Laminated core, rotary electric machine, laminated core manufacturing device, method of manufacturing laminated core, and method of manufacturing rotary electric machine

Abstract

Provided is a laminated core manufacturing device capable of preventing deformation of a laminated core cut out from a thin plate core set. A laminated core manufacturing device (1) cuts out a laminated core (32) from a thin plate core set (31) formed by laminating thin plate cores (31a), wherein the laminated core manufacturing device (1) has a stopper (6) that limits the position of the thin plate core set in the laminating direction of the thin plate core set, a fixed guide (4) that limits the position of the thin plate core set in a direction perpendicular to the laminating direction, and a cut-out guide (5) that is provided apart from the fixed guide by a gap in the laminating direction, limits the position of the thin plate core set in a direction perpendicular to the laminating direction, and moves in the direction perpendicular to the laminating direction to cut out the laminated core from the thin plate core set.

Description

Technical Field

[0001] This application relates to laminated iron cores, rotary electric machines, laminated iron core manufacturing apparatus, methods for manufacturing laminated iron cores, and methods for manufacturing rotary electric machines. Background Technology

[0002] As stator and rotor cores of rotating electric machines, laminated cores, sometimes made of thin sheet metal cores laminated with electromagnetic steel sheets, are used. These laminated cores are manufactured by cutting them from a set of thin sheet metal cores of a predetermined thickness. As a conventional laminated core manufacturing apparatus, a laminated core manufacturing apparatus is disclosed, comprising: a cutting blade that cuts the laminated core in a direction perpendicular to the lamination direction of the thin sheet metal core set; a receiving blade disposed on the opposite side of the cutting blade, spaced apart from the thin sheet metal core set; and an adjusting device that adjusts the position of the thin sheet metal core set in the lamination direction before cutting so that the cut laminated core has a predetermined thickness (see, for example, Patent Document 1).

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2004-55726 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] In existing laminated core manufacturing equipment, the thin plate core assembly is only placed on the transport track. Therefore, there is a problem that the thin plate core may shift due to the impact during cutting, thereby deforming the laminated core.

[0008] This application was made to solve the above-mentioned problems, and its purpose is to provide a laminated core manufacturing apparatus that can prevent deformation of the laminated core cut from the sheet core assembly.

[0009] Methods for solving problems

[0010] The laminated core manufacturing apparatus of this application cuts out laminated cores from a sheet metal core assembly formed by laminating sheet metal cores. The apparatus includes: a stop member that restricts the position of the sheet metal core assembly in the lamination direction; a fixing guide member that restricts the position of the sheet metal core assembly in a direction perpendicular to the lamination direction; and a cutting guide member that is spaced apart from the fixing guide member in the lamination direction, restricts the position of the sheet metal core assembly in the direction perpendicular to the lamination direction, and moves in the direction perpendicular to the lamination direction to cut out the laminated core from the sheet metal core assembly. The stop member contacts one end of the sheet metal core assembly in the lamination direction, and the amount of movement of the cutting guide member is greater than the length of contact between the stop member and the sheet metal core assembly in the direction perpendicular to the lamination direction. The cutting guide member moves relative to the stop member to cut out the laminated core from the sheet metal core assembly.

[0011] Invention Effects

[0012] The laminated core manufacturing apparatus of this application includes: a fixed guide that restricts the position of a sheet metal core assembly in a direction perpendicular to the lamination direction; and a cutting guide that is spaced apart from the fixed guide in the lamination direction, restricts the position of the sheet metal core assembly in a direction perpendicular to the lamination direction, and moves in a direction perpendicular to the lamination direction to cut out the laminated core from the sheet metal core assembly. A stop member contacts one end of the sheet metal core assembly in the lamination direction. The amount of movement of the cutting guide member is greater than the length of contact between the stop member and the sheet metal core assembly in the direction perpendicular to the lamination direction. The cutting guide member moves relative to the stop member to cut out the laminated core from the sheet metal core assembly. Therefore, deformation of the laminated core cut out from the sheet metal core assembly can be prevented. Attached Figure Description

[0013] Figure 1 This is a perspective view of the stacked iron core manufacturing apparatus of Embodiment 1.

[0014] Figure 2 This is a top view of the stacked iron core manufacturing apparatus of Embodiment 1.

[0015] Figure 3 This is a side view of the stacked iron core manufacturing apparatus of Embodiment 1.

[0016] Figure 4 This is an enlarged view of the stacked iron core manufacturing apparatus of Embodiment 1.

[0017] Figure 5 This is a diagram illustrating the cutting process of the laminated iron core in Embodiment 1.

[0018] Figure 6 This is a diagram illustrating the discharge process of the stacked iron core in Embodiment 1.

[0019] Figure 7This is a schematic diagram of an apparatus consisting of a stacked iron core manufacturing apparatus and a stamping apparatus according to Embodiment 1.

[0020] Figure 8 This is a top view of the stacked iron core manufacturing apparatus of Embodiment 1.

[0021] Figure 9 This is a top view of the stacked iron core manufacturing apparatus of Embodiment 1.

[0022] Figure 10 This is an explanatory diagram showing the operation of the stacked iron core manufacturing apparatus according to Embodiment 1.

[0023] Figure 11 This is a cross-sectional view of the rotary motor according to Embodiment 1.

