JP2003259610A - Manufacturing method and manufacturing apparatus for laminated iron core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To stably punch an iron core piece from a laminated material including an amorphous thin plate without generating cracks, etc.
Obtain a strongly caulked laminated iron core. SOLUTION: An amorphous thin plate 1 and a metal plate 3 are bonded and integrated via an adhesive film 2, and the laminated material 4 is passed through a press die apparatus so that the amorphous thin plate 1 is located on a die surface side 11. Then, the punch 15 is advanced and retracted from the metal plate side 3 to punch out the laminated material 4 to form a required portion of the iron core piece and a caulking portion 12b.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to the production of a laminated core in which an amorphous thin plate and a metal plate are joined together via an adhesive film to punch and laminate the core pieces.

[0002]

2. Description of the Related Art Iron cores used in motors and transformers are manufactured as a wound iron core from an amorphous thin plate with high magnetic permeability and extremely low iron loss in order to further improve efficiency, output, energy saving, and size reduction. A proposal has been made to do so.

However, an amorphous thin plate has mechanical material properties that are highly brittle, that the plate thickness is generally extremely thin and difficult to punch, and the punching productivity is low.
Furthermore, since it is difficult to form the crimped portion, there are few proposals for a laminated core that is punched and crimped as an iron core piece.

As the prior art, a plurality of amorphous thin plates are laminated and integrated with a heat-resistant adhesive material, an iron core piece is punched from the amorphous laminated plate, and the caulking projections and the caulking through holes formed on the iron core piece are used for caulking. There are those that manufacture laminated cores.

[0005]

Although the above-mentioned prior art has some effects, the amorphous material itself is so brittle that it is still difficult to punch the core piece in a stable manner. Further, the caulking projections for caulking the iron core pieces are formed by cutting and bending one part, but cracks or breakage may occur during the formation process. In addition, even if crimping protrusions are formed, the core pieces laminated due to the mechanical brittleness of the amorphous material have low crimping strength, and when the size of the core pieces becomes large, the crimping is unstable and it is difficult to obtain a good laminated core. There is.

An object of the present invention is to obtain a laminated iron core capable of stably punching an iron core piece from a laminated material containing an amorphous thin plate, strengthening the caulking strength, and exhibiting high efficiency, high output and energy saving. To do. Another object of the present invention is an apparatus for industrially and stably manufacturing a laminated iron core by punching an iron core piece with a good end face shape from the laminated material.

[0007]

The first gist of the present invention is to bond an amorphous thin plate and a metal plate to each other through an adhesive film so as to be integrated, and the laminated material is positioned on the die surface side of the amorphous thin plate. As shown in the drawing, the plate is passed through the press die device, the punch is moved back and forth from the metal plate side to the die side, the laminated material is punched out to form the required parts of the core piece and the caulking part, and the core piece is punched out and caulked and laminated. A method for manufacturing a laminated iron core is characterized in that A second gist is that the metal plate bonded to the amorphous thin plate through an adhesive film is an electromagnetic steel plate,
It is a low carbon steel plate or an Fe-Ni alloy plate. The third gist is that the caulking portion formed on the iron core piece is
A through hole is punched in the first laminated core piece, and the second and subsequent laminated core pieces have crimping protrusions formed while being narrowed by a protrusion forming punch and a receiver.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described based on one embodiment with reference to the drawings. FIG. 1 is a view showing a laminated material in one embodiment of the present invention. FIG. 2 is a view for explaining a manufacturing process of a laminated iron core made of a laminated material by a progressive die apparatus, FIG. 3 is a diagram for explaining punching of an iron core piece from the laminated material, and FIG. 4 is a caulking projection on the iron core piece. For explaining the formation of the core, FIG. 5 is a view showing the caulking lamination of the iron core pieces, and FIG.
FIG. 3 is a diagram showing a laminated iron core manufactured in one example of the present invention.

In the drawings, 1 is an amorphous thin plate. The amorphous thin plate 1 is extremely thin, for example, 0.02-
It is 0.06 mm thick and has excellent magnetic properties such as high magnetic permeability and extremely low iron loss, but on the other hand, it has the property of being hard and brittle. It is difficult to stably punch, caulk and stack. Therefore, in the present invention, first, the amorphous thin plate 1 is integrated as the laminated material 4 joined to the metal plate 3 via the adhesive film 2. The joining is performed by inserting the adhesive film 2 between the amorphous thin plate 1 and the metal plate 3 which are respectively sent by the transport roll 5, and pressing the adhesive film 6 with the adhesive roll 6.

The adhesive film 2 is an amorphous thin plate 1.
The metal plate 3 and the metal plate 3 are joined as described above. For example, a polyimide adhesive film, an epoxy adhesive film, or the like is adopted, and one having an insulating property is preferable.

