is an explanatory diagram illustrating the operation of the main part of the manufacturing apparatus shown in FIG. 3 when the manufacturing method of the laminate shown in FIG. 9 is performed. 10 is an explanatory diagram illustrating the operation of the main part of the manufacturing apparatus shown in FIG. 3 when the manufacturing method of the laminate shown in FIG. 9 is performed. 10 is an explanatory diagram illustrating the operation of the main part of the manufacturing apparatus shown in FIG. 3 when the manufacturing method of the laminate shown in FIG. 9 is performed.

This application is based on Japanese Patent Application No. 2023-005468 filed on January 17, 2023 in Japan, the contents of which form part of the present application.
The present disclosure will become more fully understood from the following detailed description. Further scope of application of the present application will become apparent from the following detailed description. However, the detailed description and specific examples are preferred embodiments of the present disclosure and are set forth for illustrative purposes only. From this detailed description, various changes and modifications will become apparent to those skilled in the art within the spirit and scope of the present disclosure.
Applicant does not intend to dedicate any of the described embodiments to the public, and all disclosed modifications and alternatives, which may not literally fall within the scope of the claims, are considered part of the invention under the doctrine of equivalents.

Embodiments for implementing the present disclosure will be described below with reference to the drawings. The following will show a schematic representation of the scope necessary for the explanation to achieve the objectives of the present disclosure, and will mainly explain the scope necessary for explaining the relevant parts of the present disclosure. For parts for which explanation is omitted, it will be assumed that they are based on publicly known technology. Furthermore, identical or equivalent components in the drawings will be given the same or similar reference numerals, and redundant explanations will be omitted. Furthermore, when multiple identical or equivalent components are included in a single drawing, only some of them may be referenced to make the drawing easier to understand. Furthermore, unless otherwise specified in the specification, each component of the present disclosure is not limited to one, and multiple components may exist.

The laminate manufacturing apparatus 1 (see Figure 3) and laminate manufacturing method according to the first embodiment described below manufacture a laminate by molding and stacking two types of core members: a locking core member 10 (see Figure 1) with locking pieces 13A and a non-locking core member 20 (see Figure 2) without locking pieces 13A. Therefore, before describing the manufacturing apparatus 1 and manufacturing method in detail, we will briefly explain the structure of the above-mentioned core members.

In this embodiment, the laminated core members may be capable of being stacked in multiple units to form a block core, and these block cores may be stacked singly or in multiple units to form a motor core, such as a stator core for an inner rotor type rotating electrical machine. In this disclosure, the term "laminated body" refers to a body made up of multiple iron core members simply stacked together, and a body made up of such laminated bodies joined by welding or the like is referred to as a "motor core," and the two are distinguished from each other. Furthermore, the motor core described above may be either a split stator core or a non-split stator core, or may form a non-split rotor core rather than a stator core.

1A and 1B are diagrams showing an example of a locking core member supplied to a laminate manufacturing apparatus according to a first embodiment of the present disclosure, with FIG. 1A being a plan view and FIG. 1B being an enlarged view of portion A of FIG. 1A. A locking core member 10 constituting part of multiple core members according to this embodiment can be constructed from a single plate-shaped electromagnetic steel sheet (sometimes referred to as a "core piece") having a predetermined thickness, as shown in FIG. 1A. Specifically, this locking core member 10 can include a substantially annular yoke 11 having a through-hole formed in its center in which a rotor core can be disposed, teeth 12 that are generally T-shaped in plan view and provided on the inner periphery of the yoke 11 so as to protrude toward the center of the yoke 11, and multiple locking core member-side recesses 13 (an example of a locking core member-side contour shape) formed on the outer periphery of the yoke 11, some of which can function as locking pieces 13A.

The teeth 12 provided on the inner peripheral surface of the locking core member 10 may be multiple, for example, eight, and may be arranged at approximately equal intervals along the inner peripheral surface. Armature coils may be wound around these teeth 12 when assembled into a stator core. The specific shape and arrangement of the teeth 12 may be modified as appropriate.

The locking core member-side recesses 13 provided on the outer peripheral surface of the locking core member 10 may be provided in multiple locations, for example, four, at approximately equal intervals along the outer periphery of the locking core member 10. In addition, the four locking core member-side recesses 13 are preferably located radially outside one of the eight teeth 12 provided on the inner peripheral surface of the locking core member 10, as shown in FIG. 1A. Typically, the magnetic flux density generated radially outside the teeth 12 tends to be lower than at other locations when the locking core member 10 is operated as part of the motor core. Therefore, locating the locking core member-side recesses 13 radially outside the teeth 12 as described above can suppress deterioration of the magnetic characteristics of the motor core due to the provision of the locking core member-side recesses 13.

As shown in Figure 1B, a portion of the inner peripheral surface of the locking core member-side recess 13 can function as a locking piece 13A. The locking piece 13A functions as an area that is supported by the squeeze 80, described below, after the locking core member 10 has been stamped and formed. While Figure 1 illustrates an example in which the locking core member-side recess 13 is an arc-shaped depression, with the bottom periphery of the depression functioning as the locking piece 13A, the shape of the locking core member-side recess 13 and the arrangement of the locking piece 13A can be modified as appropriate as long as their functions are maintained. Similarly, the number of locking core member-side recesses 13 and locking pieces 13A can also be modified as appropriate.