[0024] Figure 12 This is a perspective view of the stacked iron core manufacturing apparatus of Embodiment 2.

[0025] Figure 13 This is a top view of the stacked iron core manufacturing apparatus of Embodiment 2.

[0026] Figure 14 This is a side view of the stacked iron core manufacturing apparatus of Embodiment 2.

[0027] Figure 15 This is an enlarged view of the stacked iron core manufacturing apparatus of Embodiment 2.

[0028] Figure 16 This is a cross-sectional view of the stacked iron core manufacturing apparatus of Embodiment 2.

[0029] Figure 17 This is a diagram illustrating the discharge process of the stacked iron core in Embodiment 2.

[0030] Figure 18 This is a diagram illustrating the cutting process of the laminated iron core in Embodiment 2.

[0031] Figure 19 This is a diagram illustrating the cutting process of the laminated iron core in Embodiment 2.

[0032] Figure 20 This is an explanatory diagram showing the state when the stacked iron core has been cut out in Embodiment 2.

[0033] Figure 21 This is an enlarged view of the stacked iron core manufacturing apparatus of Embodiment 3.

[0034] Figure 22 This is an enlarged view of the stacked iron core manufacturing apparatus of Embodiment 3. Detailed Implementation

[0035] The laminated iron core manufacturing apparatus for implementing the embodiments of this application will now be described in detail with reference to the accompanying drawings. In the drawings, the same reference numerals denote the same or equivalent parts.

[0036] Implementation Method 1

[0037] Figure 1 This is a perspective view of the laminated iron core manufacturing apparatus according to Embodiment 1. Figure 1 As shown, the laminated iron core manufacturing apparatus 1 of this embodiment consists of a base 2 and a cutting unit 3. The laminated iron core manufacturing apparatus 1 of this embodiment has the function of cutting out laminated iron cores 32 of a determined length from the inserted sheet iron core assembly 31. The sheet iron core assembly 31 is, for example, formed by stacking sheet iron cores 31a made of electromagnetic steel sheets using a stamping device. The cutting unit 3 is movable on the base 2 along the stacking direction of the inserted sheet iron core assembly 31. The cutting unit 3 consists of a fixing guide 4, a cutting guide 5, a stop 6, and a discharge block 7. Here, in Figure 1 In this process, the stacking direction of the thin plate core assembly 31, which is placed in the stacked core manufacturing device 1, is set as the x-axis direction, the direction that is perpendicular to the x-axis and parallel to the surface of the base 2 is set as the y-axis direction, and the direction that is perpendicular to both the x-axis and the y-axis is set as the z-axis direction.

[0038] Figure 2 This is a top view of the laminated iron core manufacturing apparatus 1 according to this embodiment, viewed from the z-axis direction. Furthermore, Figure 3 This is a side view of the laminated iron core manufacturing apparatus 1 according to this embodiment, viewed from the x-axis direction. Figure 3 As shown, a groove 5a is formed along the x-axis of the fixing guide 4 and the cutting guide 5, into which a portion of the periphery of the sheet metal core 31a is embedded. Therefore, the sheet metal core assembly 31, inserted into the laminated core manufacturing apparatus 1, is restricted in its position along the y-axis by the groove 5a formed in the fixing guide 4 and the cutting guide 5. This groove 5a has a shape slightly larger than the outer shape of the sheet metal core 31a, and when the sheet metal core assembly 31 is inserted into the groove 5a of the fixing guide 4 and the cutting guide 5, a gap is created between the sidewall of the groove 5a and the sheet metal core assembly 31. Furthermore, as... Figure 2 As shown, the fixing guide 4 and the cutting guide 5 are arranged with a gap in the x-axis direction. This gap is set to be less than the thickness of the sheet metal core 31a. The fixing guide 4 is restricted from movement in the y-axis direction. The cutting guide 5 is movable in the y-axis direction. The stop 6 is configured to contact a portion of the front end of the sheet metal core assembly 31. Furthermore, as... Figure 3 As shown, the stop 6 is positioned so as not to obstruct the movement of the cutting guide 5 in the y-axis direction. The discharge block 7 is movable in the x-axis direction.

[0039] Next, the operation of the laminated iron core manufacturing apparatus 1 of this embodiment will be explained. For example... Figure 1 and Figure 2 As shown, the sheet metal core assembly 31 is fed into the laminated core manufacturing apparatus 1 along the x-axis. The sheet metal core assembly 31 is inserted until its front end contacts the stop member 6, while still embedded in the slots 5a of the fixing guide 4 and the cutting guide 5. A load is applied to the sheet metal core assembly 31 towards the stop member 6 by a load application part (not shown).

[0040] Figure 4 This is an enlarged view showing the portion of the laminated iron core manufacturing apparatus 1 of this embodiment that separates the gap between the fixing guide 4 and the cutting guide 5. Figure 4 As shown, the gap separating the fixed guide 4 and the cutting guide 5 is set to be less than or equal to the thickness of the sheet metal core 31a. Furthermore, it is assumed that a slit 31b of the sheet metal core assembly 31 exists within this gap. Figure 5 This diagram illustrates the cutting process of the laminated iron core in the laminated iron core manufacturing apparatus 1 of this embodiment. Figure 5 As shown, the cutting guide 5 moves in the y-axis direction, thereby enabling the laminated core 32 to be cut from the sheet core assembly 31. At this time, as... Figure 4 As shown, the sheet metal core 31c of the sheet metal core assembly 31, located on the side of the slit 31b closest to the fixed guide 4, has its movement in the y-axis direction restricted by the fixed guide 4. On the other hand, the sheet metal core 31d of the sheet metal core assembly 31, located on the side of the slit 31b closest to the cutting guide 5, moves together with the cutting guide 5 in the y-axis direction. In this way, the laminated core 32 is cut out from the sheet metal core assembly 31 with the slit 31b as the boundary.