The metal plate 3 is, for example, a magnetic steel plate having a thin plate thickness and a low iron loss in order to achieve high output, high efficiency, energy saving and downsizing of a motor by a laminated iron core, and iron loss is more or less than that of the electromagnetic steel plate. Inferior but low carbon steel sheet with excellent workability,
Or Fe- with high magnetic permeability and excellent workability and corrosion resistance
A Ni alloy plate is adopted. These metal plates 3 have punching workability, and together with the adhesive film 2, they assist the punching process of the amorphous thin plate 1 and have an action of preventing cracks and breakage.

The laminated material 4 is passed through the progressive die apparatus so that the amorphous thin plate 1 side is the die surface side so as to be punched from the metal plate 3 side, and as shown in FIG. Are punched and formed at intervals on both sides in the width direction.

At the station 2, slots 9 are punched out radially around the planned axial hole area 8. The punching is shown in FIG.
As shown in FIG. 1, the punch 10 first contacts the metal plate 3 to start punching shearing, and progresses to the amorphous thin plate 1 through the adhesive film 2. The metal plate 3 has punching workability. Since the amorphous thin plate 1 is integrally bonded to the sheet via the adhesive film 2, the amorphous thin plate 1
Is punched together with the metal plate 3 and the adhesive film 2 without cracking or breaking.

The clearance between the punch 10 and the die 11 of the press die device for punching the laminated material 4 is made narrower than when punching a single metal plate having the same thickness as the laminated material 4, and is based on the thickness of the amorphous thin plate 1. It has been set. In this way, the thickness of the amorphous thin plate 1 is weighted more than the total thickness of the laminated material 4, and the clearance is determined, so that the end face shape of the laminated material 4 is improved by punching the amorphous thin plate 1 on the die side.

The caulking portion 12 is formed at the station 3 in the laminated material 4 from which the slot 9 has been removed. Stack 1
The caulking portion 12 is punched and punched as a through hole 12a in the second iron core piece, and the second and subsequent iron core pieces are formed as a caulking projection and a caulking projection 12b having a recess formed on the back surface thereof. The through hole 12a and the caulking projection 12
The formation of b can be easily changed by changing the depth of the punch (not shown) forming the caulked portion to the die side by a known slide cam or the like.

The through hole 12a forming the caulking portion 12
Also, the caulking projections 12b are formed on the inside and outside of the slot 9 on the circumference centered on the center of the planned axial hole 8 and at predetermined intervals. The through hole 12a is formed by punching in a narrow area, and the caulking projection 12b is formed as shown in FIG.
As shown in Fig. 2, one part is left and the other part is cut down to form a protrusion in a narrow area. If it is an amorphous single plate, cracks and bending damages occur frequently in the process of punching and forming, but In the present invention, the metal plate 3 having good workability
Since the amorphous thin plate 1 is bonded via the adhesive film 2 to the metal plate 3, the metal plate 3 is cut down without being cracked or broken to form the caulking projection 12b.

When forming the caulking projection 12b,
The side to be cut down is supported by the receiving tool 14 as shown in FIG. 4, and is crimped with the projection forming punch 15 in a clamped state.
It is preferable to form 2b. By thus sandwiching and applying a load from both sides to perform the forming process, the forming process of the caulking projection 12b from the laminated material 4 in which the amorphous thin plates 1 are laminated can be performed more stably.

In this embodiment, the caulking portion 12 is formed at three locations inside the slot 9 and nine locations outside, but the number can be changed depending on the shape and size of the core piece. Also, the formation location thereof can be appropriately changed according to the shape and size of the iron core piece, the thickness of the processed material, and the like.

The laminated material 4 having the crimped portion 12 formed thereon is sent to the station 4. The station 4 is a play station in this embodiment.

The core material 16 of the laminated material 4 sent to the station 5 is punched out, that is, the inner shape 17 and the outer shape 18 are punched out, and the punching is performed as shown in FIG. The removed core piece 16 is caulked by the caulking projection 12b which is inserted into the caulking recess of the iron core piece 19 previously laminated in the die hole (not shown). This iron core piece 16 is punched, the laminated iron core piece 19 is caulked, and lamination is repeated until a desired laminated thickness is obtained, and a laminated iron core 20 as shown in FIG. 6 is obtained.

In the obtained laminated core 20, the amorphous thin plate 1 is laminated with the metal plate 3, so that high output, high efficiency,
If the iron loss is low and the output is the same, the core is smaller than the laminated core made of only metal plates.

In the above embodiment, the laminated core is the rotor laminated core, but the present invention is not limited to this, and a stator laminated core, a transformer laminated core, etc. can be manufactured in the same manner.