2A and 2B are diagrams showing an example of a non-locking core member supplied to a laminate manufacturing apparatus according to a first embodiment of the present disclosure, with FIG. 2A being a plan view and FIG. 2B being an enlarged view of portion B of FIG. 2A. Non-locking core member 20, constituting part of multiple core members according to this embodiment, can be constructed from a single plate-shaped electromagnetic steel sheet having a predetermined thickness, as shown in FIG. 2A. Specifically, non-locking core member 20 can include a substantially annular yoke 21 having a through-hole formed in its center through which a rotor core can be disposed, teeth 22 that are generally T-shaped in plan view and provided on the inner circumferential surface of yoke 21 so as to protrude toward the center of yoke 21, and multiple non-locking core member-side recesses 23 (an example of a non-locking core member-side contour shape) formed on the outer circumferential surface of yoke 21. In other words, non-locking core member 20 can be said to have a configuration similar to that of locking core member 10 described above, except that it includes non-locking core member-side recesses 23 instead of locking core member-side recesses 13. Therefore, the yoke 11 and teeth 12 of the locking core member 10 and the yoke 21 and teeth 22 of the non-locking core member 20 may have the same dimensions, arrangement, and number.

As shown in Figure 2B, the non-locking core member side recesses 23 provided on the outer peripheral surface of the non-locking core member 20 may be provided in multiple locations, for example, four, at approximately equal intervals along the outer periphery of the non-locking core member 20. In addition, it is preferable that the four non-locking core members 20 be provided in the same locations as the locking core member side recesses 13 described above, i.e., radially outside any of the eight teeth 22 provided on the inner peripheral surface of the non-locking core member 20.

Here, when the locking core member 10 and the non-locking core member 20 are laminated, the non-locking core member side recess 23 is formed in a position that overlaps the locking core member side recess 13, but its radial depth is adjusted to be longer than that of the locking core member side recess 13. In other words, when the locking core member 10 and the non-locking core member 20 are laminated, the locking core member side recess 13 includes a portion that is located outside the non-locking core member side recess 23 in a planar view. This outside portion can function as the locking piece 13A. More specifically, the locking core member side recess 13 has a shorter radial depth than the non-locking core member side recess 23, as shown by the dotted line in Figure 2B. The region of the locking core member 10 that forms this difference D1 functions as the above-mentioned locking piece 13A, as shown in Figure 1B. The difference D1 may be a small difference, and may be set to, for example, the thickness of the locking core member 10 and the non-locking core member 20 or less.

Below, we will explain the manufacturing apparatus and manufacturing method for stamping and forming the locking core member 10 and non-locking core member 20 of the above-mentioned configuration to produce a laminate.

(Laminate manufacturing device)
Fig. 3 is a schematic explanatory diagram showing an example of a laminate manufacturing apparatus according to the first embodiment of the present disclosure. As shown in Fig. 3, the laminate manufacturing apparatus 1 according to this embodiment may include a punching and forming unit 3 that punches and forms locking core members 10 and non-locking core members 20 from a metal plate 2, and a lamination unit 4 that stacks the locking core members 10 and non-locking core members 20 to form a laminate. In the following description, the direction indicated by arrow X in Fig. 3 will be referred to as the left-right direction, and similarly, the direction indicated by arrow Y will be referred to as the front-rear direction, and the direction indicated by arrow Z will be referred to as the up-down direction.

As shown in Figure 3, the punching and molding section 3 of the laminate manufacturing apparatus 1 can be mainly composed of a progressive die mechanism 30. This progressive die mechanism 30 includes a conveying mechanism 31 that conveys the metal plate 2 along the first conveying direction A1, a die unit 32 for punching the metal plate 2 into a predetermined shape, and a press machine 33 that can operate the die unit 32 in a direction intersecting the first conveying direction A1.

The conveying mechanism 31 is a mechanism for conveying the metal plate 2 in a first conveying direction A1 (e.g., left-right direction). The metal plate 2 conveyed by the conveying mechanism 31 can be formed as a strip made of electromagnetic steel plate that is long in one direction.

A number of punching areas, for example, three punching areas P1 to P3, may be provided in sequence at a predetermined interval along the transport path of the metal plate 2 transported by the transport mechanism 31. The first to third punching areas P1 to P3 may be provided with the first to third dies 40, 50, and 60, respectively, as described below. In this regard, the transport of the metal plate 2 by the transport mechanism 31 may be carried out intermittently at a transport pitch equal to the interval between each punching area.

The press machine 33 may be a device capable of moving the die unit 32 in the vertical direction. This press machine 33 moves the entire die unit 32 in the vertical direction. Therefore, when the die unit 32 moves up and down, all of the punches of the first to third dies 40, 50, and 60 described below also move up and down.

The die unit 32 includes a first die 40 capable of forming non-locking core member side recesses 23 in multiple locking piece forming regions X (see Figures 7A and 8A) where the locking pieces 13A of the metal plate 2 are formed, a second die 50 capable of forming locking core member side recesses 13 in the locking piece forming regions X of the metal plate 2, and a third die 60 capable of separating the locking core member 10 and non-locking core member 20 from the metal plate 2. As described above, the first to third dies 40, 50, 60 may be arranged in the first to third punching regions P1 to P3, respectively.

Describing the die unit 32 in more detail, the die unit 32 primarily comprises a punch plate 34 that forms the upper die, is attached to a punch holder (not shown), and has multiple punches attached to it; a die plate 35 that forms the lower die, and has multiple dies attached to it; and a stripper 36 that is elastically attached to the punch holder. In addition to the components described above, the die unit 32 may also include guide pins that guide the vertical movement of the punch plate, positioning pins that position it horizontally, and springs that support the stripper; however, as these are all well-known components in the technical field of progressive press dies, illustrations and detailed explanations will be omitted.