[0041] Furthermore, depending on the insertion state of the sheet metal core assembly 31, sometimes there is no slit 31b between the gap separating the fixed guide 4 and the cutting guide 5. In this case, it is difficult for the cutting guide 5 to move in the y-axis direction. In this situation, the load required to move the cutting guide 5 in the y-axis direction is measured in advance, and the cutting operation is interrupted if the load exceeds a certain fixed value. Then, the load of the load application part is adjusted, and the cutting operation is performed again. By repeating this operation, the cutting operation can be reliably performed.

[0042] Figure 6 This diagram illustrates the discharge process of the stacked iron core in the stacked iron core manufacturing apparatus 1 of this embodiment. Figure 6 As shown, the stacked iron core 32 is cut out relative to the cutting guide 5 in the y-axis direction, and the discharge block 7 moves in the x-axis direction, thereby allowing the stacked iron core 32 to be discharged from the stacked iron core manufacturing apparatus 1.

[0043] In the stacked iron core manufacturing apparatus 1 constructed in this way, the following five effects are obtained.

[0044] The first benefit is that deformation of the laminated iron core cut from the sheet metal core assembly can be prevented during the cutting and unloading processes of the laminated iron core. Grooves 5a are formed along the x-axis of the fixing guide 4 and the cutting guide 5, allowing a portion of the sheet metal core 31a to be embedded within them. Therefore, the positions of the sheet metal core assembly 31 and the laminated iron core 32 in the y-axis direction are always restricted. Thus, deformation of the laminated iron core 32 cut from the sheet metal core assembly 31 can be prevented during the cutting and unloading processes of the laminated iron core. Furthermore, after the laminated iron core is cut out, a process to ensure the shape of the laminated iron core is consistent is unnecessary, thereby improving productivity.

[0045] The second effect is that the core occupancy factor of the thin plate core assembly is increased, and the warping of the thin plate core is suppressed. By applying a load to the thin plate core assembly 31 toward the stop member 6 through the load application part, the core occupancy factor of the thin plate core assembly 31 is increased, and the warping of the thin plate core 31a is suppressed.

[0046] The third effect is improved productivity in the cutting process of the laminated iron core. The stop 6 is positioned so as not to obstruct the movement of the cutting guide 5 in the y-axis direction; therefore, the stop 6 does not hinder the cutting process of the laminated iron core. Consequently, the step of retracting the stop 6 is eliminated, thus improving productivity.

[0047] The fourth benefit is the reduction in equipment costs associated with the cutting process of the laminated iron core. When the thin-plate iron core assembly 31 is inserted into the cutting guide 5, a gap exists between the sidewall of the slot 5a and the thin-plate iron core assembly 31. Therefore, during the cutting process of the laminated iron core, an impact load is applied to the thin-plate iron core assembly 31. Consequently, the load required to move the cutting guide 5 in the y-axis direction during the cutting process is reduced, thus saving equipment costs.

[0048] The fifth effect is that, during the cutting process of the laminated iron core, the generation of cutting chips caused by friction between the sheet iron core and the cutting guide, as well as the wear of the cutting guide, can be reduced. The stop 6 is configured to contact a portion of the front end of the sheet iron core assembly 31, thus reducing the amount of movement of the cutting guide 5 in the y-axis direction during the cutting process. That is, the laminated iron core can be cut only if the amount of movement of the cutting guide 5 in the y-axis direction is greater than the length of contact between the stop 6 and the sheet iron core assembly 31 in the y-axis direction. Therefore, by minimizing the length of contact between the stop 6 and the sheet iron core assembly 31 in the y-axis direction, the amount of movement of the cutting guide 5 in the y-axis direction during the cutting process can be reduced. As a result, when cutting the laminated iron core 32 from the sheet iron core assembly 31, the generation of cutting chips caused by friction between the sheet iron core 31c (closer to the fixed guide 4 side than the kerf 31b) and the cutting guide 5, as well as the wear of the cutting guide 5, can be reduced.

[0049] Furthermore, in the laminated core manufacturing apparatus of this embodiment, the base 2 is located vertically below the cutting unit 3. It can also be configured such that... Figure 3 The groove 5a shown is shaped to enclose the back of the thin plate core assembly 31, ensuring that the thin plate core assembly 31 does not fall off in the z-axis direction. With this structure, the base 2 can operate even when it is vertically above the cutting unit 3.

[0050] Figure 7 This is a schematic diagram of an apparatus that combines the laminated iron core manufacturing apparatus and the stamping apparatus for the thin-plate iron core assembly of this embodiment. Figure 7 As shown, the stacking direction of the sheet metal core assembly is set to be parallel to the direction of gravity, and the stacked core manufacturing device 1 is arranged vertically below the stamping device 8 of the sheet metal core assembly. The stacked core 32 cut by the cutting guide 5 is discharged vertically downward by gravity, so the discharge block 7 can be omitted. In addition, the sheet metal core assembly 31 is directly fed from the stamping device 8 of the sheet metal core assembly into the stacked core manufacturing device 1, thus simplifying the manufacturing process.