Further, in the above embodiment, the caulking portion is composed of the caulking protrusion and the through hole with one side cut down. However, the invention is not limited to this, and the V-shaped protrusion or the inverted C-shaped protrusion and the through hole may be formed. The crimping portion can be configured.

[0024]

According to the first aspect of the present invention, the amorphous thin plate and the metal plate are joined and integrated with each other through the adhesive film, and the laminated material is press-molded so that the amorphous thin plate side is positioned on the die surface. Since the punch is passed through the apparatus, the punch is advanced and retracted from the metal plate side, the laminated material is punched out to form the required portions of the core piece and the caulked portion, and the outer shape of the core piece is punched out. Starting punching shear from the plate,
The punching shearing proceeds to reach an amorphous thin plate joined via an adhesive film, and the amorphous thin plate is punched by the metal plate and the adhesive film without being cracked or broken, and the iron core pieces are laminated.

Further, the crimping portion is formed by forming a through hole in the first laminated core piece and a crimped projection in the second and subsequent laminated core pieces while narrowing the crimped projection with the projection forming punch and the receiving member. Therefore, the crimping projections are more stably formed from the amorphous thin plate, the strength of crimping the core pieces is strong, and the shape accuracy of the laminated core becomes better.

According to claim 3, since the metal plate adhered to the amorphous thin plate through the adhesive film is an electromagnetic steel plate, a low carbon steel plate, or a Fe-Ni alloy plate, the electromagnetic steel plate is high. It is possible to obtain a laminated iron core having high output, high efficiency, and great energy saving. With the low carbon steel plate, the core piece can be easily punched and the crimped portion can be formed, and a low cost laminated core can be obtained.
Further, the Fe-Ni alloy plate has effects such as good output and efficiency, and obtaining a strong laminated core in a bad environment.

According to a fourth aspect of the present invention, the clearance between the die and the punch of the press die device for advancing and retreating the punch from the metal plate side to the die side with respect to the laminated material is set to the thickness of the amorphous thin plate facing the die. Because it is based on
Even a laminated material including an amorphous thin plate can be punched into a predetermined shape with a good punched end surface shape, and the appearance and shape of an iron core formed by laminating punched iron core pieces are excellent.

[Brief description of drawings]

FIG. 1 is a diagram showing a laminated material used in one embodiment of the present invention.

FIG. 2 is a diagram showing a manufacturing process of a laminated iron core according to an embodiment of the present invention by a progressive die device.

FIG. 3 is a diagram for explaining punching of an iron core piece from a laminated material in one embodiment of the present invention.

FIG. 4 is a view showing forming a caulking projection on an iron core piece in one embodiment of the present invention.

FIG. 5 is a diagram showing a part of a caulked laminated core piece according to one embodiment of the present invention.

FIG. 6 is a diagram showing a laminated core manufactured in one example of the present invention.

[Explanation of symbols]

1 Amorphous thin plate 2 Adhesive film 3 metal plates 4 laminated materials 5 transport rolls 6 Adhesive roll 7 Guide roll 8 axis hole planned area 9 slots 10 punches 11 die 12 Caulking part 13 strippers 14 Receiving tool 15 Protrusion forming punch 16 iron core pieces 17 Internal shape 18 outline 19 Stacked iron core pieces 20 laminated iron core

Claims (4)

[Claims] 1. A method for manufacturing an iron core, comprising punching and crimping and laminating an iron core piece from a laminated material including an amorphous thin plate, wherein the amorphous thin plate and the metal plate are adhered and integrated with each other via an adhesive film, and the laminated material is converted into the amorphous thin plate. The plate is passed through a press die device so that it is located on the die surface side, the punch is advanced and retracted from the metal plate side, the laminated material is punched out to form the required parts of the core piece and the caulked part, and the core piece is punched out. A method for manufacturing a laminated core, comprising laminating by crimping. 2. The caulking portion formed on the iron core piece has a through hole formed in the first laminated core piece and a caulking projection formed in the second and subsequent laminated core pieces while being narrowed by a projection forming punch and a receiving tool. The method for manufacturing a laminated iron core according to claim 1, wherein 3. The metal plate adhered to the amorphous thin plate through an adhesive film is an electromagnetic steel plate, a low carbon steel plate, or F
It is an e-Ni alloy plate, The manufacturing method of the laminated iron core of Claim 1 or Claim 2 characterized by the above-mentioned. 4. A manufacturing apparatus for a laminated core, comprising punching and crimping and laminating an iron core piece from a laminated material including an amorphous thin plate, and a punch of a press die device for advancing and retracting the punch from the metal plate side of the laminated material to the die side. An apparatus for manufacturing a laminated core, wherein a die clearance is determined based on a thickness of the amorphous thin plate facing the die.