As described above, the laminate manufacturing apparatus 1 according to this embodiment is designed to switch between two types of core materials and punch them out, thereby enabling the subsequent stacking process in the stacking section 4 to be carried out efficiently. To switch between two types of core materials and punch them out, punching is performed using the first to third dies 40, 50, and 60. When punching out two core materials with different shapes, it is conceivable that dedicated dies for forming these two core materials would be prepared, and the two dedicated dies would be controlled on and off to punch out the two core materials with different shapes. However, controlling the on and off of two dies in parallel complicates the control.

Taking the above points into consideration, the die unit 32 of the laminate manufacturing apparatus 1 according to this embodiment has been designed with the structures of the first to third dies 40, 50, and 60 in mind to punch out and form two iron core components of different shapes while reducing the number of dies that require on/off control. Therefore, the structures of the first to third dies 40, 50, and 60 are described in detail below.

The first mold 40, which constitutes part of the mold unit 32, can be composed of a first punch 41 fixed to the punch plate 34 and a first die (not shown) provided in a position opposite the first punch 41 on the die plate 35. The first mold 40 is disposed in the first punching area P1 located upstream in the first conveying direction A1. This first mold 40 can punch out and form the non-locking core member side recess 23 in the locking piece forming area X of the metal plate 2.

In addition, the punching and forming operation by the first die 40 is controlled on and off based on a control signal from the control device 100, which will be described later. Therefore, when the punching and forming operation of the first die 40 is set to off, the punching operation by the first die 40 is not performed, and the non-locking core member side recess 23 is punched into the metal plate 2 only when the punching and forming operation of the first die 40 is on.

The structure for controlling the on/off of the first die 40 is not particularly limited, but can be achieved, for example, by providing a control cam (not shown) at the base of the first punch 41 that allows or restricts the first punch 41 from moving up and down relative to the punch plate 34. Specifically, when the punching operation of the first die 40 is off, this control cam is operated based on a control signal from the control device 100 to move the base of the first punch 41 to a position where it does not support the base. In this state, when the first punch 41 is lowered by the press 33 and comes into contact with the metal plate 2, the first punch 41 is pushed by the metal plate 2 and retracted into the punch plate 34, preventing the punching operation. Alternatively, a configuration may be adopted in which a control cam different from the one described above is used to hold the first punch 41 in a position where it does not come into contact with the metal plate 2.

The second die 50, which constitutes part of the die unit 32, can be composed of a second punch 51 fixed to the punch plate 34 and a second die (not shown) provided on the die plate 35 in a position opposite the second punch 51. The second die 50 is disposed downstream of the first punching area P1 in the first conveying direction A1. This second die 50 is capable of punching out and forming the locking core member side recess 13 in the locking piece forming area X of the metal plate 2. The punching operation by the second die 50 is not on/off controlled as in the case of the first die 40, and is always performed when the press machine 33 is operating.

As described above, the locking core member-side recess 13 includes a portion located outside the non-locking core member-side recess 23 in a plan view when the locking core member 10 and the non-locking core member 20 are stacked. Therefore, the second punch 51 used to punch out the locking core member-side recess 13 is preferably adjusted to have a smaller outer diameter than the first punch 41 used to punch out the non-locking core member-side recess 23. Furthermore, the positions of both the first punch 41 and the second punch 51 are adjusted so as to punch out the locking piece-forming region X of the metal plate 2. Therefore, when the metal plate 2 is transported to the second punching region P2 after the first die 40 has performed a punching operation in the first punching region P1, the second die 50 simply passes through the region already punched by the first die 40 (i.e., blank punching).

As described above, when the second die 50 is used in a blank punching operation on the metal plate 2 that has been punched by the first die 40, the metal plate 2 and the second punch 51 do not come into contact during the punching operation by the second die 50. As a result, fine debris that can occur during the punching operation is not generated. This prevents scratches on the metal plate 2 or the die due to contact with such fine debris. It also prevents deformation of the metal plate 2 due to contact between the metal plate 2 and the second punch 51. Furthermore, because punching is not performed by the second die 50, the locking core member side recess 13 is not formed in the non-locking core member 20.

The third mold 60, which constitutes part of the mold unit 32, can be composed of a third punch 61 fixed to the punch plate 34 and a third die 62 provided on the die plate 35 in a position opposite the third punch 61. The third mold 60 is disposed downstream of the second punching area P2 in the first conveying direction A1. The third mold 60 is a mold for performing so-called outer periphery punching, and is capable of punching out and forming the outer peripheries of the locking iron core member 10 and the non-locking iron core member 20. The punching operation by the third mold 60, like the second mold 50, is always performed when the press machine 33 is operating.

As shown in FIG. 3, the lamination unit 4 of the laminate manufacturing apparatus 1 includes at least a receiving member 70 that receives the locking core members 10 and non-locking core members 20 separated from the metal plate 2, and a squeezer 80 as an example of a support mechanism capable of supporting the locking pieces 13A of the locking core members 10 separated from the metal plate. In the lamination unit 4 in FIG. 3, the locking core members 10 and non-locking core members 20 after being punched are shown as cross-sections taken along line C-C in FIG. 1. To facilitate understanding of the state of the locking pieces 13A, only the dimensions of the locking pieces 13A are shown larger than their actual dimensions in the lamination unit 4 in FIG. 3, and the through holes and teeth 12, 22 formed in the centers of the core members 10, 20 are omitted. Furthermore, in the lamination unit 4 in FIG. 3, the core members are shown with a small gap between them so that the boundaries between the core members transported in a stacked state can be seen.