[0051] Figure 8 and Figure 9 This is a top view of another laminated core manufacturing apparatus according to this embodiment. In the laminated core manufacturing apparatus of this embodiment, the length of the cutting guide 5 in the x-axis direction is set to be greater than the maximum thickness of the laminated core 32. Furthermore, the thickness of the laminated core cut by this apparatus is determined by the relative position of the cutting guide 5 and the stop 6 in the x-axis direction. Figure 8 In the stacked iron core manufacturing apparatus shown, stoppers 6 of varying lengths along the x-axis are used to adjust the thickness of the stacked iron core 32. Furthermore, in Figure 9 In the stacked core manufacturing apparatus shown, the thickness of the stacked core 32 is adjusted by moving the position of the stop members 6 of the same length in the x-axis direction. Thus, in the stacked core manufacturing apparatus of this embodiment, the thickness of the stacked core can be adjusted by changing the stop members to different lengths or by moving the position of the stop members of the same length, thereby improving productivity.

[0052] In the laminated core manufacturing apparatus of this embodiment, the cutting unit 3 can move along the lamination direction of the sheet core assembly 31, i.e., the x-axis direction. By making the moving speed of the cutting unit 3 in the x-axis direction correlated with the input speed of the sheet core assembly 31 in the x-axis direction into the laminated core manufacturing apparatus, the laminated core can be continuously cut from the sheet core assembly.

[0053] Figure 10 This is an explanatory diagram illustrating the operation of continuously cutting stacked iron cores from a sheet iron core assembly in the stacked iron core manufacturing apparatus of this embodiment. Figure 10As shown in (a), the sheet metal core assembly 31 is inserted into the laminated core manufacturing apparatus 1 from the left along the x-axis. The front end of the sheet metal core assembly 31 contacts the stop member 6, and the laminated core begins to be cut. Then, as... Figure 10 As shown in (b), the cutting guide 5 moves upward along the y-axis to cut out the laminated iron core 32, and the discharge block 7 moves to the right along the x-axis, thereby discharging the laminated iron core 32. During this cutting and discharge, the cutting unit 3 moves to the right along the x-axis on the base 2 at the same speed as the input speed of the sheet iron core assembly 31 in the x-axis direction. Then, as... Figure 10 As shown in (c), the cutting guide 5 and the discharge block 7 return to their initial positions. During this return, the cutting unit 3 also moves to the right along the x-axis at the same speed as the input speed of the sheet metal core assembly 31 in the x-axis direction. Finally, as... Figure 10 As shown in (d), the cutting unit 3 moves to the left along the x-axis on the base 2 and returns to its initial position. Then, as... Figure 10 As shown in (a), the thin-plate core assembly 31 is inserted into the laminated core manufacturing apparatus 1 from the left along the x-axis direction. Thus, the laminated core manufacturing apparatus of this embodiment, through repeated processes... Figure 10 The actions shown in (a) to (d) enable the continuous cutting of laminated cores from the sheet core assembly.

[0054] Furthermore, in this embodiment, when there is no slit 31b of the sheet metal core assembly 31 between the gap separating the fixed guide 4 and the cutting guide 5, the cutting operation is interrupted when the load causing the cutting guide 5 to move in the y-axis direction exceeds a certain fixed value. The load of the load application part is then adjusted, and the cutting operation is performed again. Alternatively, the position information of the slit 31b of the sheet metal core assembly 31 can be read using an image sensor or the like, and the position of the stop 6 can be adjusted so that the slit 31b is reliably located between the gap separating the fixed guide 4 and the cutting guide 5. If this structure is adopted, the cutting operation does not need to be interrupted, thus improving productivity.

[0055] Figure 11 This is a cross-sectional view of a rotary electric motor using a laminated iron core manufactured by the laminated iron core manufacturing apparatus of this embodiment. The rotary electric motor 21 consists of a rotor 22, which rotates; a stator 23, which generates a force that causes the rotor 22 to rotate; and a frame 24 that fixes the stator 23 and supports the rotor 22 so that it can rotate. The stator 23 consists of a laminated iron core 32 and coils 33 wound around the laminated iron core 32 with an insulating material between them.

[0056] Implementation Method 2

[0057] Sometimes, adhesive is applied to the sides of the sheet metal core assembly to prevent the stacked sheet metal cores from separating. The stacked core manufacturing apparatus of Embodiment 2 cuts out the stacked core from the sheet metal core assembly, which has an adhesive layer made of adhesive on its sides.

[0058] Figure 12 This is a perspective view of the laminated iron core manufacturing apparatus of this embodiment. Figure 12 As shown, the laminated iron core manufacturing apparatus 1 of this embodiment consists of a base 2 and a cutting unit 3. An adhesive layer 31e is formed on the side of the sheet iron core assembly 31. The cutting unit 3 is movable on the base 2 along the lamination direction of the inserted sheet iron core assembly 31. The cutting unit 3 consists of a fixing guide 4, a cutting guide 5, a stop 6, a cutting blade 9, and a receiving blade 10. The structures of the fixing guide 4, the cutting guide 5, and the stop 6 are the same as those of the fixing guide, the cutting guide, and the stop in Embodiment 1. Furthermore, the x-axis, y-axis, and z-axis in this embodiment are the same as in Embodiment 1.