The receiving member 70 can be configured as a jig located, for example, below the third die 62, capable of receiving the locking core members 10 and non-locking core members 20 conveyed from the progressive die mechanism 30. The receiving member 70 can include a base 71 on which the locking core members 10 and non-locking core members 20 conveyed from the progressive die mechanism 30 can be placed, a plurality of support poles 72 extending upward from the top surface of the base 71 and supporting the locking core members 10 and non-locking core members 20 from the sides, and a transport arm 73 that moves the base 71 in any direction.

In the above configuration, the transport arm 73 may be capable of supporting the lower side of the pedestal 71 and of moving the pedestal 71 in a predetermined direction, for example, at least one of the forward/backward, left/right, and up/down directions. In addition, the transport arm 73 may function as a rotation mechanism that rotates the pedestal 71. In other words, the transport arm 73 may be capable of rotating the supported pedestal 71 around a rotation axis extending in the up/down direction, thereby transferring the stack placed on the pedestal 71.

The structure of the receiving member 70 described above is one example, and is not limited to the above structure as long as it is capable of receiving each of the iron core members 10, 20 supplied from the progressive die mechanism 30. Specifically, the receiving member 70 can also be configured with other transport means such as a conveyor or slope.

The squeezer 80 may be disposed between the third die 62 and the receiving member 70, and may support the locking core members 10 and non-locking core members 20 separated from the metal plate 2 and supplied from the progressive die mechanism 30 from the sides while transporting them along a second transport direction A2 that intersects with the first transport direction A1. In this embodiment, the second transport direction A2 corresponds to the up-down direction.

Figure 4 is a schematic cross-sectional view taken along line D-D in Figure 3. The squeezer 80 is disposed downstream of the third die 62 in the second conveying direction A2, and is capable of conveying the locking core members 10 and non-locking core members 20 conveyed from the progressive die mechanism 30 along the conveying direction while supporting them from the sides. As shown in Figures 3 and 4, the squeezer 80 can be configured as a substantially cylindrical member with one end connected to the lower end of the third die 62. Furthermore, the squeezer 80 can convey the locking core members 10 and non-locking core members 20 that have been punched and extruded below the third die 62 in a stacked state.

The locking core members 10 and non-locking core members 20 conveyed from the progressive die mechanism 30 can be sequentially conveyed and supported at the upper end of the squeeze 80. Therefore, each time a new locking core member 10 or non-locking core member 20 is conveyed into the squeeze 80, the locking core members 10 and non-locking core members 20 already held within the squeeze 80 are pressed against the newly conveyed locking core member 10 or non-locking core member 20, and are conveyed downward within the squeeze 80 by the amount of their wall thickness.

In addition, the squeeze 80 may include an upstream squeeze portion 81 located upstream in the second conveying direction A2 and supporting both the locking core member 10 and the non-locking core member 20 from the side as they pass through the squeeze 80, and a downstream squeeze portion 82 located downstream in the conveying direction of the core members and supporting the locking piece 13A of the locking core member 10 from the side as it passes through the squeeze 80.

As shown in Figure 4, the squeeze upstream section 81 may have an inner circumferential surface 83 that is sized to match the shape of the locking core members 10 and non-locking core members 20 being transported through the squeeze 80. This allows the sides (i.e., outer peripheries) of the locking core members 10 and non-locking core members 20 passing through the squeeze 80 to be supported by abutting against the inner circumferential surface 83 of the squeeze upstream section 81.

As shown in FIG. 4, the inner peripheral surface 83 of the squeeze upstream section 81 in this embodiment is shaped to match the outer peripheral shapes of the locking core member 10 and the non-locking core member 20, excluding the locking core member-side recess 13 and the non-locking core member-side recess 23. However, the specific structure of the inner peripheral surface 83 is not limited to this, as long as it is capable of supporting the locking core member 10 and the non-locking core member 20 from the sides. For example, the inner peripheral surface 83 may be shaped to abut only a portion of the outer peripheral surface of each core member. Furthermore, for ease of understanding, examples are shown in FIG. 3 and FIG. 10 (described later), in which a relatively small number of core members are transported through the squeeze 80. However, the number of core members that can be transported through the squeeze 80 may be in the tens to hundreds. The total number of core members constituting the stack may also be in the tens to hundreds.

Figure 5 is a schematic cross-sectional view taken along line E-E in Figure 3. As shown in Figure 5, the squeeze downstream portion 82 may have a locking protrusion 85 formed on its inner circumferential surface at a position opposite the locking piece 13A of the locking core member 10, extending toward the center of the squeeze 80. This locking protrusion 85 can abut against the locking piece 13A from the side to support the locking core member 10.

The inner peripheral surface of the squeeze downstream section 82 does not support either the locking core member 10 or the non-locking core member 20 except for the portion where the locking protrusion 85 is formed. In other words, a gap 84 is formed between the inner peripheral surface of the squeeze downstream section 82, excluding the portion where the locking protrusion 85 is formed, and the outer peripheral surface of each core member. The shape of the inner peripheral surface of the squeeze downstream section 82 can be changed as appropriate to match the shape of the locking core member 10 and non-locking core member 20 being transported.

When the above-described squeeze 80 is used, only the locking core member 10 is supported and transported in the downstream squeeze section 82, while the non-locking core member 20 is not supported laterally by the squeeze 80 and moves within the downstream squeeze section 82 while resting on the top surface of the locking core member 10 located downstream. The non-locking core member 20 within the downstream squeeze section 82 is simultaneously transported out of the squeeze 80 when the locking core member 10 located below it is transported out of the lower end of the squeeze 80.

In addition, in order to control each of the above-mentioned components, the manufacturing apparatus 1 according to this embodiment may further include a control device 100. This control device 100 may be communicatively connected to each component via wired or wireless communication, for example, as shown by the dotted lines in Figure 3. The control device 100 may be a computer including a sequencer (Programmable Logic Controller, PLC). This control device 100 can at least perform on/off control of the punching operation by the first mold 40.