[0059] Figure 13 This is a top view of the laminated iron core manufacturing apparatus 1 according to this embodiment, viewed from the z-axis direction. Furthermore, Figure 14 This is a side view of the laminated iron core manufacturing apparatus 1 according to this embodiment, viewed from the x-axis direction. Furthermore, Figure 15 This is an enlarged view showing the portion of the laminated iron core manufacturing apparatus 1 of this embodiment that separates the cutting blade 9 and the receiving blade 10. Furthermore, Figure 16 yes Figure 13 AA section view in the image.

[0060] The cutting blade 9 is capable of moving in the y-axis direction. The receiving blade 10 is restricted from moving in the y-axis direction. Furthermore, as... Figure 15 As shown, the x-axis distance between the cutting blade 9 and the receiving blade 10 is set to be greater than or equal to the thickness of the sheet metal core. When the cutting blade 9 moves in the y-axis direction, it contacts the sheet metal core 31d of the sheet metal core assembly 31. The receiving blade 10 functions to prevent the sheet metal core 31c, located on the input side closer to the sheet metal core 31d contacted by the cutting blade 9, from moving in the y-axis direction. Furthermore, similar to the discharge block shown in Embodiment 1, the receiving blade 10 moves in the x-axis direction, thereby allowing the laminated sheet metal core 32 to be discharged from the laminated sheet metal core manufacturing apparatus 1. Additionally, as... Figure 15 As shown, the x-axis spacing between the fixed guide 4 and the cutting guide 5 is set to be wider than the x-axis spacing between the cutting blade 9 and the receiving blade 10.

[0061] like Figure 16As shown, the cutting blade 9 has a protrusion 9a that projects toward the hole 5b formed in the cutting guide 5. The hole 5b formed in the cutting guide 5 is constructed to have a width in the y-axis direction larger than the protrusion 9a of the cutting blade 9. Figure 16 During the movement of the cutting blade 9 to the right along the y-axis, the protrusion 9a contacts the side of the hole 5b. Therefore, the cutting guide 5 can move in the y-axis direction in conjunction with the movement of the cutting blade 9 in the y-axis direction.

[0062] Next, the operation of the laminated iron core manufacturing apparatus 1 according to this embodiment will be described. Similar to Embodiment 1, the sheet iron core assembly 31 is fed into the laminated iron core manufacturing apparatus 1 along the x-axis direction. The sheet iron core assembly 31 is inserted until its front end contacts the stop member 6 while it is embedded in the groove 5a of the fixing guide 4 and the cutting guide 5.

[0063] Next, the cutting blade 9 moves in the y-axis direction, thereby cutting the laminated core 32 from the thin plate core assembly 31. At this time, as... Figure 16 As shown, the width of the hole 5b of the cutting guide 5 in the y-axis direction is larger than the width of the protrusion 9a of the cutting blade 9. Therefore, firstly, the cutting blade 9 contacts the sheet metal core assembly 31. Then, the protrusion 9a of the cutting blade 9 contacts the side of the hole 5b of the cutting guide 5, and the cutting blade 9 and the cutting guide 5 move in conjunction in the y-axis direction. The sheet metal core assembly 31 contacted by the cutting blade 9 is to move in the y-axis direction; however, the sheet metal core assembly 31 closer to the input side than the cutting blade 9 contacts the receiving blade 10, whose movement in the y-axis direction is restricted. In this way, the load applied between the cutting blade 9 and the receiving blade 10 can impart a shearing force to the sheet metal core assembly 31.

[0064] Figure 17 This diagram illustrates the discharge process of the stacked iron core in the stacked iron core manufacturing apparatus 1 of this embodiment. Figure 17 As shown, the stacked iron core 32 is cut out by moving relative to the cutting blade 9 and the cutting guide 5 in the y-axis direction, while the receiving blade 10 moves in the x-axis direction, thereby allowing the stacked iron core 32 to be discharged from the stacked iron core manufacturing apparatus 1. In this way, the stacked iron core manufacturing apparatus of this embodiment can reliably cut out the stacked iron core from the sheet iron core assembly with an adhesive layer formed on its side.

[0065] In the stacked iron core manufacturing apparatus 1 configured in this way, the five effects described in Embodiment 1 are obtained.

[0066] Furthermore, in this embodiment, the gap in the x-axis direction between the fixed guide 4 and the cutting guide 5 is set to be greater than or equal to the thickness of the sheet metal core. Therefore, the slit of the sheet metal core assembly 31 reliably exists within this gap. Thus, the sheet metal core will not be trapped in the gap between the fixed guide 4 and the cutting guide 5. Furthermore, the gap in the x-axis direction between the cutting blade 9 and the receiving blade 10 is also set to be greater than or equal to the thickness of the sheet metal core. Therefore, there is no problem of the cutting blade 9 and the receiving blade 10 contacting the same sheet metal core during cutting. Therefore, the adjustment of the slit position described in Embodiment 1 is unnecessary, resulting in increased productivity due to reduced equipment costs and shorter production cycle time.