As described above, if the unlatched core member 20 and the locked core member 10 are simultaneously removed, the time interval between the unlatched core member 20 being removed and the next locked core member 10 being removed from the lower end of the squeezer 80 is longer. Therefore, if the receiving member 70 is replaced or rotated at this timing, the stacking of the core members can be carried out continuously and accurately without temporarily stopping the device to replace or rotate the receiving member 70, and without using special devices to control the timing of the supply of the core members to the receiving member 70.

In this embodiment, a squeeze 80 is exemplified as a support mechanism capable of supporting the locking piece 13A, and this squeeze 80 selectively locks the locking piece 13A of the locking core member 10, thereby controlling the timing of supply to the receiving member 70. However, any support structure that allows similar control other than the squeeze 80 described above can also be used.

As explained above, the laminate manufacturing device 1 according to this embodiment selectively punches out and forms the core members 10, which have locking pieces, and the non-locking core members 20, which do not have locking pieces, and supports the locking pieces at any timing, making it possible to control the timing of supply of the core members. Therefore, it becomes possible to stack the core members without employing special equipment.

In addition, in the laminate manufacturing apparatus 1 according to this embodiment, the locking core member side recess 13 and the non-locking core member side recess 23 are provided at common positions on the locking core member 10 and the non-locking core member 20, respectively, and the locking pieces 13A are formed by slightly varying the depth of these recesses. Therefore, the influence on the magnetic characteristics of the motor core due to the presence or absence of the locking pieces 13A can be almost completely eliminated.

In the laminate manufacturing apparatus 1 according to the present embodiment described above, the second mold 50 and the third mold 60 are disposed in the second and third punching regions P2 and P3, respectively. However, the second mold 50 and the third mold 60 can also be combined into a single mold. Specifically, instead of the second mold 50 and the third mold 60, a fourth mold formed by combining the second mold 50 and the third mold 60 can be disposed in the fourth punching region located downstream of the first punching region P1 in the first conveying direction A1. In this way, the number of molds and punching regions can be reduced, improving the efficiency of punching and molding operations.

In addition, in this embodiment, shapes including locking core member side recesses 13 and non-locking core member side recesses 23 are exemplified as examples of the locking core member side contour shape and non-locking core member side contour shape formed in locking piece forming region X, but these contour shapes are not limited to recesses. Specifically, for example, the locking core member side contour shape may be a shape that can form a convex portion that protrudes outward and functions as a locking piece in locking piece forming region X of locking core member 10, and the non-locking core member side contour shape may be a shape that can form a curved surface that is continuous with the other outer peripheral surface of non-locking core member 20 in locking piece forming region X of non-locking core member 20. In this case, too, the locking core member side contour shape will include the portion located outside the non-locking core member side contour shape in a planar view when the locking core member and non-locking core member are stacked (specifically, the convex portion described above).

(Method for manufacturing laminate)
Next, a method for manufacturing a laminate according to the present embodiment will be described. In the following description, an example will be given in which a laminate is manufactured using the laminate manufacturing apparatus 1 described above, but the laminate manufacturing method of the present disclosure can also be implemented using an apparatus other than the manufacturing apparatus 1. The laminate manufacturing method according to the present embodiment, which is realized by the laminate manufacturing apparatus 1, can be provided in the form of a program for causing a processor of a control device 100 that controls each component of the laminate manufacturing apparatus 1 to execute a predetermined operation, or in the form of a non-transitory computer-readable recording medium on which this program is stored. Note that the following description of the effects and the like also serves as a description of the effects of the manufacturing apparatus 1 according to the present embodiment.

First, we will explain the process for stamping out the locking core member 10 and the non-locking core member 20 in the manufacturing method of the laminate in this embodiment. The stamping forming method in the laminate manufacturing method of this embodiment includes at least the following steps: when forming the non-locking core member 20, stamping out multiple locking piece forming regions X of the metal plate 2 using a first mold 40 to form the non-locking core member side recesses 23 of the non-locking core member 20, in order to selectively stamp out and form the locking core member 10 and the non-locking core member 20 from the metal plate 2 being transported along the first transport direction A1; when forming the locking core member 10 and the non-locking core member 20, stamping out the locking piece forming regions X of the metal plate 2 using a second mold 50 to form the locking core member side recesses 13 of the locking core member 10; and when forming the locking core member 10 and the non-locking core member 20, stamping out the metal plate 2 using a third mold 60 to separate the locking core member 10 and the non-locking core member 20 from the metal plate 2.

Figure 6 is a flowchart showing an example of a method for manufacturing a laminate according to the first embodiment of the present disclosure. To explain the control process of the manufacturing apparatus 1 when executing the method for manufacturing a laminate according to this embodiment, as shown in Figure 6, first, intermittent conveyance of the strip-shaped metal plate 2 is initiated by the conveying mechanism 31 (step S01). This intermittent conveyance may be such that the distance between each of the punching areas P1 to P3 arranged along the first conveying direction A1 is the conveying pitch.

Next, the type of core material to be formed in the first punching area P1 is identified (step S02) based on the work recipe, etc., input by the user of the manufacturing device 1. If, as a result of this identification, the core material to be formed in the first punching area P1 is a non-locking core material 20 (Yes in step S03), the first mold 40 is turned on (step S04). On the other hand, if the core material to be formed in the first punching area P1 is not a non-locking core material 20, i.e., a locking core material 10 (No in step S03), the first mold 40 remains in the off state and the process proceeds to the next step.

When the on/off control of the first mold 40 is complete, the conveying mechanism 31 stops conveying, and the press 33 is operated to perform the punching operation (step S05). At this time, if there is also a metal plate 2 in the second and third punching areas P2 and P3, punching operations are also performed by the second and third molds 50 and 60 in addition to the first mold 40. When the above-mentioned punching operation is complete, conveying of the metal plate 2 resumes (step S06), and the process returns to step S02 to perform the series of processes described above.

Next, the changes in the punched shape of metal plate 2 when a locking core member 10 or a non-locking core member 20 is punched out in a specific area of metal plate 2 will be explained using Figures 7 and 8. In the following explanation, in order to clarify which specific area of metal plate 2 shown in the figure is the area that forms which core member, the metal plate that is punched out to form locking core member 10 will be referred to as "metal plate 2-10," and the metal plate that is punched out to form non-locking core member 20 will be referred to as "metal plate 2-20."

Figure 7 is a schematic plan view of the metal plate in each operating state shown in Figure 6, and is an explanatory diagram showing the state of the metal plate when punching out a locking core member. First, the case of punching out and forming a locking core member 10 at a specific position on the metal plate 2 will be explained with reference to Figure 7. It is preferable to form the teeth 12 of the locking core member 10 in advance on the metal plate 2-10 before transporting it into the progressive die mechanism 30, as shown in Figure 7A. The formation of the teeth 12 can be carried out using a progressive die mechanism similar to the one described above.

The metal plate 2-10 is transported by the transport mechanism 31, and when the metal plate 2-10 reaches the first punching area P1, the press 33 is operated to lower the die unit 32. Here, because the locking core member 10 is being formed in the metal plate 2-10 shown in FIG. 8, the punching operation by the first die 40 is turned off (see step S03 in FIG. 6). Therefore, as shown in FIG. 7B, the first punched hole 41A (see FIG. 8B) formed by the first die 40 is not formed in the metal plate 2-10 that has reached the first punching area P1.

When the lowering operation of the die unit 32 in the first punching area P1 is completed, the metal plate 2-10 is transported to the second punching area P2 by the transport mechanism 31. When the metal plate 2-10 reaches the second punching area P2, the press machine 33 is operated again to lower the die unit 32. Because the second die 50 is always in the on state, this descent causes second punched holes 51A to be formed by the second die 50 in the four locking piece forming areas X of the metal plate 2-10, as shown in Figure 7C.

When the lowering operation of the die unit 32 in the second punching area P2 is completed, the metal plate 2-10 is transported to the third punching area P3 by the transport mechanism 31. When the metal plate 2-10 reaches the third punching area P3, the press 33 is operated again to lower the die unit 32. The third die 60 performs outer peripheral punching and, like the second die 50, is always on. As a result of this descent, the locking core member 10 is punched out of the metal plate 2-10 and transported below the third die 62, as shown in Figure 7D.

Figure 8 is a schematic plan view of the metal plate in each operating state shown in Figure 6, and is an explanatory diagram showing the state of the metal plate when punching out a non-locking core member. Next, with reference to Figure 8, we will explain how to punch out and form a non-locking core member 20 at a specific position on the metal plate 2. As with the metal plate 2-10, it is recommended that the teeth 22 of the non-locking core member 20 be formed in advance on the metal plate 2-20 before transporting it into the progressive die mechanism 30, as shown in Figure 8A.

The metal plate 2-20 is transported by the transport mechanism 31, and when the metal plate 2-20 reaches the first punching area P1, the press 33 is operated to lower the die unit 32. Here, because the non-locking core member 20 is to be formed in the metal plate 2-20 shown in Figure 8, the punching operation by the first die 40 is in the ON state (see step S03 in Figure 6). Therefore, first punched holes 41A are formed by the first die 40 in the four locking piece forming areas X of the metal plate 2-20, as shown in Figure 8B.

When the lowering operation of the die unit 32 in the first punching area P1 is completed, the metal plate 2-20 is transported to the second punching area P2 by the transport mechanism 31. When the metal plate 2-20 reaches the second punching area P2, the press 33 is operated again to lower the die unit 32. Because the second die 50 is always in the on state, this descent causes the second die 50 to perform a punching operation in the four locking piece forming areas X of the metal plate 2-10, as shown in Figure 8C. However, this metal plate 2-20 already has the first punched hole 41A formed in the first punching area P1. Furthermore, as described above, the locking core member side recess 13 includes a portion located (radially) outside the non-locking core member side recess 23 in a planar view when the locking core member 10 and non-locking core member 20 are stacked. Therefore, at least the inner portion of the second punch 51 passes through the first punched hole 41A without coming into contact with the metal plate 2.

Here, during the punching operation using the second die 50 described above, in order to prevent fine debris from being generated, for example, by the second punch 51 coming into contact with a portion of the radially outer side of the first punched hole 41A, it is advisable to adjust the size and shape of the second punch 51 so that it is completely contained within the first punched hole 41A, as shown in Figure 8C.

When the lowering operation of the die unit 32 in the second punching area P2 is completed, the metal plate 2-20 is transported to the third punching area P3 by the transport mechanism 31. When the metal plate 2-20 reaches the third punching area P3, the press 33 is operated again to lower the die unit 32. The third die 60 performs outer peripheral punching and, like the second die 50, is always on. As a result of this descent, the non-locking core member 20 is punched out of the metal plate 2-20 and transported below the third die 62, as shown in Figure 8D.

As described above, according to the punching molding process of the laminate manufacturing method of this embodiment, two core members with different external shapes, i.e., a locking core member 10 and a non-locking core member 20, can be selectively punched and molded simply by controlling the on/off of the first mold 40.