[0067] In addition, in the stacked iron core manufacturing apparatus of this embodiment, the case where there are two or more slits 31b of thin plate iron core groups 31 between the cutting blade 9 and the receiving blade 10 is considered. Figure 18 This diagram illustrates the cutting process in the laminated core manufacturing apparatus of this embodiment when no adhesive layer is formed on the side of the sheet metal core assembly 31. When no adhesive layer is formed on the side of the sheet metal core assembly 31, the sheet metal core 31f between the sheet metal core 31d contacted by the cutting blade 9 and the sheet metal core 31c contacted by the receiving blade 10 may shift or detach from the sheet metal core assembly 31. This is because the sheet metal core 31f is not restricted from moving in the y-axis direction by the receiving blade 10 or the fixing guide 4.

[0068] Figure 19 This is an explanatory diagram of the cutting process in the laminated iron core manufacturing apparatus of this embodiment, where an adhesive layer is formed on the side of the thin plate iron core assembly 31. (See diagram for reference.) Figure 19 As shown, for example, when the adhesive layer 31e is cut first at the slit between the sheet metal cores 31f and 31d, the load applied to the cutting blade 9 is reduced. Therefore, the adhesive layer 31e at the slit between the sheet metal cores 31f and 31c is not cut before the cutting is completed. As a result, even without being restricted in the y-axis direction by the receiving blade 10 or the fixing guide 4, the sheet metal core 31f is fixed by the adhesive layer 31e, and thus, the sheet metal core 31f will not shift or fall off from the sheet metal core assembly 31. This is also true even if there are three or more slits in the sheet metal core assembly 31. Therefore, even when there are two or more slits 31b in the sheet metal core assembly 31 between the cutting blade 9 and the receiving blade 10, the cutting can be completed without problems.

[0069] Furthermore, in this embodiment, it is preferable that the cutting blade 9 and the receiving blade 10 contact the adhesive layer 31e formed on the side of the sheet metal core assembly 31. If the cutting blade 9 and the receiving blade 10 do not contact the adhesive layer 31e, the adhesive layer may elongate before it is cut open, reducing the fixing force between the sheet metal cores. By contacting the cutting blade 9 and the receiving blade 10 with the adhesive layer 31e, elongation of the adhesive layer in the portions not in contact with the cutting blade 9 and the receiving blade 10 can be suppressed. Moreover, by making the width of the hole 5b of the cutting guide 5 in the y-axis direction larger than the width of the protrusion 9a of the cutting blade 9, an impact load is applied to the sheet metal core assembly 31 during the cutting process of the laminated core. Therefore, less load is required to move the cutting blade 9 in the y-axis direction during the cutting process, thus saving equipment costs.

[0070] In this embodiment, an adhesive layer is formed on the side of the thin plate core assembly to fix the thin plate core. Alternatively, an adhesive layer can be provided between the layers of the thin plate core constituting the thin plate core assembly to fix the thin plate core. However, in conventional laminated core manufacturing apparatuses, the thickness of the laminated core formed by bonding between the layers is determined by the number of laminated sheets of the thin plate core. Therefore, there is a problem that the thickness of the laminated core is unstable due to deviations in the thickness of the thin plate core and the thickness of the adhesive layer. In the laminated core manufacturing apparatus of this embodiment, the thickness of the laminated core is not determined by the number of laminated sheets of the thin plate core, but by the relative position in the x-axis direction between the cutting guide and the stop member. Therefore, the thickness of the laminated core can be stabilized regardless of the thickness of the thin plate core and the thickness of the adhesive layer.

[0071] Figure 20 This is an explanatory diagram showing the state when the laminated iron core is cut out from the assembly of thin plate iron cores in which an adhesive layer is provided between the layers of the thin plate iron core in the laminated iron core manufacturing apparatus of this embodiment. Figure 20 This illustrates the state of the adhesive layer 41 remaining on the end face 42 of the laminated core 32 after it has been cut from the sheet core assembly 31. Figure 20 The thickness of the adhesive layer 41 is exaggerated in the image. The actual thickness of the adhesive layer 41 is much smaller than the thickness of the sheet core 31a. Thus, the adhesive layer 41 remains on at least one of the end face 42 of the cut-out laminated core 32 and the end face 43 of the sheet core assembly 31 after the laminated core 32 has been cut out.

[0072] Furthermore, the thin-plate iron cores constituting the thin-plate iron core assembly can also be fixed by riveting. However, in existing laminated iron core manufacturing apparatuses, the thickness of the laminated iron core fixed by riveting is determined by the number of laminations of the thin-plate iron core. Therefore, in such laminated iron cores, there is a problem that the thickness of the laminated iron core is unstable due to deviations in the thickness of the thin-plate iron core. In the laminated iron core manufacturing apparatus of this embodiment, the thickness of the laminated iron core is not determined by the number of laminations of the thin-plate iron core, but by the relative position in the x-axis direction between the cutting guide and the stop member. Therefore, the thickness of the laminated iron core can be stabilized regardless of the thickness of the thin-plate iron core.