Next, we will explain the process of manufacturing a laminate by stacking stamped-formed locking core members 10 and non-locking core members 20 in the method for manufacturing a laminate according to this embodiment. The stacking process in the method for manufacturing a laminate according to this embodiment includes at least a step of controlling the timing of supplying the locking core members 10 and non-locking core members 20 to the receiving member 70 by supporting the locking pieces 13A of the locking core members 10 punched out from the metal plate 2. In this embodiment, this step is mainly achieved by the squeeze 80.

Figure 9 is a flowchart showing an example of a process carried out following each process shown in Figure 6. Also, Figure 10 is an operational explanatory diagram showing the main parts of the manufacturing apparatus shown in Figure 3 when the laminate manufacturing method shown in Figure 9 is executed. Below, the process of manufacturing a laminate in the laminate manufacturing method according to this embodiment will be explained with reference to Figures 9 and 10.

As shown in Figure 9, the stacking process in the manufacturing method of the laminate in this embodiment begins when the above-mentioned punching and molding process progresses and the locking core member 10 and the non-locking core member 20 begin to be transported from the progressive die mechanism 30 (step S11).

Here, in the manufacturing method of a laminate according to this embodiment, rolling or replacing the receiving member 70 is performed each time a core member group G consisting of four core members is stacked on the receiving member 70. In this regard, among the core members (four in FIG. 8 ) constituting one core member group G, the one or more core members located downstream should be designated as locking core members 10, and the one or more core members located upstream should be designated as non-locking core members 20. In other words, among the core members constituting one core member group G, at least the first core member punched out by the progressive die mechanism 30 should be designated as locking core members 10, and the rest should be designated as non-locking core members 20. This is because, when rolling or replacing the receiving member 70, it is necessary to support the core member located furthest downstream of the core member group G in order to temporarily stop the supply of core members to the receiving member 70. In this embodiment, the progressive die mechanism 30 punches out two locking core members 10 and two non-locking core members 20 alternately, thereby forming a core member group G in which two locking core members 10 and two non-locking core members 20 are stacked sequentially from the downstream side.

The locking core member 10 and non-locking core member 20 punched out by the third die 60 are pressed downward by the third punch 61, moving below the third die 62 and being forced into the squeeze 80 from the upper end of the squeeze 80 connected to the third die 62. The locking core member 10 and non-locking core member 20 forced into the squeeze 80 have at least a portion of their outer circumferential surface supported from the side by the inner circumferential surface 83 of the squeeze upstream section 81, and are transported through the squeeze 80 in a stacked state (step S12).

As the squeeze 80 continues to transport each core member, the locked core member 10 and the non-locked core member 20 that have been transported through the squeeze upstream section 81 reach the squeeze downstream section 82. Of the core members that have reached the squeeze downstream section 82, the locked core member 10 maintains lateral support as its locking piece 13A comes into contact with the locking protrusion 85 provided on the inner surface of the squeeze downstream section 82. On the other hand, since the non-locked core member 20 does not have a locking piece 13A, its lateral support is released and it is placed on and supported by the upper surface of the locked core member 10 located downstream (see Figure 10A).

As the conveyance of each core member by the squeeze 80 continues, the most downstream locking core member 10 of each core member constituting one core member group G is conveyed out from the lower end of the squeeze 80. Next, the locking core member 10 that has been conveyed through the squeeze downstream section 82 in a stacked state with its underside abutting the upper surface of the most downstream locking core member 10 (hereinafter, for ease of understanding, this locking core member 10 will be referred to as the "second locking core member 10") is also conveyed out from the lower end of the squeeze 80.

Here, the second locking core member 10 has two non-locking core members 20 included in the same core member group G placed on and supported by it on its upper surface. The non-locking core members 20 are not supported by the squeeze downstream portion 82. Therefore, when the second locking core member 10 is carried out from the lower end of the squeeze 80, the two non-locking core members 20 are also carried out from the lower end of the squeeze 80 at the same time, as shown in Figure 10B. At this time, the locking core member 10 stacked upstream of the two non-locking core members 20 is being transported to a position away from the lower end of the squeeze 80.

When the second locking core member 10 and the two non-locking core members 20 supported on its upper surface are placed on the base 71 of the receiving member 70 (Yes in step S13), as shown in FIG. 10C, the receiving member 70 is rotated or the receiving member 70 is replaced (step S14). The rotating operation can be performed by operating the transport arm 73 to rotate the base 71 on which one core member group G is placed. Here, when the rotating operation is performed, the next locking core member 10 to be transferred to the receiving member 70 is transferred to a position away from the lower end of the squeeze 80, as described above. Therefore, a relatively long time is ensured before this locking core member 10 is transferred from the lower end of the squeeze 80. Therefore, no new core members are transferred from the squeeze 80 during the rotating operation. Furthermore, if the desired number of core members 10 are stacked on the base 71 in step S14, the receiving member 70 can be replaced. When the transfer or replacement of the receiving member 70 is completed in step S14, the process returns to step S13 and waits until the next group of iron core members G is carried out.

As described above, according to the lamination process of the laminate manufacturing method of this embodiment, simply by modifying the shape of a portion of the inner circumferential surface of the squeeze 80, it is possible to adjust the timing of supply of each iron core member discharged from the lower end of the squeeze 80. Therefore, laminates can be manufactured continuously with a simple structure. Furthermore, because the downstream squeeze portion 82 has a structure that supports only the locking core member 10, a long period of time is ensured until the next discharge of each group of iron core members G, so that stacking and replacement of the receiving member 70 can be performed without stopping the equipment. This improves the production efficiency of laminates.