[0073] Implementation Method 3

[0074] The thin-plate core assembly is affected by variations in the thickness of the thin-plate core and the precision of the apparatus used to manufacture the thin-plate core assembly by stacking the thin-plate cores. Sometimes, the thin-plate cores are stacked in an inclined state from a direction perpendicular to the stacking direction. The stacked core manufacturing apparatus of Embodiment 3 can cut the stacked core from the thin-plate core assembly formed by stacking the thin-plate cores in an inclined state. The structure of the stacked core manufacturing apparatus of this embodiment is the same as that of the stacked core manufacturing apparatus of Embodiment 1. However, the gap in the x-axis direction between the fixed guide and the cutting guide is specified within a predetermined range.

[0075] In the laminated core manufacturing apparatus of Embodiment 1, when the gap in the x-axis direction between the fixed guide 4 and the cutting guide 5 exceeds the thickness of the sheet core, the thickness of the cut laminated core may sometimes deviate. For example, in the apparatus referring to Embodiment 1... Figure 4 When considering this situation, consider the following case: if the gap in the x-axis direction between the fixed guide 4 and the cutting guide 5 exceeds the thickness of the sheet metal core, there are two slits 31b between the fixed guide 4 and the cutting guide 5 that separate the sheet metal core assembly 31. In this case, the laminated core is cut from the sheet metal core assembly at one of the two slits 31b, and the thickness of the cut laminated core deviates from the thickness of a single sheet metal core. To prevent this deviation in the thickness of the laminated core, in the laminated core manufacturing apparatus of Embodiment 1, the gap in the x-axis direction between the fixed guide 4 and the cutting guide 5 is set to be less than or equal to the thickness of the sheet metal core 31a.

[0076] In contrast, in the stacked core manufacturing apparatus of this embodiment, the gap 44 in the x-axis direction between the fixed guide 4 and the cutting guide 5 is set to be more than half the thickness of the thin plate core 31a and less than the thickness of the thin plate core 31a. Figure 21This is an enlarged view showing the portion of the laminated core manufacturing apparatus of this embodiment that separates the fixing guide 4 and the cutting guide 5. If the distance of the gap in the x-axis direction between the fixing guide 4 and the cutting guide 5 is reduced, the cutting guide 5 sometimes has difficulty moving in the y-axis direction when the sheet metal core assembly is fed into the laminated core manufacturing apparatus in a tilted state. For example, as... Figure 21 As shown, when the sheet metal core is tilted, regarding the sheet metal core 31g located in the gap separating the fixed guide 4 and the cutting guide 5, sometimes one end in the y-axis direction is restricted by the fixed guide 4, and the other end in the y-axis direction is restricted by the cutting guide 5. When the sheet metal core 31g is in this state, it is difficult for the cutting guide 5 to move in the y-axis direction. In this case, as described in Embodiment 1, the load required to move the cutting guide 5 in the y-axis direction is measured in advance, and if the load exceeds a certain fixed value, the cutting operation is interrupted. Then, the load of the load application part is adjusted, and the cutting operation is performed again.

[0077] Figure 22 This is an enlarged view showing the portion separating the fixed guide 4 and the cut-out guide 5 when the load on the load application part has been adjusted. (See attached image.) Figure 22 As shown, this action is repeated until one end of the thin plate core 31g in the y-axis direction is no longer restricted by the fixed guide 4, thereby enabling the cutting action to be reliably performed.

[0078] In order to reliably perform the cutting operation through this repetitive action, in the stacked core manufacturing apparatus of this embodiment, the gap 44 in the x-axis direction between the fixed guide 4 and the cutting guide 5 is set to be more than half and less than the thickness of the sheet metal core 31a. In the stacked core manufacturing apparatus configured in this way, even if a sheet metal core assembly formed by stacking sheet metal cores in an inclined state is fed in, the thickness of the stacked core will not deviate, and the stacked core can be reliably cut out.

[0079] This application describes various exemplary embodiments; however, the various features, forms and functions described in one or more embodiments are not limited to specific embodiments and can be applied to embodiments individually or in various combinations.

[0080] Therefore, numerous variations not illustrated are contemplated within the scope of the technology disclosed in this application. For example, these include variations of at least one structural element, addition of at least one structural element, omission of at least one structural element, and extraction of at least one structural element combined with structural elements of other embodiments.

[0081] Label Explanation

[0082] 1: Laminated iron core manufacturing device; 2: Base; 3: Cutting unit; 4: Fixing guide; 5: Cutting guide; 5a: Slot; 5b: Hole; 6: Stop; 7: Discharge block; 8: Stamping device; 9: Cutting knife; 9a: Protrusion; 10: Receiving knife; 21: Rotary motor; 22: Rotor; 23: Stator; 24: Frame; 31: Thin plate iron core assembly; 31a, 31c, 31d, 31f, 31g: Thin plate iron core; 31b: Cutting slit; 31e: Adhesive layer; 32: Laminated iron core; 33: Coil; 41: Adhesive layer; 42, 43: End face; 44: Gap.

Claims

1. A laminated iron core manufacturing apparatus, comprising cutting out a laminated iron core formed by stacking said thin-plate iron cores from a thin-plate iron core assembly, characterized in that, The laminated iron core manufacturing apparatus has the following features: A stop member that restricts the position of the thin plate core assembly in the stacking direction of the thin plate core assembly; A fixed guide restricts the position of the sheet metal core assembly in a direction perpendicular to the stacking direction; as well as A cutting guide, which is spaced apart from the fixing guide in the stacking direction, restricts the position of the sheet metal core assembly in a direction perpendicular to the stacking direction, and moves in a direction perpendicular to the stacking direction to cut the stacked core from the sheet metal core assembly. The stop member contacts one end of the thin plate core assembly in the stacking direction. The amount of movement of the cutting guide is greater than the length of the contact between the stop member and the thin plate core assembly in the direction perpendicular to the stacking direction. The cutting guide moves relative to the stop member to cut the stacked core from the thin plate core assembly.