As an option, in the above embodiment, one iron core member group G has been illustrated with the two downstream core members 10 as locking iron core members and the two upstream core members 20 as non-locking iron core members, but it is also possible to have only one downstream core member 10 as a locking iron core member and the remaining three as non-locking iron core members 20. In this way, by increasing the number of non-locking iron core members 20 that make up the iron core member group G, it is possible to ensure a longer time until the iron core members included in the next iron core member group G are transported out of the squeezer 80.

This disclosure is not limited to the above-described embodiments, and various modifications can be made without departing from the spirit of this disclosure. All such modifications are within the scope of the technical concept of this disclosure.

All references, including publications, patent applications, and patents, cited in this specification are hereby incorporated by reference to the same extent as if each reference was individually and specifically indicated to be incorporated by reference and set forth in its entirety herein.

The use of nouns and similar referents in connection with the description of this disclosure (particularly in connection with the claims that follow) shall be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms "comprises," "has," "includes," and "comprises" shall be construed as open-ended terms (i.e., meaning "including, but not limited to"), unless otherwise noted. The recitation of numerical ranges herein is intended merely to serve as a shorthand method for individually referring to each value falling within the range, unless otherwise indicated herein, and each value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or clearly contradicted by context. Any example or exemplary language used herein (e.g., "e.g., "etc.") is intended merely to better illustrate the disclosure and does not pose a limitation on the scope of the disclosure, unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the present disclosure.

Preferred embodiments of the disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. Variations of these preferred embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects that skilled artisans will apply such variations as appropriate, and intends to practice the disclosure otherwise than as specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, this disclosure includes any combination of the above-described elements in all variations thereof unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims (6)

A method for manufacturing a laminate in which a plurality of core members including locking core members having locking pieces at a plurality of locations on the outer circumferential surface and non-locking core members having no locking pieces are selectively punched out from a metal plate conveyed along a first conveyance direction, and the plurality of punched core members are stacked,
When forming the non-locking core member, a step of punching out a plurality of locking piece forming regions of the metal plate where the locking pieces are formed using a first die capable of forming a non-locking core member side contour shape formed on the outer peripheral surface of the non-locking core member;
When forming the locking core member and the non-locking core member, a step of punching out the locking piece forming region of the metal plate using a second die capable of forming a locking core member side contour shape including the locking piece formed on the outer peripheral surface of the locking core member, the locking core member side contour shape including a portion located outside the non-locking core member side contour shape in a plan view when the locking core member and the non-locking core member are stacked;
punching the metal plate using a third die to separate the locking core member and the non-locking core member from the metal plate;
and a step of controlling the timing of supplying the locking core member and the non-locking core member to a receiving member by supporting the locking piece of the locking core member separated from the metal plate.
A method for manufacturing a laminate. First to third punching areas are provided in this order from the upstream side of the first conveying direction along the first conveying direction,
the step of punching the metal plate using the first die is carried out in the first punching area, the step of punching the metal plate using the second die is carried out in the second punching area, and the step of punching the metal plate using the third die is carried out in the third punching area.
A method for producing the laminate according to claim 1. First and fourth punching areas are provided in this order from the upstream side of the first conveying direction along the first conveying direction,
the step of punching the metal plate using the first die is carried out in the first punching area, and the step of punching the metal plate using the second die and the step of punching the metal plate using the third die are carried out in the fourth punching area by a fourth die composed of the second die and the third die.
A method for producing the laminate according to claim 1. The step of controlling the timing of supplying the locking core members and the non-locking core members to the receiving member comprises the steps of: supplying the locking core members and the non-locking core members separated from the metal plate to a squeezer; and supplying the core members to the receiving member from a downstream end of the squeezer in a second transport direction intersecting with the first transport direction,
The squeeze device includes an upstream squeeze device portion located upstream of the squeeze device in the second conveying direction and supporting the locking core members and the non-locking core members from the sides as they pass through the squeeze device, and a downstream squeeze device portion located downstream of the squeeze device in the second conveying direction and supporting the locking pieces of the locking core members from the sides as they pass through the squeeze device.
A method for producing the laminate according to claim 1. a conveying mechanism that conveys, along a first conveying direction, a metal plate that can selectively punch out and form a plurality of core members, including locking core members that have locking pieces at multiple locations on their outer circumferential surfaces and non-locking core members that do not have the locking pieces;
a first mold capable of forming a non-locking core member side contour shape to be formed on the outer circumferential surface of the non-locking core member in a plurality of locking piece forming regions where the locking pieces of the metal plate are formed;
a second mold capable of forming a locking core member side contour shape including the locking pieces formed on the outer peripheral surface of the locking core member in the locking piece forming region of the metal plate, the locking core member side contour shape including a portion positioned outside the non-locking core member side contour shape in a plan view when the locking core member and the non-locking core member are stacked;
a third mold capable of separating the locking core member and the non-locking core member from the metal plate;
a press machine capable of operating the first die, the second die, and the third die;
a receiving member for receiving the locking core member and the non-locking core member separated from the metal plate;
a support mechanism capable of supporting the locking piece of the locking core member separated from the metal plate;
A control device that controls the execution of the punching operation by the first die.
Laminate manufacturing equipment. the support mechanism includes a squeezer that can transport the locking core member and the non-locking core member separated from the metal plate in a second transport direction that intersects with the first transport direction,
The squeeze device includes an upstream squeeze device portion located upstream of the squeeze device in the second conveying direction and supporting the locking core members and the non-locking core members from the sides as they pass through the squeeze device, and a downstream squeeze device portion located downstream of the squeeze device in the second conveying direction and supporting the locking pieces of the locking core members from the sides as they pass through the squeeze device.
The laminate manufacturing apparatus according to claim 5 .