2. The laminated iron core manufacturing apparatus according to claim 1, characterized in that, The interval of the gap is set to be more than half the thickness of the thin plate core and less than the thickness of the thin plate core.

3. The laminated iron core manufacturing apparatus according to claim 1, characterized in that, The laminated core manufacturing apparatus also includes a load application unit that applies a load to the sheet core assembly in the lamination direction.

4. The laminated iron core manufacturing apparatus according to claim 2, characterized in that, The laminated core manufacturing apparatus also includes a load application unit that applies a load to the sheet core assembly in the lamination direction.

5. The laminated iron core manufacturing apparatus according to any one of claims 1 to 4, characterized in that, The stop member is movable along the stacking direction.

6. The laminated iron core manufacturing apparatus according to any one of claims 1 to 4, characterized in that, The stacked core manufacturing apparatus further includes a discharge block that discharges the stacked core cut out by the cutting guide along the stacking direction.

7. The laminated iron core manufacturing apparatus according to claim 5, characterized in that, The stacked core manufacturing apparatus further includes a discharge block that discharges the stacked core cut out by the cutting guide along the stacking direction.

8. The laminated iron core manufacturing apparatus according to any one of claims 1 to 4, characterized in that, The cutting guide has a groove that restricts the position of the sheet metal core assembly, and there is a gap between the sidewall of the groove and the sheet metal core assembly whose position is restricted by the groove.

9. The laminated iron core manufacturing apparatus according to claim 5, characterized in that, The cutting guide has a groove that restricts the position of the sheet metal core assembly, and there is a gap between the sidewall of the groove and the sheet metal core assembly whose position is restricted by the groove.

10. The laminated iron core manufacturing apparatus according to claim 6, characterized in that, The cutting guide has a groove that restricts the position of the sheet metal core assembly, and there is a gap between the sidewall of the groove and the sheet metal core assembly whose position is restricted by the groove.

11. The laminated iron core manufacturing apparatus according to claim 7, characterized in that, The cutting guide has a groove that restricts the position of the sheet metal core assembly, and there is a gap between the sidewall of the groove and the sheet metal core assembly whose position is restricted by the groove.

12. The laminated iron core manufacturing apparatus according to claim 1, characterized in that, The laminated core manufacturing apparatus further comprises: a cutting blade that moves in conjunction with the cutting guide in a direction perpendicular to the lamination direction; and a receiving blade disposed on the side opposite to the cutting blade, separated from the thin-plate core assembly, and spaced apart from the cutting blade in the lamination direction.

13. The laminated iron core manufacturing apparatus according to claim 12, characterized in that, The receiving blade discharges the stacked iron core cut by the cutting guide from the cutting guide along the stacking direction.

14. The laminated iron core manufacturing apparatus according to claim 12 or 13, characterized in that, The thin plate core assembly has an adhesive layer on its side in the stacking direction, and the cutting blade contacts the adhesive layer.

15. A method for manufacturing a laminated iron core, comprising cutting a laminated iron core formed by stacking said thin-plate iron cores from a thin-plate iron core assembly, characterized in that, A stop member is used to restrict the position of the thin plate core assembly in a direction perpendicular to the stacking direction of the thin plate core assembly by contacting one end of the thin plate core assembly in the stacking direction, and the amount of movement of the thin plate core assembly in the direction perpendicular to the stacking direction is greater than the length of contact between the stop member and the thin plate core assembly in the direction perpendicular to the stacking direction, so that the thin plate core assembly moves relative to the stop member and cuts the stacked core out of the thin plate core assembly in the direction perpendicular to the stacking direction.

16. A method for manufacturing a rotary electric motor, characterized in that, A rotary electric motor is manufactured using the laminated iron core manufactured by the method of manufacturing laminated iron core as described in claim 15.

17. A laminated iron core, comprising a laminated iron core cut from a sheet iron core assembly formed by laminating sheet iron cores using the laminated iron core manufacturing apparatus according to any one of claims 1-14, characterized in that, The laminated core has an adhesive layer formed by applying an adhesive to the side surface in the lamination direction to prevent the laminated sheet cores from separating in the lamination direction, the adhesive layer being disposed up to one end of the side surface in the lamination direction of the laminated core.

18. A laminated iron core, comprising a laminated iron core cut from a sheet iron core assembly formed by laminating sheet iron cores using the laminated iron core manufacturing apparatus according to any one of claims 1-14, characterized in that, The laminated iron cores have an adhesive layer between adjacent thin plate iron cores in the lamination direction, and the adhesive layer is disposed on one end face of the laminated iron core in the lamination direction.

19. A rotary electric motor comprising a stator, a rotor, and a frame that fixes the stator and supports the rotor for rotatability, characterized in that, The stator includes the laminated iron core of claim 17 or 18, and a coil wound around the laminated iron core with an insulating material between them.

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